Training Certificate

Prolific Consultants FZE Certificate of Course Completion will be issued to all attendees.

Course Introduction

Owing to their important role in nearly all industrial processes, sizing and selection of new  equipment like thermal equipment (boilers, steam  heat exchangers, fired gas heaters), rotating equipment (pumps, turbines, gas and air compressors), are critical to both process efficiency  and investment. The course highlights the relation between processes demands and suitable equipment sizing and selection. The piping system design required for each equipment will be studied. The course presents the major types of these equipment and demonstrates their recent technological aspects for installation, operation, maintenance & troubleshooting.

Course Objective

1. To lay out the major types of process plant equipment and process variables
2. To illustrate methods of estimating processes plant demand, such as:
   1. Thermal energy and steam consumption
   2. Air consumption
   3. Boiler feed water treatment
3. Demonstration of advanced information in basic design issues for major equipment
4. To present the main requirements for installation and good operability concerning each type of equipment
5. To study  sizing  and selecting   of equipment properly
6. To clarify the vital role of different types of maintenance regimes in successful and continuous production operation
7. To present examples of troubleshooting through some case studies

Suitable For

Engineers of any discipline, managers, technician, technologists, and other technical personnel.

Training Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions, and motivate everybody find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences. Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work & Practical Exercises
• 20% Videos & General Discussions

Course Content

Boilers

• Boiler house
• Various types of boilers
• The ancillary equipment and their integral role in the safety of the boiler
• Correct operation, control procedures for the safe operation.
• Inspection and maintenance program
• Minimize forced outages and prevent serious damage to boiler equipment

Boiler water treatment

• Harmful effects from improper treatment.
• Sizing and selection of water treatment plant
• External and internal water treatment
• Boiler deposits &blowdown control.

Steam consumption

• Steam engineering principles and heat transfer
• Methods of estimating and measuring steam consumption
• steam consumption of plant items: tanks, vats,  air heaters and  heat exchangers

Steam distribution and condensate return

• Steam traps and steam trapping
• Pipeline ancillaries
• Condensate removal

Heat exchangers

• Main types of heat exchangers and their primary components
• Specifying design requirements and design of primary exchanger components
• Heat exchanger selection
• The heat load, heat exchanger and steam load relationship
• Oversized heat exchangers
• Practical methods of preventing stall
• Typical inspection procedures: locating leaks, tube inspection techniques, eddy current testing, ultrasonic  examination

ROTATING EQUIPMENT:

Pumps

• Pump types, characteristics and operation
• Classification of pumps
• Specific speed and pump type
• Sizing and selection of pumps
• Pump characteristics: head, capacity, power, efficiency, total system head and curves
• Centrifugal pump construction features
• Net positive suction Head (NPSH) and cavitation
• Pipe line design

Turbines

• Turbine types and applications
• Major components of a turbine
• Turbine design and construction
• Governor
• Lubrication, vibration analysis, bearing temperature
• Turbine control
• Erection of a turbine
• Turbine piping

Air Compressors

• Assessment of air consumption of plant
• Sizing and selection of compressor plant
• Selection of compressor ancillary equipment
• Compressor installation
• Main line installation
• Final service line installation

Processes control

• Basic Control Theory
• Control Hardware: Electric/Pneumatic Actuation
• Control Hardware: Self-acting Actuation
• Control Applications
• Safety Valves

Applying predictive maintenance regime

Maintenance and Inspection

Troubleshooting (case study)