new advanced diploma of plant engineering...

ADVANCED DIPLOMA OF

PLANT ENGINEERING : MECHANICAL

www.smartbrains.in

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 &

Management). Operating nation wise over the last 8 years, our courses are widely acknowledged within the

energy community for quality and up-to-date information. Our success and distinguished reputation is down

to our commitment to the industry, a high-level of expertise, sector knowledge, cultural diversity and

experience that comes from organising many courses.

SmartBrains Institute provides premium training courses for energy industry executives and fresh engineering

graduates. Programs are designed by experienced high level Engineers/Managers and professionals as an

option to broaden their skill sets to include management tools and techniques that are applicable to various

profiles in renewable energy industries. Our success and distinguished reputation is thanks to our

commitment to provide first-class programmes to our clients. Combining leading professionals from across the

industry as lecturers and an interactive, practical format, the lessons learnt in a SmartBrains for energy course

are directly transferable back to the workplace.

To be recognized by industry and employers as

a highly reputable training organization.

P rov ide dynamic l eader sh ip , sound

management and excellence in training.

Continue to improve our services through

quality management processes. Invest in and

value our people through professional

development activities, Grow our business

through innovation and to continue to be

financially secure. Be influential in the

economic development of the industries we

serve nation wise.

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: -


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.


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:


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


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


— 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


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.


��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.


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.


—�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.


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.



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.



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


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


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

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