New Advanced Diploma of Plant Engineering...
Transcript of New Advanced Diploma of Plant Engineering...
ADVANCED DIPLOMA OF
PLANT ENGINEERING : MECHANICAL
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SmartBrains is the global market leader in providing high-level training services to the energy sector (Oil and
Gas, Petrochemical, Refinery, LNG, Power Plants, Fiscal, Contracts, Strategy & Finance and Leadership &
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graduates. Programs are designed by experienced high level Engineers/Managers and professionals as an
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ABOUT SMARTBRAINS
WHY SMARTBRAINS OUR STRATEGIC OBJECTIVES
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
SmartBrains is the ultimate choice for all the working and
non working engineers in energy sector training
requirements. Our extensive portfolio of energy training
courses are:
ü 100% focused on Oil & Gas industry.
ü Guided by the industry renowned professionals with
unprecedented knowledge of Oil & Gas industry
ü High interactive program with practical and relevant
case studies.
ü Training by extensively researched self developed
cutting edge techniques.
ü Skill development techniques with comprehensive set
of documentation, practical skills and tools used in the
industry.
ü Perfect opportunity to develop network and
experiences with knowledge sharing.
ü Internationally acclaimed engineering qualification.
ü Designed for both fresh engineers and working
professionals to attain growth in renewably industry
ü One of the finest international faculty.
ü Interactive, interesting and motivational training
sessions.
ü Access to enormous reference books and research
materials.
SmartBrains engineers and technologist Pvt Ltd. has received recognition, endorsement and affiliation from
National Skill Development Corporation of India (NSDC, a PPP initiative developed by Govt. of India) and
various Skill Sector Councils of India as an authorized training provider under various trades. SmartBrains is
authorized to provide skill based training for engineering/non-engineering candidates as per their interest.
SmartBrains as a training institute will provide complete practical knowledge based skill training to the
candidates, recognition & certification to the candidates will be provided by NSDC & Sector Skill Councils.
Students who successfully complete their certification from SmartBrains may be able to apply for recognition of
their qualification within the local education system. In general most countries will recognize that an “Advanced
Program” is a qualification that requires high level of knowledge (beyond bachelor's degree). Many countries
have a process for recognition of foreign qualification which is used by new residents when they have
qualifications earned overseas. You will be awarded by a National level certification approved & provided by
National Skill Development Corporation of India (A PPP promoted by Ministry of Skill Development &
Entrepreneurship, Govt. of India) which is broadly accepted & recognized across the globe. However, in many
cases formal individual recognition within the home country may not be required because the international
validity and affiliation of this credential is very sound. This certification is broadly accepted by many national
and international firms of various countries like Australia, New Zealand, United States, United Kingdom &
many more.
ACCREDITATION & AFFILIATION
The certification program is an intensive part-time program, conducted over a period of 6 months (For
particular module), unlike other universities or academic institutions, we operate almost all year
around.
PROGRAM STRUCTURE
1. Introduction of Plant Engineering
2. Plant Process Management
3. Mechanical Equipment and Technology
4. Process Plant Layout and Piping Design
5. Plant Operations and Facility Management
6. Heating, Ventilation and Air Conditioning
7. Maintenance Management
8. Environmental Engineering
9. Safety Management
The Program is composed of 9 Units: -
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
Since electric plant layouts is about more than
formats and outlines, Intergraph gives the most
adaptable, versatile, and effective suite of plant
designing assets outline for each part of a force
vegetation's cycle. With instruments for beginning
outline, development, upkeep, and that's only the
tip of the iceberg, it's no fortuitous event that more
than 60 percent of the plants worked far and wide
are composed with Intergraph programming.
Characteristics of electrical Process Plant
Engineering are: -
P 3D Modeling and visualization Solutions
P Engineering and Schematics
P E lec t r ica l Equipment Opera t ion and
Maintenance
P Engineering, Procurement and Construction
P Troubleshooting, O & M
P Risk Management
SmartBrains is the ultimate choice for all the
working and non working engineers in
energy sector training requirements.
Our extensive portfolios of training
courses are:
P 100% focused on Process Plant
Engineering.
P Gu ided by i ndus t r y r enowned
professionals with unprecedented
knowledge of process plant industry
P High interactive program with practical
and relevant case studies.
P Training by extensively researched self
developed cutting edge techniques.
P Skill development techniques with
comprehensive set of documentation,
practical skills and tools used in the
industry.
P Perfect opportunity to develop network
and experiences with knowledge
sharing.
P Internationally acclaimed engineering
qualification.
P Designed for both fresh engineers and
working professionals to attain growth
in process plant industry
P One of the finest international faculties.
P Interactive, interesting and motivational
training sessions.
P Access to enormous reference books and
research materials. sessions.
ABOUT PROCESS PLANT ENGINEERING
MECHANICAL/PIPINGPURPOSE
WHAT YOU WILL GAIN:P Skills and know-how in the latest technologies
in all aspects of Plant Engineering.
P Technical, commercial and operational
understanding for Plant Engineering.
P Understanding of concepts for operating
plant.
P Terminology and symbols used in plant layout
P Broadly accepted world class certification in
Plant Engineering technologies.
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
The program features real-world applications and
uses a blended approach involving interactive on-line
sessions, simulation software and self-study
assignments. For each topic you will have an initial
reading assignment (which will be provided to you in
E-format). There will be a course work or problems to
be submitted and in some cases there will be practical
exercises, using simulation software and remote labs
that you can easily do from your home or office.
In order to maximize the value to your training course and to further enhance the skills
developed, we provide all participants with a tool-kit to take back to the office. The tool kit
includes a set of comprehensive documentation supporting the course programme with notes, slides,
recommended further reading and extra material relevant to the course. Some relevant manual titles
are listed below:
BOOKS
Our approach to training combines Oil
& Gas industrial experts with practical
exercises and action planning that
provides real benefits and instills
positive change. Our training experts
developed best course content based
on current need of industry.
TRAINING METHODOLOGY MULTIMEDIA BASED CONTENTS
1. Fundamentals of Mechanical Engineering
2. Practical Mechanical Drives (Belts, Chains and Gears)for Engineers and Technicians
3. Troubleshooting, Maintenance and Protection of AC� Electrical Motors and Drives
4. Practical Balancing, Alignment and Condition Monitoring of Rotating Equipment
5. Practical Hydraulic Systems Operation and Troubleshooting
6. Practical Fundamentals of Heating, Ventilation and Air Conditioning (HVAC)
7. Practical Lubrication Engineering for Engineers and Technicians
8. Fundamentals of Process Plant Layout and Piping Design
9. Practical Pumps and Compressors Control, Operation, Maintenance and Troubleshooting
10. Practical Mechanical Seals - Selection, Maintenance and Troubleshooting
11. Practical Safe Lifting Practice and Maintenance
12. Practical Energy Efficiency, Design, Engineering and Auditing
13. Practical Hazardous Areas for Engineers and Technicians
14. Practical Project Management for Engineers and Technicians
PowerPoint presentations on: -
1. Process Plant Engineering
2. Process Plant Equipment & Technology
3. Process Plant Layout and Piping Design
4. Heating Ventilation and Air Conditioning
5. Plant Operation and Facility management
PRESENTATIONEmpirical examples of organizations' challenges and
opportunities. These provide genuine insight and learning by
questioning how they should respond to these topical issues
Simulation Exercises: - Some contents of our course require
participants to take part in simulation exercises, putting into
practice the knowledge gained.
Feedback and Assessment: - Course leaders will provide
constructive feedback and offer suggestions for
improvement.
CASE STUDIES:
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
Candidates will need to go through for on the job training for successful completion of training, industries are in
collaboration with Sector Skill Councils introduce your candidature for 6 months of on the job training in
process industries (Working Plants). It will provide you an advantage of live working process with your
instructor and fellow students upgrading your skills and refresh your knowledge. It will also provide you a
platform to learn for international industry experts interactive sessions will gain valuable insights into
international practice. Industry collaboration will add following advantages for the trainee.
£ Improved Quality as per industry norms.
£ Real life experience through industrial attachment, Hands-On training and field projects.
£ Teacher practitioners, faculty attachments to industry.
£ Rich pool of industrial workshops and manufacturing plants.
£ Immediate feedback on adequency, long term on graduate performance.
£ Better employment opportunities for trainees through sustained relationship.
£ Technology transfer, innovation to marketplace.
INDUSTRIAL LINKAGE
Reliance Industries Ltd.(jamnagar)
Sanmarg Projects Pvt. Ltd.
Haldor Topsoe India Private Ltd
Chemitech Engineers Pvt. Ltd.
Alstomprojects India Ltd
Kazstroy Service
Doosan Power System India Pvt. Ltd.
Punj Lloyd Ltd.
Jackson Engineers Ltd.
Indraprastha Gas Ltd
Green Leaf Engineering
Focus Energy Ltd
Woodgroup-PSN
Nuberg Engineering Ltd.
Dee Piping System
SS gas Labs Asia Pvt. Ltd.
Tulsa Gas Technologies
Flovel Energy Pvt. Ltd.
Voyants Solutions Pvt. Ltd.
Gs Engineering & Construction
ISGEC Heavy Engineering
Jaihind Projects Ltd
Multitex Engineering Ltd
C2C Technosoft Pvt. Ltd.
Hydro Therm Engineers Pvt. Ltd.
L&T Hydrocarbon Engineering Ltd
KSG Techno Services
KSJ Engineering Services
Goyal MG Gases Pvt. Ltd.
Worley Parsons
Simon India Ltd.
Voith Hydroprivate Ltd
IFP Petro Products
CLIENTS WE WORK WITH
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
UNIT: 1 INTRODUCTION OF PLANT ENGINEERING
Plant engineering & site selection
— Definition and organization of plant engineering
— Plant engineering function
— Principles of organization
— Organization structures
— Organizational prerequisites
Role Of the plant engineer
— Legal responsibilities
— Activities
— Knowledge areas
Consideration in site selection
— Environmental considerations
— Design considerations
— Site drainage
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
— Water supply and storage
— Treatment and discharge of sewage
Plant infrastructure requirement
— Environmental issues
— Services
— Ecology and pollution
— Emission control
On-site storage and distribution of fuel
— Types including solid and liquid
— Energy content
— Applications
— Distribution systems
— Delivery and storage facility
UNIT: 2 INTRODUCTION OF OIL & FAS INDUSTRY
AND EPC CONTRACT
General Industry overview and basic concepts
• Meaning of petroleum.
• Typical oil & gas company objectives.
• Typical oil & gas company activities.
• Industry streams.
• Typical organisation chart.
• Company structures.
Oil & Gas prospecting (Exploration)
• Geological prospecting.
• Geophysical prospecting.
P Seismic (2D and 3D) acquisition.
P Seismic processing.
P Seismic interpretation.
• Offshore and onshore seismic data acquisition.
• The seismic section.
• Stratigraphical cross sections.
• Reservoir mapping.
Oil & Gas production facilities
• Typical oil production facilities
• Artificial lift systems
• Crude treatment and processing
• Natural gas processing
• Typical LNG value chain
• Gas added value products
• Offshore facilities
What is an EPC contract
• How does the risk allocation on an EPC contract
compare to other construction contracts.
• To what extent does an EPC contract guarantee the
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
project essentials: a fixed price, time and quality.
• Why would you choose an EPC contract as opposed
to other forms of contract.
• Will the use of an EPC contract mean that the works
cost more.
• The bank ability of an EPC contract.
• The EPC contract within the overall structure of a
project: The various entities and the other project
documents.
• Split EPCs: Onshore/ Offshore.
• Different models for contract risk allocation.
• Contract jargon: Lump sum, turn-key, EPCM, EPCC.
cost-plus, reimbursable.
The tender & procurement process
• The procurement time-line: From inception to contract
finalisation.
• Procurement options: e.g. one or two stage
tendering,
preferred bidders.
• The way in which procurement regulations can estrict
and limit tendering options.
• Design development in the context of procurement:
Incorporating a Front End Engineering and Design
(FEED) stage.
• Transparency and comparison between tender
figures.
• Structuring the contract price: lump sum stage
payments and milestones.
The scope of works
• Ensuring that the scope of works achieves the owner's
objectives
• The reasons why changes are required to the scope
of works and what can be done to ensure that the
contractor takes the risk of the additional costs Risks
associated with the transition from the design to on-
site construction.
• The impact of unexpected site conditions on the
contractor's ability to construct the scope
• How should the contractor's design responsibilities
be defined.
• The need for the owner to approve the contractor's
designs and the degree to which this will lessen the
contractor's single point responsibility
• What is the appropriate level of construction and
design risk for the contractor to take.
UNIT: 3 PLANT EQUIPMENT (MECHANICAL)
— Special design considerations
�P Elevated temperature service
�P Hydrogen resistance
�P Fracture toughness and impact requirements
�P Joining dissimilar metals
�P Refractory Linings
STATIC EQUIPMENTS:
Pressure Vessel Design & Maintenance
— Basic pressure vessel concepts:-
�P Main pressure vessel components.
�P Primary pressure vessel process functions .
— Materials of construction for pressure vessels:-
�P Factors that affect material selection.
�P Determining maximum allowable stresses.
�P Material selection requirements.
— Specifying design requirements for pressure vessels:-
�P The ASME code in pressure vessel design.
�P Specifying design conditions and loadings.
�P Vessel component thickness design criteria.
�P Design calculations for pressure vessel
components.
�P Design of pressure vessel supports.
Material Selection Considerations
Pressure Vessels
— Material Selection Factors:-
�P Material types.
�P Mechanical properties.
�P Environmental effects.
�P Fabricability.
�P Cost and availability.
�P Process contamination.
�P Reliability.
— Metallurgy and application of alloys:-
�P Alloy classes.
�P Carbon steel.
�P Low alloy steels.
�P Stainless steels.
�P Typical product forms.
�P Typical material selections.
— Material standards and specifications:-
�P Industry standards.
�P Carbon steel selection.
�P Low-alloy steel selection.
�P Stainless steel selection.
�P Non-ferrous materials.
— Fracture toughness:-
— Fabrication, inspection, and testing of pressure
vessels:-
�P Evaluating fabrication drawings for acceptability.
�P Inspection and testing requirements.
Pressure Vessel Maintenance
— Pressure vessel integrity program:-
�P Overall risk assessment.
�P Inspection plan.
— Fitness-for-Service Assessments
�P Overview of API RP 579 requirements
�P Data requirements
�P Assessment methods and acceptance criteria
— API-510 requirements:-
�P Scope.
�P definition.
— Pressure vessel inspection practices:-
�P Causes of vessel deterioration.
�P Inspection intervals.
�P Corrosion rate determination.
— Evaluating corroded pressure vessels for continued
operation:-
�P Determining minimum actual thickness
�P Acceptability of corroded area
— Brittle fracture assessment:-
�P Fracture toughness determination
�P Brittle fracture evaluation of existing equipment
— Details for welded repairs and alterations
�P Classification of repairs and alterations
�P Welding and design requirements.
�P Defect repairs.
— Re-rating pressure vessels.
— Changes to original design conditions.
— Hydrotest requirements.
Heat Exchangers Design & Maintenance
— Main types of heat exchangers and their primary
components:-
�P TEMA-type.
�P Air-cooled.
�P Double-pipe.
�P Plate-and-frame.
— Primary process functions of heat exchangers.
— Principal applications and limitations of shell and-tube
and air-cooled heat exchangers .
— Primary factors affecting heat transfer duty
— Specifying design requirements
— Design of primary exchanger components
�P Girth flanges.
�P Pass partition gaskets.
�P Flat channel cover.
� P Tubesheets.
� P Internal floating heads.
� P Tubes.
� P Pass partition plates.
� P Non pressure-containing parts.
— Vibration considerations:-
� P Causes of vibration.
� P Possible types of damage.
�P Design and operating parameters affecting
vibration.
� P Potential solutions to vibration problems
— Maintenance and repair:-
� P Evaluating the suitability of corroded components.
� P Typical maintenance and inspection procedures
���î Locating leaks
���î Leak repairs
���î Retubing considerations
���î Typical cleaning methods
���î Tube inspection techniques
���î Rerating exchangers
Fire Heaters Design & Maintenance
— Common fired heater designs.
— Combustion basics:-
� P Simple combustion equations
� P . Adiabatic flame temperature
� P Flammability limits and minimum oxygen
concentration.
� P .�Gas fuels
� P Liquid fuels/atomization.
� P Flue gas composition.
� P Carbon monoxide issues.
� P NOX issues.
� P Emissions
— Efficiency:-
� P Excess air.
� P Natural draft.
� P Heat recovery.
� P Air leakage.
—�Furnace construction:-
� P Casing.
� P Refractory and purpose
� P Stack and use with natural draft burners
� P Radiant tubes
� P Convection coils (plain and finned)
—�Heat transfer basics:-
� P Outside tubes.
���î Radiant heat transfer
���î Convective heat transfer.
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
���î Effect of excess air level.
�P Inside tubes.
���î Convective heat transfer.
���î Boiling (steam generation).
Storage tanks design & maintenance
— Storage tank types and features:-
P Tank types and functions.
P Primary components.
P Appurtenances.
P Design specifications.
— Material Selection:-
P Material property considerations.
P Acceptable material specification.
— Mechanical design requirements.
P Mechanical design parameters.
P Shell thickness determination.
P Wind girder requirements.
P Nozzle design details.
P Roof requirements.
P Bottom requirements.
P Designing tanks for small internal pressures.
P Optional design basis for small tanks.
P Elevated temperature storage tanks.
P Austenitic stainless steel storage tanks.
— Fabrication details:-
P Types of welded joints.
P Welding methodology.
P Weld detail requirements.
— Inspection and testing requirements:-
P Types of weld defects.
P Inspection methods.
P Inspection requirements.
P Dimensional/tolerances·
P Testing
— Vents and fire protection systems:-
P Vents for fixed roof tanks.
P Vents for floating roof tanks.
P Fire protection systems.
— Storage tank maintenance:-
P Tank inspection.
��î Objectives.
��î Prioritization.
��î�Inspection frequencies.
��î Record keeping.
��î Inspector qualification
P Tank component evaluation.
��î Shell.
��î Bottom.
��î Nozzles.
��î Roof.
��î Foundation
��î Shell and bottom settlement
P Leak detection methods.
P Tank repair and alteration.
��î General considerations.
��î Material considerations.
î General requirements for repair and alteration
î Removal, repair, and replacement of shell plate
material.
��î Repair, addition, replacement, and alteration of
shell penetrations.
��î Repair of tank bottoms.
��î Tank roof repair.
P Dismantling and reconstruction
��î Dismantling methods.
��î Reconstruction.
��î Dimensional tolerances.
P Examination and testing.
��î General.
��î Welding inspection.
��î Hydrostatic testing.
ROTATING EQUIPMENTS
Pump technology–design, operation &
maintenance
— Pump types and terminology:-
P Pumps.
P Pump terminology
P Pump types.
—Centrifugal pumps:-
P Centrifugal pump theory.
P Operating characteristics.
P Centrifugal pump operation.
P Types of centrifugal pumps.
P Parts of centrifugal pumps.
—Centrifugal pumps (continued) .
P Factors affecting performance.
P Troubleshooting centrifugal pumps.
P Inspecting centrifugal pumps components for
wear.
P Centrifugal pump overhaul.
— Positive displacement pumps.
P Reciprocating pumps.
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
P Rotary pump theory and operation.
P Special purpose pumps: metering pumps,
plunger pumps, diaphragm pumps, rotary
metering pumps.
— Packing and mechanical seals:
�P Compression/molded packing.
�P Mechanical seals.
�P Dual mechanical seals.
�P Gas seal application to liquid pumps.
— Bearing care and maintenance:
�P Basic concepts of bearings.
�P Bearing classifications.
�P Bearing care and maintenance.
—Couplings and alignment:
�P Purpose of couplings.
�P Types of couplings.
�P Alignment methods.
— Installation Design:
P location.
P Baseplate.
P Tolerances.
P Suction & discharge piping.
P Bypasses.
P Piping loads
P Handling & storage
— Pump operation:-
P New or overhauled pump startup
P Starting & stopping.
P Monitoring operation and performance.
— Valves and piping systems:
P Valves used in pump applications.
P Valve characteristics.
P Valve sizing and loss minimization.
P Valves vs variable speed drives.
— Pump drivers:
P Electric motors - design, controls, standard
motors, variable frequency drives,
maintenance.
P steam turbines – mechanical drive turbines,
application ranges, maintenance.
— Troubleshooting:
P Fundamentals.
P Symptom/cause matrix.
P Questions and answer session.
Compressor Design, Operation, and
Maintenance
— Introduction to compressor types:
�P Centrifugal, axial, reciprocating, helical
screw, ranges of application and limitations,
selection considerations.
—�Mechanical design of centrifugal compressors
P Compressor side streams, rotors, balancing,
rotor dynamics, impellers, casings, bearings,
seals, couplings, controls.
—�Design and materials of reciprocating
compressor components:
�P Design and materials, design of non-
lubricated compressors, piston rod and frame
loading, distributing forces and balancing.
—Basic Compressor Parameters:
P�Thermodynamics, capacity, power,
efficiencies, gas properties, inter cooling.
— Selection of centrifugal and reciprocating
process compressors
P Calculation methods, characteristic curves,
stability.
— Turbo-compressor train operation, inspection,
maintenance, overhaul and repair - IMO&R:
P�IMO&R planning, execution , documentation,
troubleshooting
—Operation and maintenance of reciprocating
compressors”-
P Lubrication and lubrication systems, valves,
valve problems and rebuilding, packing and
packing problems, non-lubricated
compressors, controls and cooling systems.
—Overhaul and repair of reciprocating
compressors.
�P Methods of repair and overhaul, alignment
and piston rod run-out, foundation problems
and repair, component repair and rebuild.
—Predictive vs. Preventative maintenance (PDM vs
PM) technique - reciprocating compressors:
P Types of maintenance programs, purpose of
pm, inspection and inspection forms, vendor
and contractor requirements, planning and
implementation.
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
—�Basic approaches to machinery
troubleshooting
P Troubleshooting compressor problems: typical
problems and solutions diagnostic tests,
compressed air system evaluation.
—Safety in compressor operation and
maintenance:-
P Basic safety rules, safety devices and
shutdowns, safety maintenance procedures.
—Machinery reliability audits and reviews:
P Overview, reliability impact on plants.
Steam Turbine Design, Operation, and
Maintenance
—Steam turbines:-
�P Operating principles, impulse turbines,
reaction turbines, application ranges,
configurations, application constraints
—Turbine components:-
P Turbine rotors, blading, diaphragms, nozzles,
steam chests, glands and gland systems,
bearings, balancing, rotor dynamics,
governing systems, lube oil management.
—Overview of selection and sizing of steam
turbines for reliability:
P Thermodynamics, steam (water) rates,
condensing and back pressure turbines,
single and multistage types, process
considerations
—Operation and maintenance of steam turbines:
P Commissioning, start-up, run-in and shut-
down, surveillance and health monitoring,
performance measurement, monitoring and
tracking, steam turbine washing, steam
turbine inspection, maintenance, overhaul
and repair (IMO&R).
—Basic approaches to machinery troubleshooting:
P Examples from recent failure incidents
attributed to design defects, processing and
manufacturing deficiencies, assembly errors,
off-design or unintended service conditions,
maintenance deficiencies etc.
—Predictive vs. Preventive Maintenance
Techniques.
P Determination of which method to use
— Machinery reliability audits and reviews:
P Overview, reliability impact on plants.
Mechanical Seals, Selection, Operation
and Maintenance
—Basic principles of mechanical seals:-
P Principles of operation.
P Thermal considerations.
P Maintaining the fluid film.
—Design and types:-
P Design – overview.
P Types – overview.
P Seal classification.
P Seal designs.
—Metal bellows and pusher seals:
P Three views of the bellows seal.
P Convolutions.
P Comparison of bellows with pusher seals.
P Welded bellows materials.
P High temperature sealing.
P Cartridge seals.
—Seal environment.
P Sealing abrasives.
P Sealing crystallizing fluid.
P Sealing hot water.
—Mechanical seal selection:-
P Materials of construction.
P MS specifications.
P Seal arrangement selection.
P Secondary sealing devices.
— Seal design audit.
—Seal installation.
P Measuring seal faces.
P Secondary/auxiliary sealing devices .
—Gas seals technology:-
P Selection.
P Auxiliary systems.
—Mechanical seal failure analysis.
— Mechanical seal standardization/consolidation
P Principles.
P Examples.
—Controlling fugitive emissions from MS.
—Seal calculations.
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
P�Leakage potential calculations.
P Analyzing flashing between seal faces.
P Calculating heat generation.
P�Balance calculations.
P Changing balance ratios.
—Mechanical seal execution examples:
P�Ethylene product pump seals.
P Hot tar pump tandem seal.
P Gear pump double seal.
P Sundyneâ compressor seal.
—ANSI/API 682 seal specifications.
—Alternatives to mechanical seals.
Machinery Failure Analysis and
Prevention
—Failure analysis and troubleshooting:
P Causes of machinery failure.
P�Contributing factors often overlooked.
—Metallurgical failure analysis methodology:
P Failure analysis of bolted joints.
P Shaft failures and their origins.
P Ductile vs. Brittle failures and stress raisers.
P Redesign opportunities.
—Machinery component analysis and reliability
improvement:
P Wear failures
P Couplings, bearings and gear failure
analysis.
— Machinery component analysis and reliability
improvement (continued):-
P Mechanical seals and o-ring failures –
selection strategies.
— Machinery component analysis and reliability
improvement (continued):-
P Machinery lubrication management
(economics & optimization).
— Vendor selection and reliability review methods:-
P Why reliability reviews are justified.
P Centrifugal pump selection examples.
— Vendor selection and reliability review methods
(continued):
P Compressor reliability review examples.
— Machinery troubleshooting:-
P The matrix approach to machinery
troubleshooting (for pumps, compressors, fans,
turbines, and others).
P Examples from Litigation Cases.
— Vibration analysis - a management overview:
P Specific machinery problems.
P Monitoring and analysis methods.
P Future outlook.
— Structured problem solving sequence:-
P Situation analysis.
P Cause analysis.
P Action generation.
P Decision making.
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
UNIT: 4 PROCESS PLANT LAYOUT AND PIPING DESIGN
Piping System Design:
—Overview of piping codes& standards :
�P Process plant piping and ASME B31.3
�P Liquid transportation piping and ASME B31.4
�P�Gas transmission piping and ASME B31.8
P�General comparison of ASME B31.3, B31.4,
and B31.8
— Piping Materials and Material Specifications.
�P�Material properties.
�P�Classification of materials.
�P�Material specifications (ASTM).
�P�Common piping materials
—Pressure design of pipe and piping system components
�P Introduction
�P Straight pipe
�P Curved sections
�P Branch connections
�P Pressure ratings of pipe fittings
— Pipe Hydraulics & Line Sizing
�P Flow rate, velocity, pipe sizing calculations
�P Reynolds number- laminar/turbulent flow
�P Darcy weisbach & hazen William equations
�P Pressure drop calculations, NPSH calculations
— Piping System Studies
�P Drum piping, pump piping, compressor piping,
heat exchanger piping, column piping, tank farm
piping, underground piping, pipe rack piping
Process Plant Layout: Piping Design & Drafting
— Flow Diagrams.
�P Block flow Diagrams-BFD,
�P Process Flow Diagram – PFD.
�P Utility Flow Diagram- UFD,
�P Piping & Instrumentation Diagram – P & ID.
�P Line Numbering,
�P Line Number requirements,
�P Instrument types & symbols – flow, temp, pressure
& level.
—�Plant Layout: Plot Plans:-
�P Plant layout specifications .
�P Codes and safety considerations
�P Development of plot plans
�P Plot plan use by disciplines
P Sample plot plans and equipment arrangement
drawings
P Layout case studies
— Plant Layout: Piping Layouts
P Equipment lists.
P Piping line lists.
Fundamentals of Pipe and Pipe Fittings
:Standards, Selection, Application, Drawing
Symbols & Dimensioning
— Definition & application of pipe
— Pipe designators-IPS, NPS, NB/DN
— Pipe wall thickness-schedule number, pipe weight.
— Pipe-lengths, ends, joining method, manufacturing
methods.
— Pipe symbols:-
P Pipe fittings .
P Elbows.
P Tees.
P Reducers.
P Coupling .
P End caps .
P Fitting dimensions and tables.
Piping system components: standards,
selection, application, drawing symbols &
dimensioning.
— Flanges, Gaskets, and Bolting:
�P Introduction.
�P Flange types
�P Flange standards and ratings
�P Gaskets.
�P Bolting.
— Valve Selection:
�P Introduction.
�P Valve functions and applications.
�P Valve types.
�P Valve stem packing.
�P Valve selection procedure.
�P Valve inspection and testing.
— Pipe hangers & supports:
�P Classification of supports.
�P Anchors, pipe guides, limit stops.
�P Pipe shoe dummy leg / trunion.
�P Field support / base support.
�P Rigid hangers rod & clevis, trapeze.
�P Flexible hangers variable & constant.
�P Pipe rack design types, height & width
calculations.
— Pipe Manufacturing Processes and Material Selection:
�P Introduction.
�P Pipe manufacturing processes.
�P Applicable standards for pipe and piping System —
components:
�P Material selection considerations.
�P Piping specification.
P Piping Plan Development.
P Preparing Piping Layout Drawings by placing
instruments, valves etc.
P Rack Piping.
P Pipe rack spacing, drawing pipe in the rack etc.
— Equipment Layouts
P Equipment data sheets
P Equipment foundations and supports
P Equipment sketches
P Equipment drawings
P Equipment nozzle specifications
P Equipment foundation drawings
—�Piping Isometrics
P Definition
P Piping Isometrics Drawin
P Isometric dimensions, notes & callouts.
P Isometric offsets, print reading exercises.
P Exercises on creation of Isometrics from.
P Piping plans and sections.
—�Piping Spools:-
P Definition
P�Types of spool drawings.
P Guidelines to Prepare Spool Drawings.
P�Print Reading Exercises.
P Exercises on creation of piping spool from piping
isometrics.
P�MTO (Material Take Off): Types, and
applications.
Plant Layout : 3D Modelling – Plant Design
Management System (PDMS)
—�Equipment Modeling
P Creating Equipment by using primitives
P Creating Equipments by using PDMS standards
catalogue.
P Creating Obstructions
P Manipulation of primitives &equipment
P Nozzles placements & manipulations
P Understanding parameters & attributes
P DB Utility
—�Pipe Design
P� Pipe & Branch creations
P� Pipe Routing & Slope piping
P Manipulating Piping components & Assemblies
P Checking Data consistency
P Checking & rectifying classes
P Locating Supports & deciding Supports span
P Generating text reports like Line & Supports Lists
—�Draft
�P�Preparing Layouts by using Draft modules
�P�Creating Views
P�Amotion& Dimensioning
—�ISO Draft
P Extracting Isometrics
�P�Preparing Isometrics for Fabrication & Erection
Piping Maintenance
— Piping Materials and Modes of Failure
�P�Materials Considerations
�P Corrosion Rate and Remaining Life Calculations
�P�Cracking Mechanisms in Piping
�P Piping Deterioration
— Piping Inspection and Evaluation
�P API-570 Requirements
�P Piping Inspection Planning and Data Analysis
�P Inspection techniques for piping and components
�P�Piping Retirement
�P Pipeline inspection and maintenance requirements
�P Pipeline defect evaluation and requirement criteria
— Piping system repair, alteration, rerating, and
pressure testing
�P�Valve Repair and Maintenance
�P API-570 piping repair, alterations, rerating, and
testing requirements
�P Piping System Repair
�P Process plant piping system alterations and rerating
�P�Pressure testing after repairs or alterations to
process plant piping systems
—�Flange Joint Assembly and Bolt Up Procedures
�P introduction
�P Establish Flange Joint Categories
�P Identify and List Flange Joints in Critical Services
�P Determine Required Bolt Type and Material
�P Select Bolt Tightening Method
�P Develop flange joint assembly and bolt up
procedures.
�P Procedure qualification.
�P Crew qualification.
�P Hot bolting.
�P Additional leakage control procedures.
—�Guidelines for hot tapping (pressure tapping):-
�P Necessary Conditions for Performing a Hot Tap.
�P Hot tap design considerations.
�P Selecting the Hot Tap Site.
�P Installation.
�P Inspection.
�P Pressure tests before cutting pipe.
�P Hot tap operations.
�P Special safety considerations.
�P Hot tap machines.
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
UNIT: 5 HEATING, VENTILATION AND AIR CONDITIONING
HVAC System Types, Design And Operation
— Design and operation.
— System design.
— System operation.
— Heat pumps.
HVAC System Types
— All-air systems.
— All-water systems.
— Air-water systems.
Fundamentals Of Noise And Vibration
— Introduction to acoustics.
— Vibration basics.
— Fundamentals of human response to sound and
vibration.
— Noise and vibration control.
Vibration Monitoring And Analysis
— Vibration analysis as a predictive maintenance tool.
— Fault detection and diagnosis using vibration
analysis.
— Vibration monitoring and analysis techniques.
Troubleshooting Mechanical System Faults
And Diagnosing Failures
— Typical problems affecting mechanical equipment.
— Fault indicators.
— Diagnosing failures.
— Mechanical troubleshooting techniques.
HVAC Fundamentals
— Properties of solids, gases and water.
— Force, work, power, energy calculations.
— Heat and temperature.
— Change of phase.
— Pressure.
Psychometric Charts
— Density, specific volume, and mass flow Psychometric
Chart.
— Development of the psychometric chart.
— Physical and thermodynamic properties of air.
— Measurement of wet and dry bulb temperature of air.
— Calculations.
Design Conditions
— Outdoor climate considerations.
— Indoor comfort considerations.
Cooling Load Calculations
— Heat flow through structures.
— Infiltration and exhilaration.
— Solar heat gains.
— External heat gains.
Indoor Air Quality
— Central air conditioning systems.
— IAQ definition.
— Effects on occupants.
— Basic investigation techniques.
— Architectural, engineering and interior design.
— Choices for good IAQ.
— The design process.
— The construction phase.
Facility Emergency Preparedness
— Planning, definitions and threat assessment.
— Command, control and communications.
— Emergency preparations and training..
— Emergency response and recovery.
Facility Security Management
— Facility security goals and responsibilities.
— Facility security and planning.
— Facility security implementation.
Operations And Maintenance
— Administering the department.
— Managing Quality facilities.
— Managing the Budget.
— Communications.
— Information systems and other technologies.
Background And Organization Of The Facility
Management Function
— The nature of facility management.
— Organization of the facility management department.
— Facility management leadership.
Planning, Programming And Budgeting
— Strategic and annual planning.
— Financial management.
— Planning and management of space.
Facility Management: Sustainability
— Definitions, background and application of
sustainability.
— Sustainability in practice.
— Sustainability financials, acceptance, and
implementation.
Facility Management: The Design-build Cycle
— Project Management.
— Programming and project development.
UNIT: 6 PLANT OPERATIONS AND FACILITY MANAGEMENT
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
UNIT: 7 MAINTENANCE MANAGEMENTPlanning And Scheduling Outages
— Scheduling considerations and requirements.
— Proper scheduling of resources and materials.
— Priority system and equipment criticality.
— Maintenance schedules.
— Managing maintenance backlogs.
Maintenance Practice. Strategies, Tools And
Techniques
— Approaches to maintenance.
— Types of outages.
— Maintenance plans, tools and techniques.
— Standard maintenance practices.
— Choosing the right maintenance strategy.
Key Performance Indicators
— Performance measurement.
— Evaluating maintenance effectiveness.
— Reporting and use of key performance indicators.
Reliability Centered Maintenance
— Introduction to RCM.
— Plant registration.
— Function and failure.
— Preventive action.
— Organizing and controlling proposed tasks.
— Implementation of RCM.
Maintenance Objectives And Principles
— Effective management of maintenance operations and
resources.
— Measures for achieving maintenance objectives.
— Key maintenance principles.
Role Of Maintenance In The Upkeep Of Plant
Machinery And Equipment
— Primary role of maintenance.
— Benefits associated with best maintenance practices.
Asset Management
— Identifying, classifying and prioritizing assets.
— Location and types.
— Maintenance strategies for various categories of assets.
— Managing assets by criticality.
Maintenance Planning
— Planning needs and objectives.
— Planning for resources.
— Maintenance budgeting.
— Implementing the maintenance plan.
— Maintenance inventory.
— Reasons for planning failures.
— Benefits of planning.
Indoor Air, Dust And Waste
Indoor Air Quality
— Air pollution.
— Typical effects on occupants.
— Design choices for good IAQ.
Properties And Effects Of Dust
— Common sources of pollution from dust.
— Common components of dust.
— Prevention and control.
Waste Disposal
— Solid waste disposal.
— Liquid waste disposal.
Health And Safety Management
— Environmental management systems and their
implementation.
— Radiation and toxicity.
— Dealing with toxic hazards.
UNIT: 8 ENVIRONMENTAL ENGINEERING
ADVANCED DIPLOMA OF PLANT ENGINEERING : MECHANICAL
Safety Of Personnel
Safety Considerations In The Workplace
— Need for workplace safety programs.
Implementing Safe Practices And Safety
Measures
— Workplace safety programs and their purpose.
— Responsibility for workplace safety programs .
— Identifying, assessing, monitoring and reviewing
risks.
— Best practices.
Ensuring Health And Safety Of Personnel
— Safety hazards and health – an overview.
— Healthy workplace initiatives.
— Legal framework.
Safety And Management Plans
Role Of Safety In The Success Of A
Maintenance Plan
— Symbiosis of safety and maintenance.
— Safety co-relation with planned and reactive
maintenance procedures.
Putting In Place An Effective Safety
Management Plan
UNIT: 9 SAFETY MANAGEMENT
— Elements of a good safety management plan.
— Implementation of an effective safety plan.
Fire Protection And Prevention
— Underlying causes of fire in a facility.
— Fire risk management.
— Fire protection equipment.
— Fire control.
— Fire detection and suppression systems.
NOIDA OFFICE:
H-86, Sector-63, Noida - 201301
Land Mark: Behind Haldiram
Phone : +91-120-4104991-94; +91-989 110 8700
VADODARA OFFICE:
9, Helix,Complex, Opp. Hotel Surya,
Sayajigunj, Vadodara - 390020
Email : [email protected]
Phone : +91-265-6595620/21; +91-33033791/92
HYDERABAD OFFICE:
6-3- 680/403, 4 floor, Regency House,
Somajiguda, Hyderabad - 500 082
Phone : +91-9703751174; +91-9703132211
PUNE OFFICE:
30(1),(3), 2nd Floor, Premanjali
Complex, Opp. Ellora Palace,
Dhankawadi, Pune - 411043
Phone :+91-9860626494; +91-9650276387