NCCER Millwright study plan

Match the required personal protective equipment to five described millwright tasks and justify each selection against the hazard present.

Write a job hazard analysis for a combined lift-and-align task that lists at least six hazards, the controls for each, and the residual risk.

Inspect five hand and power tools against a written checklist and record pass/fail plus the specific rejection reason for any failure.

State the lockout/tagout sequence for a motor-driven pump and list the verification steps that confirm zero energy before work begins.

Identify the correct fire extinguisher class and the emergency response sequence for an oil fire and an electrical fire in a shop setting.

Extract pipe size, flow direction, nozzle orientation, and instrument tags from a P&ID and a general-arrangement drawing for one vessel.

Convert dimensions between architectural, engineering, and metric scales and verify three field dimensions by calculation.

Measure five gauge-block-checked parts with a micrometer, dial caliper, and height gauge and record each reading to within 0.001 in.

Set up a dial indicator on a shaft and record total indicated runout, then compare the result to an allowable limit.

Locate and lay out a bolt-hole pattern from drawing coordinates within 1/32 in. using layout instruments only.

Calculate load weight from volume and material density and compare it to the rated capacity of the selected sling and hardware.

Compute sling tension for two-leg and four-leg bridle hitches at 30, 45, and 60 degrees and apply the correct angle factor.

Inspect slings, shackles, and hooks and identify the capacity markings, rejection criteria, and removal-from-service conditions for each.

Locate the center of gravity of an asymmetrical load and select the hitch type and tag line arrangement that keeps the load controlled.

Read a load chart and determine the maximum radius and boom configuration permitted for a stated load.

Verify a baseplate and foundation against the layout drawing, checking elevation, anchor bolt pattern, hole allowance, and shim stack thickness.

Level a machine on shims to the specified elevation using a precision level and record the readings in both axes.

Perform a soft-foot check at all mounting points and correct any gap greater than 0.002 in. before proceeding to alignment.

Check for pipe strain by measuring coupling movement while piping is connected and disconnected.

Describe the grout placement and cure sequence and identify the conditions that require a dry-pack or epoxy grout instead of a cementitious grout.

Explain and demonstrate the reverse dial indicator method, recording readings at the 12, 3, 6, and 9 o'clock positions.

Compute vertical and horizontal shim corrections from dial readings and apply bar-sag and indicator-sag corrections to the raw numbers.

Set up a laser shaft alignment system, enter machine dimensions, and interpret the offset and angularity results screen.

Identify coupling types from a sample set and match each to an application based on torque, misalignment tolerance, and service conditions.

Inspect a coupling for fit, key condition, and end float and state the acceptance criteria for each.

Classify bearings from a sample set by type and state the load direction, speed limit, and typical mounting method for each.

Mount and remove a rolling element bearing using an induction heater and a press without imposing load through the rolling elements.

Select a lubricant by viscosity grade for a stated speed and temperature and specify the grease quantity and re-lubrication interval for one bearing.

Install a lip seal and a mechanical seal with correct orientation, shaft finish requirement, and running clearance.

Diagnose three lubrication faults (over-greasing, under-lubrication, wrong viscosity) from described symptoms and oil or grease condition.

Trace a hydraulic schematic and identify the pump, relief valve, directional valve, flow control, and actuator with their symbols.

Calculate cylinder extend force, retract force, rod speed, and pump flow requirement from bore, rod diameter, pressure, and delivery rate.

Perform a safe depressurization sequence and interpret a fluid sample report against target cleanliness and water content limits.

Diagnose no-movement, slow-cycle, and overheating faults using gauge readings and a written decision sequence.

Identify the causes and corrections for air entrainment, cavitation, and external leakage in a pneumatic circuit.

Build a preventive maintenance task list for a rotating equipment train from manufacturer intervals, criticality, and failure history.

Collect vibration readings on a test asset and trend them against ISO severity zones to flag an alarm condition.

Interpret a thermography image and an oil analysis report and state the corrective action each finding drives.

Assemble a 30-day spaced review schedule covering all ten domains, weighted toward shaft alignment, rigging, and installation.

Complete a 50-question practice exam and score at least 80 percent, then log every missed item by domain.