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Training Event
 


  Prolific Certified Electrical Engineer
   
  1)   Topics Covered 

SN

Topic Description

1

Electrical Systems

2

PLC  (Programmable Logic Controllers)

3

SCADA

4

Auto CAD

5

Mechanical Systems

6

DCS Systems

 

Practical Workshops on above topics

   
1. Electrical Systems
  • Fundamentals of Electricity         
  • Electromagnetism
  • Electricity Generation & Distribution Fundamentals
  • Understanding Electrical Symbols and Single Line Diagram 
  • Hand Tools
  • Cables and Wiring
  • Electrical Measuring Devices and Testing
  • Electrical Distribution
  • L. V. Switchgear
  • Working with Electrical panels
  • Motors
  • Transformer
  • Electrical Safety
  • Workshop for the trade
  • Motor control using DRIVE (VFD)
2. PLC - Programmable Logic Controllers
3. SCADA (supervisory Control & Data Acquisition System)
4. Auto CAD

Preparation for PWD license for ELECTRICAL CONTRACTOR
5.

Mechanical Systems

Pumps

  • Defining pumping systems
  • Most important characteristics of a pumping system
  • Types of pumps
  • Positive Displacement family tree
  • Basic difference between Centrifugal and PD pumps
  • Rotary pumps
  • Market applications and Selection of  Pumps
    • Applications of PD pumps
    • General guidelines for pump selection
    • Pump characteristics v/s market applications
    • Application – High Viscosity, Low and variable viscosity
    • Application – Low shear pumping, Solids handling capability
    • Application – Multi-phase flow
    • Process Condition – High pressure
    • Process Condition – Low flow, Efficiency
    • Process Condition- Combination of high pressure / low flow and efficiency
    • Process Condition - Flow control
    • Environmental system requirements
  • Centrifugal Pump
    • Basics
    • Types (Construction  based)
    •  Construction of an impeller
    • Types of impellers
    • Seal chamber and stuffing box
    • Defining Suction Head
    • Capacity, Input horsepower, output horsepower, Efficiency
  • Pump Fundamentals
    • Pressure
    • Head v/s Pressure
    • Effect of specific gravity on Head
    • Kinetic energy
    • Design of volutes and flow patterns
    • Specific gravity and pump performance
    • Effect of fluid velocity
    • Gauge height correction
    • What is TDH and TH
  • Pump Performance parameters
    • Head-Flow characteristics
    • Power-Flow characteristics
    • Pump Efficiency
    • Efficiency v/s Flow
    • Net Positive Suction Head (NPSH) and its Characteristics
  • NPSH and Cavitation
    • Cavitation process
    • Cavitation damage
  • Preferred operating range of a centrifugal pump
    • Allowable operating range
  • Pump characteristic curves
    • Effect of RPM
    • System curves
      • System Head
      • Energy requirements to lift the fluid
      • Power required to lift the fluid
      • Static Head
      • Dynamic Head
      • Sources of Friction
      • Parameters influencing frictional losses
      • Standard Pipe Head Loss Tables
      • Calculating frictional losses
      • Frictional loss coefficients
      • Pipe lengths and associated Heads
      • Types of System Curves
        • System Curve – No control valve
        • System Curve – With control valve
  • Parallel pumps
    • Parallel pumping system
    • Parallel pumping system – Low friction
    • Parallel pumping – Mismatched pumps
  • Series pumping
  • Pump vibration
  • New generation pump example
  • How pumps get damaged – 10 Ways
  • Monitoring and Predicting Centrifugal Pump performance
    • If the pump  does not deliver enough water
    • If the pump does not deliver enough pressure
    • If the pump does not prime properly
    • If the pump is drawing too much amperage
    • Monitoring Wet end of the pump
      • Monitoring Stuffing box and Seal area
      • Monitoring Bearing case
  • Predicting pump performance
  • Preventive maintenance
    • Preventing bearing and seal failures
    • Good maintenance practices for seals and bearings
    • Recommended daily preventive maintenance checks for centrifugal pumps and drives
    • Recommended monthly and 6 monthly preventive maintenance checks for centrifugal pumps and drives
    • Recommended yearly preventive maintenance checks for centrifugal pumps and drives
  • Trouble shooting of centrifugal pumps
    • The pump is hooked up to the piping and it is running
    • The pump is still hooked up to the piping, but it is not running
    • The pump has been taken into the workshop, but has not yet been disassembled and you will be present at the disassembly
    • The pump has been disassembled. You were not present, but the parts are available for your inspection
    • Troubleshooting four possibilities of rub or wear marks
    • Centrifugal pumps – Troubleshooting guide
  •  Trouble shooting of Reciprocating Pumps
    • Pump storage tips
  • Alignments Techniques
    • What is coupling alignment?
    • Types of coupling
    • Co-linearity
    • Types of Misalignment
      • Offset, or Parallel
      • Angular
    • Measurement Conventions
    • Pre-alignment Steps
    • Alignment Tolerances
    • Thermal Growth Targets
    • Not correcting for soft foot
    • Not roughing in
    • Usage of shims
    • Not controlling backlash or unwanted movement
    • Incorrect sequence of moves
    • 4 steps of alignment
      • Angular misalignment in the Vertical Plane
      • Parallel Offset in the Vertical Plane
      • Angular misalignment in the Horizontal Plane
      • Parallel Offset in the Horizontal Plane
    • Things to watch if alignment still does not happen
    • A few helpful tips
  • Pump mounting
    • Foundations
      • Housekeeping pads
      • Inertia bases
    • Base plate selection
    • Foundation preparation
    • Base plate installation
    • Grouting
    • Pump and Motor Installation
    • Pipe Installation
    • Pipe strain
  • How to start a pump
    • Pump rotation
    • Motor Solo
    • Couplings
    • Other Startup Considerations
    • Pump Start up
    • Final Vibration Acceptance
  • Checklist
 

Compressors

  • 3 golden rules of Compressed Air usage
  • Compressed air system – Supply side and Demand side
  • Compressed air – One of the most expensive utilities on the shop floor
  • Inappropriate use of compressed air 
    • Open blowing
    • Sparging, Aspirating, Atomizing
    • Padding
    • Vacuum generation
    • Hand blowing
    • Unregulated End use
    • Abandoned equipment
  • Potential for energy saving
  • Overview of sub-systems and sub-components of a compressor system
    • Intake Air Filters
    • Compressed Air Filters
    • Why compressor cooling is required
      • Inter stage coolers
      • After coolers
    • Separators
    • Why air drying is essential
      • Air Dryers
      • Deliquescent air dryers
      • Refrigerated Air Dryers
      • Moisture drain traps
    • Air receiver
    • Lubrication
    • Heat recovery
    • Air distribution system
  • Types of compressors
  • Choice of compressors
  • Reciprocating compressor
    • Single acting air cooled
    • Double acting water cooled
  • Rotary compressor
    •  Single stage
    • 2 stage
    • Screw Compressors
      • Lubricant injected
      • Oil free
  •  Centrifugal air compressors
  • Compressor Prime Movers
  • Comparison of compressors
  • Capacity of a compressor
  • Calculating compressor efficiency
    • Isothermal efficiency
    • Volumetric efficiency
  • Leaks
    • Defining and Quantifying leakage
    • how to calculate leakage
    • Cost of leakage
    • Leak detection
      • Ultrasonic leak detection
    • How to stop leaks
  • Compressed air system performance opportunity roadmap
  • Air quality
  • Air quantity
  • Load profile
  • System pressure
    • Pressure drop and controlling system pressure      
    • What causes pressure drop ?
    • Minimizing pressure drop
    • Measurements necessary for pressure profiling a compressed air system
    • Stabilizing system pressure
      • Importance of Primary and Secondary Storage
      • Dedicated compressors
  • Control strategy
    • Matching Demand and Supply
    • System controls
    • Multiple compressor controls
    • Pressure/Flow controllers
    • Variable loads
  • Ensuring efficiency of compressed air end-use applications
  • Heat recovery and compressed air systems
    • Air cooled, rotary screw compressors
    • Water cooled compressors
  • Calculating cost of compressed power
  • The 7 step action plan to analyse and improve compressed air system
  • Tools needed for monitoring and base-lining compressed air system
  • Using Power, Pressure, and Flow to base-line System Performance and Energy Consumption
  • Maintaining air compressors
    • Lubrication
    • Cleaning
    • Belts
    • Air treatment equipment
    • Automatic traps
    • Point-of-use filters, regulators, lubricators
    • Shutting down for maintenance
    • Routine maintenance practices for various periodic frequency
  • Energy saving ideas for compressor air system
    • Energy saving concept – Usage of VFD

Reading nomenclature of compressors

  • Types of valves
    • Plate type
    • Finger type
  • Loading and Unloading characteristics of compressors
  • Types of unloading devices
  • Types of Drainage systems
  • Mounting
    • Horizontal
    • Vertical
  • Type of lubrication
    • Soft
    • Outside
  • Non lubricated compressor
  • Foundation
  • Condition monitoring
    • Temp analysis
    • Vibration analysis
    • Alignment analysis – axial and radial (laser based)
  • Preventive / Predictive maintenance
  • Breakdown maintenance
  • Trouble shooting
  • Checklist
 

Gear Box Systems

  • Type of gear box
  • Selection of gear boxes
  • Comparison of gears and their applications
  • Installation gear box system
  • Alignment
  • Back lash (use of filler gaugaes)
  • Starting of gear box system
  • Analysing gear box failure
  • Lubrication with various oils
  • Maintenance schedules of gear boxes
  • Condition monitoring
    • Bearing temp
    • Vibration
    • Back lash checking
    • Amps current to check load on the motor
    • Thermography

 Industrial Fans and Blowers

  • Types of industrial fans and blowers
  • Comparison and their applications
  • Selection criteria
  • Fan system characteristics
  • Fan performance evaluation
  • Air flow measurement and calculation
  • Methods to reduce air flow
  • Predictive and preventive maintenance
  • Condition monitoring techniques

 Bearings

  • Types of bearings
  • Selection of bearings
  • Bearing nomenclature and terminology
  • Types and techniques used for Mounting and dismounting of bearings
  • Industrial practices for Bearing Care
  • Safety during bearing mounting
  • Do’s and Don’ts of bearing usage and handling
  • Lubrication of bearings
  • Bearing life cycle

D G Set

  • Introduction
  • Why  Diesel Generator is required
  • Type of diesel generator
  • Parts of diesel generators
  • Starting procedure of a diesel generator
  •  Pre-starting checks
  • How to start DG set
  • After starting checks
  • Running parameters Stopping
  • Protection devices
  • Stopping procedure for a DG set
  • Trouble detection and trouble shooting
  • Why maintenance routine is required.
  • Maintenance routine of diesel generator set
  • Ill effects of under load running of a Diesel generator
  • Generator glossary
  • Preventive maintenance, shut down maintenance of DG sets
  • Condition monitoring of DG sets
6.

Distributed Control System  (DCS)

  • Introduction to control system
  • Applications of DCS system
  • Architectural evolution for DCS
  • Hardware architecture of DCS
  • Processor
  • Power supply
  • I/O modules
  • Communication bus
  • Operator and Engineering station
  • Redundancy
  • Comparison between the hardware PLC & DCS
  • Designing control system solution using DCS
  • Instrumentation and control
  • Detail engineering
  • General outlay
  • Earthing requirements
  • Communication bus system
  • Redundancy level
  • Standard codes and practices required at site
  • Training and documentation
  • Schedule of quantity
  • Engineering and software development
  • Practical exposure on Fisher Rosemount DCS system
  • Overview of Delta V System Components & Topologies
  • Detailed Information on Controllers, I/O Cards, Carriers, System Power Supplies,
  • Delta V Control Networks
  • Installation of Operating System & Delta V Software Components
  • Application development
  • Technical evolution / Comparison between leading DCS system

     (Yokogawa, Tata Honeywell, Fisher Rosemount)

  • Hardware architecture
  • I/O handling capabilities
  • Configuration and programming details
  • Operator and Engineering station
  • Processing speed
  • Redundancy
  • Communication bus
 
   
 

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