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

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)

PLC - Programmable Logic Controllers

SCADA (supervisory Control & Data Acquisition System)

Auto CAD

Preparation for PWD license for ELECTRICAL CONTRACTOR

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

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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PROFILE

Prolific Certified Electrical Engineer