July 11, 2012 A-M RFP Curriculum Development Estimates

Estimate parameters: a) b) c) d) e) 12 student class Stages = 40 hours Unique steel industry course content provided from A-M Training hardware projections based on 4 student/ 1 trainer ratio Field Skill Demonstrations (FSD) occur in-mill, conducted by A-M personnel. Rubric development time for the FSDs not included in these estimates. f) Development resources listed are current and reasonably available to the developer. g) Development estimates include lecture and lab development. h) Development estimates do not include assessment (test) development. Development Estimates by Stage Stage 1Basic Theory AC & DC . 4 hours Stage 2Schematics & Print Reading .. 6 hours Stage 3Test Instruments 6 hours Stage 4Motors 8 hours Stage 5Power Supplies . 12 hours Stage 6Power Distribution 14 hours Stage 7DC Cranes 24 hours Stage 8Analog & Digital .. 10 hours Stage 9Computers & PLCs 18 hours Stage 10AC/DC Digital Drives 18 hours Stage 11Instrumentation . 32 hours Stage 12Pneumatics & Hydraulics 8 hours Stage 13Construction & Installation .. 10 hours Stage 14HVAC . 16 hours Stage 15RCM . 12 hours

Stage 1 Basic DC/AC Theory: fundamentals of electricity & electronics Nature of matter: law of charged bodies; molecules, atoms, electrons, protons, neutrons, ionization, coulomb, electrostatic fields, and induction. Static electricity: static electricity applications DC vs AC current; conventional flow vs. electron flow Basic electrical circuit theory: voltage, current, resistance; introduce series, parallel, and series-parallel circuits. OHMS Law: basic Ohms Law concepts and understanding; electrical prefixes; RCL concepts in AC & DC circuits. Meter Usage & Safety: safely measure electrical quantities (I, E, R) Understanding circuit protection: fuses, (time delay and instantaneous); circuit breakers, overload protection. Electrical Fire Safety: fire extinguisher types. Stage 1 Development Resources
INDT-113, 204, & 106 (safety content); NSF modules; INDT-103 (protection content); related A/V materials

Stage 1 Trainer/Hardware projections

Basic electrical principles trainer; digital multimeters (DVM)

Stage 2 Schematic & Print Reading: understanding electrical circuits Electrical symbols, types of prints, associated hardware AC/DC relays, contactors, motor starters, blowout structures Timers and timing circuits Basic hydraulic systems and prints Recognize symbols and hardware and connect as a circuit LAB: Given a schematic connect and demonstrate circuit. 2

FIELD SKILL DEMONSTRATION: Explain 250V DC constant potential (CP) panel (crane control.) Stage 2 Development Resources
INDT-102, 103, 104, 204; related A/V materials (crane print)

Stage 2 Trainer/Hardware projections

(hardware from Stage 1 and Stage 12 would be utilized)

Stage 3 Test Instruments: understanding electrical test instruments. Safe and proper operation of testing instruments. Test equipment: 1. Analog & Digital Multimeters 2. Megohmeter 3. Oscilloscopes 4. Frequency Generator 5. Volt-Ohm Meters 6. Hi-Pot 7. Hot Sticks Stage 3 Development Resources
INDT-103, Magnetech; 113; ATP textbook; related A/V materials

Stage 3 Trainer/Hardware projections

6 analog and 6 digital multimeters; 3 meggers; 6 oscopes; 6 freq generators; 6 VOM; 3 Hi-Pots; 1 hot stick for demonstration

Stage 4A Introduction to DC Motors: DC electrical motors and associated mechanical devices and industrial motor control circuits. Type DC motors: series, shunt, and compound. 3

Motor controls, relays, protective devices, and starting components. Wring out motor identifying leads, and motor compounding (cumulative or differentially) Accelerating, decelerating, dynamic braking, CEMF, and field weakening Protective devices, speed control, plugging, anti-plugging, and reversing circuits. 1. Maintain, repair, and troubleshoot different types of DC motors/control systems. 2. Nameplate data 3. Speed & torque characteristics of series, shunt, and compound motors. 4. Identify DC motors and associated components. 5. Troubleshooting a 250VDC constant potential panel. LAB: Motor circuit analysis, reading schematics & troubleshooting Stage 4A Development Resources
INDT-103, 113; related A/V materials

Stage 4A Trainer/Hardware projections

Three (3) motor trainers with DC & AC (single and three phase) motors, control devices, DC/AC drive capabilities. Motor types to include dual voltage cap start, split phase, induction, synchronous, and wound rotor.

Stage 4B Introduction to AC Motors Understanding AC Motor Control AC induction motors and associated devices and control circuits. Relays, protective devices, starting components, and wringing out motors. Single phase motors Shaded pole, Capacitor start, Split phase identify leads Selsyn motors, encoders, resolvers, and positioning devices Three phase motors synchronous and controls

wound rotor starters (secondary resistance starter) Starting methods Across the line starting Reduced voltage starting (primary resistance) Autotransformer starters Wye/delta starters Dual voltage connections: high & low voltage connections, identify leads LAB: Motor circuit analysis & troubleshooting Stage 4B Development Resources
INDT-103, 113; related A/V materials

Stage 4B Trainer/Hardware projections

Trainers from 4A plus: Selsyn motors, encoders, resolvers, and positioning devices

Stage 5 Power Supplies: Covers various components of power supply systems. Basics of a three-phase bridge rectifier, common semi-conductions and basic regulation systems. Single Phase: Principles of transformer theory; ring out windings, hook up in high and low voltage configurations with consideration for additive and subtractive polarities. Calculate current and voltage levels given power considerations. Semiconductors in power supplies: diodes, SCRs and transistors. Power supply filtering, voltage doublers, voltage dividers, center tap transformers, current transformers, potential transformers, and wattmeters. LAB: Recognize and measure power supply waveforms using a function generator & oscilloscope. Three phase: Compute voltage & current in Delta & Wye configurations. LAB: Identify windings and hook-up (4) delta / wye transformer configurations. FIELD SKILL DEMONSTRATION: Trainees will be taught where and why they read certain voltage levels throughout the mill.

Stage 5 Development Resources

INDT-204, 113; related labs & A/V materials

Stage 5 Trainer/Hardware projections

Breadboards, discrete components, wire, and sufficient transformers to set-up six (6) work stations. Test equipment requirements (function generator, oscope) from Stage 3 training hardware.

Stage 6 Power Distribution: Power devices and switchgear, safe procedures dealing with high voltage equipment. Power Generation Feeders, bus lines, branch circuits, tie breakers. Reading one line diagrams. 3-phase Transformers. Substations, breaker types, voltage designations (A, B, C, D, etc.) Switching and correct protocol / switchboards / emergencies /power outages. Fault identifiers. Proper clearing of faults and troubleshooting techniques. 70-E safety requirements. Maintenance Items: Batteries & charges, cable splicing, taping & types of tape. Racking breakers in and out. (voltage level responsibility) Trip and close power. Locking out & safe grounding procedures/responsibilities. Breaker troubleshooting / repairs. Potential dangers. Power instruments; hi-pot, hot sticks, Meggar procedures. 1. Demonstrate knowledge of power transformers - describe low and high voltage connections. 2. Identify various components on a power supply system. 3. 70-E LAB: Read out transformer windings, rectifiers, and hook them up for proper output voltages. Stage 6 Development Resources

INDT-204, 113, 103; ENRG-107; PPTC-103; IMTC-122; related labs & A/V materials. A-M HV & emergency response procedures.

Stage 6 Trainer/Hardware projections

Breadboards, discrete components, wire, and sufficient transformers to set-up six (6) work stations. Test equipment requirements (function generator, oscope) from Stage 3 training hardware. Mock-up switchgear & high voltage circuit breakers. Cable splicing tools & materials.

Stage 7 DC Cranes: 250V DC Overhead Cranes; analyze, troubleshoot and maintain the electrical drive components. Crane operation, electrical theory, and maintenance. Crane safety procedures and warning devices. Control and power schematics, including ore bridges and stackers Test components for proper operation Course Content: Hoist and lowering principles / power & control schematics. Trolley power and control schematics. Bridge power and control schematics. Dynamic braking, plugging control, controllers, warning devices, acceleration controls, hoist power limit, brake systems and magnet controllers (skew limits, panagraphs, and anemometers) LAB: Safely troubleshoot and repair problems in power and control systems. FIELD SKILL DEMONSTRATION: Crane inspection & troubleshooting of three crane problems. Stage 7 Development Resources
INDT-103, 113; A-M DC crane control and power prints.

Stage 7 Trainer/Hardware projections

DC motor and motor control hardware from Stage 4A. Test equipment requirements from Stage 3 training hardware. 250VDC overhead crane mock-up (control).

Stage 8 Analog & Digital: analog & digital devices Analog Ohms law review, resistor color code, solid state theory, voltage dividers and biasing, inductance, capacitance, tuned circuits, vacuum tubes (diodes, triodes, Tetrodes, pentodes), semiconductors such as diodes, Zener diodes, thyristors (SCRs, Triacs) transistors as switches, transistors as amplifiers, integrated circuits, operational amps, oscillators. LAB: Troubleshooting techniques. Digital Binary numbering system, logic gates, logic families, digital applications, counters, encoders, decoders, seven segment displays, flip flops, latches, memory circuits, series and parallel shift registers and optoisolators. LAB: Troubleshooting techniques for digital circuits. Devices and Transducers Proximity switches, limit switches, LVDTs load cells, encoders, tachometer generators, thermocouples, thermistors, bi metal strips, Bourdon Tubes, pressure transducer, I-Ps, and Smart devices. Stage 8 Development Resources
INDT-204, 113, 103, 105; EECT-214, 238, Instrumentation; EECT-112, Digital Fund; NSF module. A-M curriculum (vacuum tubes)

Stage 8 Trainer/Hardware projections

Analog/Digital training boards, discrete components, ICs, and gates sufficient to set -up six (6) work stations. Test equipment requirements (function generator, oscopes, DVMs) from Stage 3 training hardware. Digital logic probes (6). Devices from Stage 4 B; Transducers from Stage 11, Part A.

Stage 9A Computers and PLCs: Intro to Computers and PLCs Interpret, isolate, and diagnose common hardware problems. Basic ladder logic interpretation with application to diagnostics with instructions in RSLogix 5000. PLC Level One: Control Logix and RSLogix 5000

Programming various lab assignments for discrete I/O, proper addressing, examine on and off contracts, relays, timers (TON and TOF), forcing, programming and troubleshooting techniques. PLC Level Two: Programming installation of common devices and control loops schemes. (PLC Level Three: covered in Stage 11: programming common burner management and Flame Permissive Controls.) 1. Convert a wire diagram to ladder logic. 2. Writing a Control Logix program using examine on and off contacts, timers, and discrete I/O. 3. Establish RSLinx connection, downloading and running program. 5. Online editing, searching and forcing. LAB: Troubleshooting by clearing and repairing processor and or I/O faults.

Stage 9B Computers and PLCs: PCs and PLCs, microprocessor evolution, ALU, CPU, memory examples RAM and ROM, hard drives, flash drives, DMA, video concepts, common peripherals (keyboard, mouse, printers, monitor, drivers) mother board improvements, (legacy ports through USB), examples of application software, firmware, and hardware. Serial and parallel communications, different protocols, networking basics, micro computers, and smart devices. PLC Level One: Allen Bradley PLC 5, Programming various lab assignments for discrete I/O, proper addressing, examine on and off contacts, relays, timers (TON and TOF), forcing, programming and troubleshooting techniques. PLC Level Two: Control Logix: various lab assignments for discrete I/O, proper addressing, examine on and off contacts, relays, timers (TON and TOF), forcing, programming, and troubleshooting techniques. FIELD SKILL DEMONSTRATION: 1. Write a PLC 5 program using examine on and off contacts, timers, and discrete I/O 2. Write Control Logix program using examine on and off contacts, timers, and discrete I/O 9

Stage 9 Development Resources

INDT-100, 205, 206, 212; and A/V materials.

Stage 9 Trainer/Hardware projections

Three (3) PLC trainer stations (A-B PLC-5 & Control Logix) with field devices (I/Os) and RSLinx communication network. Test equipment requirements from Stage 3 training hardware.

Stage 10 AC and DC Digital Drives: AC and DC Digital Drives DC drive principles of operation: Three phase bridges using SCRs GTOs and IGBTs. Voltage, Current, and Speed Controllers with open loop & closed loop control. Feedback devices: encoders, tachometer, generators, current shunts, current transformers and voltage feedback. Gating circuits and braking methods: stop, regenerative braking, and dynamic braking. AC drive principles of operation: gating and braking methods, DC injection braking, dynamic braking, regenerative braking variable voltage inverters, current source inverters, pulse width modulators. Power Flex 700 AC Drive Allen Bradley 1395 DC Drive Power Flex DC Drive Remote drive operation and networking Maintenance and troubleshooting techniques FIELD SKILL DEMONSTRATION: 1. Location and type of digital drives installed. 2. Drive alarms and faults/reset drive 3. Identify components on a drive system 4. Reload and setup a spare drive for operation. Stage 10 Development Resources
INDT-103, 217; A/V materials; NSF grant modules; A-B materials (Flex)

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Stage 10 Trainer/Hardware projections

DC drive hardware from motors trainer in Stage 4A, (3) STATIONS. Power Flex 700 AC drive; A-B 1395 DC Drive; remote drive operation capable.

Stage 11 Instrumentation Part A: Combustion & instrumentation Pressure and flow, the control valve, piping and instrument diagrams, the purge procedure, temperature measurement, PID control, flame theory, safety and burner management. Calibrate and maintain Pressure, Level and Flow transmitters Utilize the HART communications System Maintenance of Control Valves Adjust and maintain Pneumatic Instrumentation Purge procedure Maintenance of Temperature Measuring Systems Become familiar with Automatic Control Systems Become familiar with Flame Safety and Burner Equipment FIELD SKILL DEMONSTRATION: 1. Written evaluation covering course content. 2. Hands on evaluation covering labs performed during class. 3. Calibrating flow transmitter. 4. Control valve assembly / disassembly.

Instrumentation Part B: Instrumentation Extended training: automatic closed loop control, feedback devices, and process control and PID adjustments.

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 Combustion control & burner management: flame lockout relays, purge cycles, primary and combustion air, tuning the efficiency of a burner, Maxon valve, flame rod and ultra violet flame detectors and pilot safety concepts. Process analyzers: liquid and gas Temperature: Pyrometers (Ircon), HMDs. LAB: Student will write a PLC burner program using Control Logix. FIELD SKILL DEMONSTRATION: Instrumentation Part B / Maintenance 1. Write a burner program for a PLC using Control Logix and guidelines covered in class room. 2. Identify combustion process in mill or assigned work area by drawing a diagram of a system including electrical components with devices and explain how they work and relate to the whole production process of your mill. Stage 11 Development Resources
INDT-211, PROC- 203, EECT-214; ATP publications and A/V materials.

Stage 11 Trainer/Hardware projections

Three (3) Instrumentation trainers equipped for pressure, level, flow transmitters. HART communications system required. Various control valves and pneumatic instrumentation hardware. Process analyzers liquid & gas. Control Logix PLC from Stage 9. Test equipment requirements from Stage 3 training hardware.

Stage 12 Pneumatics and Hydraulics: fluid flow and pressure principles, pneumatic/hydraulic piping symbols and print reading, piping, hose fittings, directional valves, actuators, cylinders, pumps and compressors alignment, air treatment, and rigging. Safety is stressed. Pneumatics and Hydraulics Pumps and compressors types and construction System and pressure regulators Reservoirs, accumulator, tanks Cylinders, actuators Directional flow control valves Piping, tubing, hoses, fittings, system accessories (gauges, etc.) 12

 Blue print, schematic symbols and interpreting Preventative maintenance and maintaining system Building hydraulic circuits in lab and troubleshooting Coupling alignment Introduction and the importance of coupling alignment Types of couplings Coupling maintenance (lubrication, etc.) Coupling alignment (methods in class) Introduction to laser alignment (in class) Rigging Introduction to rigging Cables and slings (construction and safety factors) Lifting accessories (eye bolts, hooks, etc.) Weight and balance computations Practical lifts LAB: Rig and lift several objects in lab FIELD SKILL DEMONSTRATION: 1. Troubleshooting hydraulic system. 2. Lifts using safe and proper (plumb and level) techniques. 3. Identifying hydraulic system: identify components and electrical devices; draw system layout, draw electrical schematic and explain system. Stage 12 Development Resources
INDT-104, 201, 203, 214; IMTC-111, 107; IZ and A/V materials.

Stage 12 Trainer/Hardware projections

Three (3) Fluid Power trainers with faults. Three (3) coupling alignment stations demonstrating various types of couplers. Three (3) rigging trainers. Test equipment requirements from Stage 3 training hardware.

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Stage 13 Construction and Maintenance: NEC and electrical codes and standards. Plan a job to include layout and measuring. Conduit cutting, threading, reaming and bending, junction boxes, conduit bodies, and fittings: condulets, clamps, straps, hangers, templates, brackets, receptacles and switches. Lighting panels, wiring methods and grounding methods. Fabrication and construction techniques, flexible conduit installation & applications. LAB: Conduit bending projects using rigid conduit. Lay out of bends and calculating developed length. Bending stub up, box off set, back-to-back bends, including 2 and 4 bend saddles. FIELD SKILL DEMONSTRATION: 1. Bending conduit specifications. 2. Complete a conduit installation job from beginning-to-end including pulling wire and making terminations. Stage 13 Development Resources
IMTC-122; EECT-105, NEC 2011; NFPA 70E and A/V materials.

Stage 13 Trainer/Hardware projections

Three (3) industrial wiring trainers. Conduit benders, wire pullers, construction consumables. Test equipment requirements from Stage 3 training hardware.

Stage 14 HVAC: Heating Ventilation Air Conditioning Refrigeration components; principles of operation and laws of thermodynamics. Discuss actual mill systems, trouble shooting and cause and effect scenarios. Window and wall AC units. Split system, DX coil, air cooled, water cooled. Chillers and heat exchangers. Gas forced air, boilers steam and hydronic. 14

 HVAC hardware and control devices FIELD SKILL DEMONSTRATION: 1. Written evaluation covering material presented in course. 2. Two AC systems, one crane or moving equipment system, one operators pulpit HVAC system: Draw layout of system and components and electrical schematic of power and control circuit. Stage 14 Development Resources
HVAC-101, 103, 202; INDT-107

Stage 12 Trainer/Hardware projections

Three (3) HVAC training stations with cooling and heating capabilities. Three (3) HVAC gauge sets. Test equipment requirements from Stage 3 training hardware.

Stage 15 Maintenance / RCM Understanding Maintenance (Day 1 of 3) AM Introduction and History of Work Identification The Changing World of Maintenance Growing Expectations Review Asset Reliability Process and Assessment Changing Understanding of How Equipment Behaves New Maintenance Techniques Work Identification Process & Parallel Maintenance Methodologies PM Defining Maintenance Understanding & Developing Functions Based on Performance Standards

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 Primary Functions Secondary Functions

Completing the Information Worksheet (Day 2 of 3) AM Understanding, Developing, & Recording Functional Failures General Failed State Partial vs. Total Failure Determining & Describing Failure Modes & Effects (FMEA) Causes of Failures Age related Random Infant Mortality Human Error PM Failure Consequences Understanding the Four Failure Consequences Hidden Safety/Environmental Operational Non-Operational Decision Diagram Review Determining Safety/Environmental, Operational & NonOperational Consequences Proactive Worth Doing Tasks Protective Devices

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Failure Management Strategies I & II and Implementation (Day 3 of 3) AM Understanding Proactive Tasks & Techniques for Age-Related & Random Failures Schedule Restoration Schedule Discard On-condition Default Actions Compulsory Redesigns (Safety or Environmental Implication) No Scheduled Maintenance Failure-Finding Tasks for Hidden Functions PM World Class Equipment Reliability Strategy Other Work ID Strategies Applying & Implementing the Process at ArcelorMittal Stage 15 Development Resources
IMTC-107, A-M maintenance curriculum and A/V materials.

Stage 15 Trainer/Hardware projections

(none)

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