Blueprint Reading: Fundamentals for the Water and Wastewater Maintenance Operator (Fundamentals for the Water and Wastewater Main Operator Series)

Experience has shown that when maintenance operators can understand and properly use blueprints and schematics they have little difficulty in correctly interpreting and using plant unit process drawings. Blueprint Reading bridges the gap between available training materials and the information water and wastewater maintenance operators need to know. It covers basic principles of blueprint reading and deals with principles and applications of schematics and symbols. Each chapter presents essential, practical knowledge vital to understanding and interpreting plant operations and that enhances the reader's ability to properly maintain plant systems. Experience has shown that when maintenance operators can understand and properly use blueprints and schematics they have little difficulty in correctly interpreting and using plant unit process drawings. Blueprint Reading bridges the gap between available training materials and the information water and wastewater maintenance operators need to know. It covers basic principles of blueprint reading and deals with principles and applications of schematics and symbols. Each chapter presents essential, practical knowledge vital to understanding and interpreting plant operations and that enhances the reader's ability to properly maintain plant systems. Blueprint Reading 2 Dedication 4 Preface 5 Table of Contents 7 Blueprint Reading 14 Part I: Blueprints 14 Chapter 1: Blueprints: The Universal Language 15 INTRODUCTION 15 1.1 GROPING IN THE DARK 16 1.2 BLUEPRINT STANDARDS 17 1.2.1 STANDARDS-SETTING ORGANIZATIONS 18 Blueprint Reading 28 Chapter 2: Basic Math Review 28 INTRODUCTION 28 KEY TERMS USED IN THIS CHAPTER 28 2.1 THE MAINTENANCE OPERATOR’S “TOOLBOX? 29 2.2 UNITS OF MEASUREMENT 31 2.3 FRACTIONS AND DECIMAL FRACTIONS 32 2.4 REVIEW OF BASIC MATH OPERATIONS 33 2.4.1 ADDITION 33 2.6.2 SUBTRACTING FRACTIONS 39 Blueprint Reading 49 Chapter 3: Alphabet of Lines 49 INTRODUCTION 49 KEY TERMS USED IN THIS CHAPTER 49 3.1 JUST A BUNCH OF DRAWN LINES? 49 3.2 VISIBLE LINES 50 3.3 HIDDEN LINES 51 3.4 SECTION LINES 51 3.6 DIMENSION AND EXTENSION LINES 52 3.7 LEADERS 53 3.8 CUTTING PLANE OR VIEWING PLANE LINES 53 3.9 BREAK LINES 54 3.10 PHANTOM LINES 54 3.11 LINE GAGE 56 SELF-TEST 57 Blueprint Reading 58 Chapter 4: Views 58 KEY TERMS USED IN THIS CHAPTER 58 4.1 ORTHOGRAPHIC PROJECTIONS 58 4.2 ONE-VIEW DRAWINGS 61 4.3 TWO-VIEW DRAWINGS 61 4.4 THREE-VIEW DRAWINGS 63 4.5 AUXILIARY VIEWS 65 SELF-TEST 66 Blueprint Reading 68 Chapter 5: Dimensions and Shop Notes 68 INTRODUCTION 68 KEY TERMS USED IN THIS CHAPTER 68 5.1 DIMENSIONING 68 5.2 DECIMAL AND SIZE DIMENSIONS 69 5.3 DEFINITION OF DIMENSIONING TERMS 70 5.3.1 NOMINAL SIZE 70 5.3.2 BASIC SIZE 71 5.3.3 ALLOWANCE 72 5.3.4 DESIGN SIZE 72 5.3.5 LIMITS 72 5.3.6 TOLERANCE 72 5.3.7 DATUMS 74 5.4 TYPES OF DIMENSIONS 74 5.4.1 LINEAR DIMENSIONS 75 5.4.2 ANGULAR DIMENSIONS 75 Blueprint Reading 79 Chapter 6: Machine Drawings 79 KEY TERMS USED IN THIS CHAPTER 79 6.1 UNDERSTANDING MACHINES AND MACHINE TOOLS 80 6.2 THE CENTRIFUGAL PUMP DRAWING SIMPLIFIED 80 6.2.1 THE CENTRIFUGAL PUMP 80 6.2.2 CENTRIFUGAL PUMP: DESCRIPTION 81 6.2.3 CENTRIFUGAL PUMP: COMPONENTS 81 6.3 PACKING GLAND DRAWING 82 6.4 SUBMERSIBLE PUMP DRAWING SIMPLIFIED 83 Blueprint Reading 87 Chapter 7: Sheet Metal Drawings 87 KEY TERMS USED IN THIS CHAPTER 87 7.1 SHEET METAL 87 7.2 DIMENSION CALCULATIONS 88 7.2.1 CALCULATIONS FOR ALLOWANCES IN BEND 88 7.2.1.1 Set-Back Table 88 7.2.1.2 Formulae Used to Determine Developed Length 90 7.3 HEMS AND JOINTS 91 SELF-TEST 92 Blueprint Reading 94 Chapter 8: Hydraulic and Pneumatic Drawings 94 INTRODUCTION 94 KEY TERMS USED IN THIS CHAPTER 94 8.1 HYDRAULIC AND PNEUMATIC SYSTEMS 94 8.1.1 STANDARD HYDRAULIC SYSTEM 95 8.1.2 STANDARD PNEUMATIC SYSTEM 95 8.1.3 HYDRAULIC AND PNEUMATIC SYSTEMS 96 8.1.3.1 Similarities 96 8.1.3.2 Differences 96 8.2 TYPE OF HYDRAULIC AND PNEUMATIC DRAWINGS 96 8.3 GRAPHIC SYMBOLS FOR FLUID POWER SYSTEMS 99 8.3.1 SYMBOLS FOR METHODS OF OPERATION CONTROLS 99 8.3.2 SYMBOLS FOR ROTARY DEVICES 99 8.3.3 SYMBOLS FOR LINES 99 Blueprint Reading 106 Chapter 9: Welding Blueprints and Symbols 106 INTRODUCTION 106 KEY TERMS USED IN THIS CHAPTER 106 9.1 WELDING DRAWINGS 107 9.2 WELDING PROCESSES 107 9.3 TYPES OF WELDED JOINTS 107 9.3.1 BUTT JOINTS 108 9.3.2 LAP JOINTS 108 9.3.3 TEE JOINTS 109 9.3.4 EDGE JOINTS 109 9.3.5 CORNER JOINTS 109 9.4 BASIC WELD SYMBOLS 109 9.4.1 SYMBOLS FOR ARC AND GAS WELDS 109 9.4.2 SYMBOLS FOR RESISTANCE WELDS 109 9.4.3 SYMBOLS FOR SUPPLEMENTARY WELDS 109 9.5 THE WELDING SYMBOL 111 9.5.1 REFERENCE LINE 112 9.5.2 ARROWHEAD 112 9.5.3 WELD SYMBOL 113 9.5.4 DIMENSIONS 113 9.5.5.1 Contour Symbol 114 9.5.5.2 Groove Angle 114 9.5.5.3 Spot Weld 114 Blueprint Reading 119 Chapter 10: Electrical Drawings 119 INTRODUCTION 119 KEY TERMS USED IN THIS CHAPTER 119 10.1 TROUBLESHOOTING AND ELECTRICAL DRAWINGS 119 10.2 ELECTRICAL SYMBOLS 120 10.3 ELECTRICAL VOLTAGE AND POWER 121 10.3.1 WHAT IS VOLTAGE? 121 10.3.2 HOW IS VOLTAGE PRODUCED? 121 10.3.3 HOW IS ELECTRICITY DELIVERED TO THE PLANT? 121 10.3.4 ELECTRIC POWER 122 10.4 ELECTRICAL DRAWINGS 122 10.4.1 TYPES OF ARCHITECTURAL DRAWINGS 122 10.4.2 CIRCUIT DRAWINGS 123 10.4.3 LADDER DRAWING 124 Blueprint Reading 127 Chaper 11: Air Conditioning and Refrigeration Drawings 127 INTRODUCTION 127 KEY TERMS USED IN THIS CHAPTER 127 11.1 AIR CONDITIONING AND REFRIGERATION 127 11.2 REFRIGERATION 128 11.2.1 BASIC PRINCIPLES OF REFRIGERATION 128 11.2.2 REFRIGERATION SYSTEM COMPONENTS 129 11.2.3 REFRIGERATION SYSTEM OPERATION 129 11.2.4 USING REFRIGERATION DRAWINGS IN TROUBLESHOOTING 129 11.2.5 REFRIGERATION COMPONENT DRAWINGS 131 11.3 AIR CONDITIONING 131 11.3.1 OPERATION OF A SIMPLE AIR-CONDITIONING SYSTEM 131 11.3.2 DESIGN OF AIR-CONDITIONING SYSTEMS 132 11.3.3 AIR-CONDITIONING DRAWINGS 133 SELF-TEST 133 Blueprint Reading 135 Part II: Schematics 135 Chapter 12: Schematics and Symbols 136 INTRODUCTION 136 KEY TERMS USED IN THIS CHAPTER 136 12.1 SCHEMATICS 136 12.2 HOW TO USE SCHEMATIC DIAGRAMS 136 12.2.1 SCHEMATIC CIRCUIT LAYOUT 139 12.3 SCHEMATIC SYMBOLS 139 12.3.1 LINES ON A SCHEMATIC 140 12.3.2 LINES CONNECT SYMBOLS 140 12.4 SCHEMATIC DIAGRAM: AN EXAMPLE 140 12.4.1 A SCHEMATIC BY ANY OTHER NAME IS A LINE DIAGRAM 142 12.5 SCHEMATICS AND TROUBLESHOOTING 143 Blueprint Reading 145 Chapter 13: Electrical Schematics 145 INTRODUCTION 145 KEY TERMS USED IN THIS CHAPTER 145 13.1 ELECTRICAL DRAWINGS 146 13.2 ELECTRICAL SYMBOLS 146 13.2.1 SCHEMATIC LINES 146 13.2.2 POWER SUPPLIES: ELECTRICAL SYSTEMS 147 13.2.3 POWER SUPPLIES: ELECTRONICS 149 13.2.4 ELECTRICAL LOADS 151 13.2.5 SWITCHES 151 13.2.6 INDUCTORS COILS 151 13.2.7 TRANSFORMERS 152 13.2.8 FUSES 154 13.2.9 CIRCUIT BREAKERS 154 13.2.10 ELECTRICAL CONTACTS 155 13.2.11 RESISTORS 155 13.3 READING PLANT SCHEMATICS 155 SELF-TEST 158 Blueprint Reading 161 Chapter 14: General Piping Systems and System Schematics 161 INTRODUCTION 161 KEY TERMS USED IN THIS CHAPTER 161 14.1 PIPING SYSTEMS 162 14.2 PIPING SYMBOLS: GENERAL 162 14.2.1 PIPING JOINTS 162 14.2.1.1 Screwed Joints 163 14.2.1.2 Welded Joints 163 14.2.1.3 Flanged Joints 163 14.2.1.4 Bell-and-Spigot Joints 164 14.2.1.5 Soldered Joints 164 14.2.2 SYMBOLS FOR JOINTS AND FITTINGS 164 14.2.3 VALVES 164 14.2.3.1 Valves: Definition and Function 165 14.2.3.2 Valve Construction 167 14.2.3.3 Types of Valves 167 14.2.3.3.1 Ball Valve 168 14.2.3.3.2 Cock Valve 168 14.2.3.3.3 Gate Valves 169 14.2.3.3.4 Globe Valve 169 14.2.3.3.5 Check Valve 170 14.3 HYDRAULIC AND PNEUMATIC SYSTEM SCHEMATIC SYMBOLS 171 14.3.1 FLUID-POWER SYSTEMS 171 14.3.2 SYMBOLS USED FOR HYDRAULIC AND PNEUMATIC COMPONENTS 172 14.4 AIR-CONDITIONING AND REFRIGERATION SYSTEM SCHEMATIC SYMBOLS 172 14.4.1 SCHEMATIC SYMBOLS USED IN REFRIGERATION SYSTEMS 172 14.4.1.1 Refrigeration Piping Symbols 172 14.4.1.2 Refrigeration Fittings Symbols 173 14.4.1.3 Refrigeration Valve Symbols 174 14.4.1.4 Refrigeration Accessory Symbols 174 14.4.1.5 Refrigeration Component Symbols 174 14.4.2 SCHEMATIC SYMBOLS USED IN AIR-CONDITIONING AND REFRIGERATION AIR DISTRIBUTION SYSTEMS 176 SELF-TEST 177 Blueprint Reading 178 Part II: Schematics 178 Chapter 15: Final Review Examination 178 Blueprint Reading 182 Appendix A 182 Chapter 1 182 Chapter 2 182 Chapter 3 183 Chapter 4 183 Chapter 5 184 Blueprint Reading 188 Appendix B 188 Maintenance operators that can understand and properly use blueprints and schematics have little difficulty in correctly interpreting and using plant unit process drawings. This guide covers basic principles of blueprint reading and deals with principles and applications of schematics and symbols.