troubleshooting.pdf

Centrifugal Compressors and Steam Turbines

Operation / Maintenance and Trouble Shooting 5 Day Training Programme

Course Director Dr.G.G.Rajan Kochi – India

ABOUT THE TRAINING PROGRAMME

This training programme covers a study of gas compression and

expansion laws applied to industrial processes . this covers theory, practice and

troubleshooting applications of the different types of rotating machines such as

compressors and steam turbines, usually encountered in plants, and their related

aspects.

The objective of the programme is to provide a practical and experienced

based approach to the problems posed by compressors and turbines and the

means to solve them. With the knowledge gained in this programme, the

participants shall be able to analyze the operating parameters and strive to

improve the performance of these rotating machines.

Last but not the least, the programme content will be a very valuable for

those who are interested in improving the energy efficiency of their equipment

and reduce operating costs.

Participants for the programme are those involved in operation,

maintenance, process design, project and inspection engineers who are

involved in compressor and steam turbine units.

Certain case studies and clippings will be covered during the programme

for the benefit of the participants.

Dr.G.G.Rajan

Course Director

Kochi / India

CONTENTS

CENTRIFUGAL COMPRESSORS and STEAM TURBINES

Theory of compression

Ideal gas equation and practical application

Isentropic, polytropic, isothermal compression

Calculations mass and volume capacity

Practical compression laws

Discharge temperature

Power for compression

Characteristic curves

Steam Turbine Velocities triangle

Impulse, reaction, type of blades

Mach number: effect on temperature, pressure and density; subsonic and

supersonic machines

Dimensionless coefficients, specific speeds

Axial and centrifugal compressors Parts of compressors

Seals / sealing for compressors

Characteristic curves: invariant representations

Surge and stonewall; range of working efficiency

Capacity control methods

Start-up, vibration survey

Steam turbines Type of steam turbines

Turbine efficiency determination

Characteristics of a turbine: speed, specific consumption, efficiency

Influence of inlet and exhaust steam state

Speed governor and control systems

Combined heat Power cycle concept

Safety devices

Technology Casings, diaphragms, stator, blades

Rotor, journal and thrust bearings, internal and shaft seals, coupling

Balance and critical speeds

Lubrication and seal systems

Typical mechanical incidents

Case studies

5 Day Training Program Faculty. Dr.G.G.Rajan / Cochin / India

COOLING TOWERS - OPERATION, MAINTENANCE AND TROUBLE

SHOOTING

COOLING TOWERS - OPERATION, MAINTENANCE AND TROUBLE SHOOTING

5 Day Training Program.

This program is designed for the operations / maintenance / process / project engineers

working in the utility / process section of chemical industry and power plants. Cooling towers

constitute the most crucial section of the industry, the effective operation of which controls the

other operating parameters such as system pressure, temperature, humidity etc.

This program covers the

Theory of air – water contact operations

Evaporative cooling

Cooling tower theory

Type of cooling towers

Efficiency calculation

Cooling tower Maintenance

Cooling water chemistry.

Cooling tower performance monitoring etc.

Certain class room exercises are also covered in this program.

Cooling water quality is one of the most important parameters that affect the performance

of the process units. Cooling water quality is to be monitored to prevent scale formation or

corrosion of tube bundles in condensers, coolers etc. Basics of cooling water chemistry and the

methods of predicting scaling / corrosive tendency of cooling water is also covered with

appropriate example. At the end of the training program, the participants shall be well versed in

cooling tower theory, operation and maintenance activities of their own industry.

Dr.G.G.Rajan

Cochin / India

COURSE CONTENT COOLING TOWER FUNDAMENTALS

i. Introduction

ii. Air-water contact operation – Theory of Cooling

iii. Heat transfer surfaces-design and maintenance

iv. Water distribution system on its effect on performance

v. Cooling tower fill performance

vi. Air recirculation and the effect on performance

vii. Causes of performance deterioration

COOLING TOWER – MECHANICAL DETAILS

i. Functions of a cooling tower

ii. Types of cooling towers and their applications:

iii. Closed air-cooled systems

iv. Evaporative cooling towers - induced and forced draft

v. Counter flow versus Cross flow

vi. Materials of construction

vii. Efficiency of latest types of cooling towers and the cost savings associated

with them

COOLING TOWER PERFORMANCE & CONTROL SYSTEMS

i. Use of DDC controls for proactive, user-friendly diagnostics

ii. Monitoring capacity including use of computers

iii. Water treatment control

iv. Latest fan control options

v. Specifications

vi. Using controls for cost reduction

INSPECTING COOLING TOWERS

i. Year round operation

ii. Motor, fan and clearance

iii. Nozzles

iv. Fill

v. Solids filtration efficiency

vi. Fouling, scaling, corrosion

vii. Water contamination

viii. How to assess your existing cooling tower

WATER QUALITY AND IT’S IMPACT ON PROCESS

i. Water quality as it relates to cooling towers

ii. Microbiological activity- types of micro organisms and strategies for control

iii. Prevention of scaling, fouling and corrosion

iv. Cycles of concentration

v. Minimizing cost at its source

vi. Solids filtration efficiency

vii. Fouling, scaling, corrosion

viii. Water contamination

WATER QUALITY PROBLEMS IN CTs.

i. Effects of microbiological activity on total cooling program success, as well

as circulating system integrity and efficiency

ii. Strategies for defouling and microbial control

iii. Prevention of scaling, fouling and corrosion

iv. Cycles of concentration

v. Non-destructive testing of tube bundles

OZONE TREATMENT OPTION

i. The ozone treatment system for cooling water- as compared to mechanical

and chemical treatment

ii. Efficiency in controlling microbiological contamination, fouling, scaling and

corrosion

iii. Cost considerations of operation, energy, water, environmental and liability

considerations, and cycles of concentration

CHEMICAL TREATMENT OPTION

i. The chemical treatment system for cooling water as compared to mechanical

and ozone treatment

ii. Efficiency in controlling microbiological contamination, fouling, scaling and

corrosion

iii. Cost considerations of operation, energy, water, environmental and liability

considerations, and cycles of concentration

ENVIRONMENTAL ISSUES

i. Water conservation methods

ii. Comparison of water treatment methods from environmental standpoint

iii. Controlling microbiological contamination, fouling, scaling and corrosion

using environmentally friendly water treatment options

iv. Recycling system efficiency to control concentration cycles

COST SAVINGS

i. Water consumption

ii. Operating costs

iii. Using free cooling during winter

iv. Icing

COOLING TOWER MAINTENANCE GUIDELINES

i. What causes deterioration of cooling towers

ii. Standard maintenance procedures

iii. Troubleshooting

iv. Seasonal operation

v. Startup/shutdown

vi. Standard maintenance procedures

vii. Do's and don'ts for efficient operation

viii. Example of cost reduction through preventive maintenance

ix. Life cycle cost analysis

FEBRUARY 2005

DISTILLATION OPERATION , CONTROL & TROUBLE SHOOTING

(5 DAY TRAINING PROGRAM)

FACULTY: DR.G.G.RAJAN, Cochin, India

Program Contents Petroleum Chemistry – Basics

I. Material Balance

II. Conversion Processes

III. Physical and Chemical Properties.

Introduction to Distillation

I. Distillation principle

II. Distillation equipment

III. Column Internals

IV. Vapor – liquid equilibrium

V. Factors affecting distillation column operation

VI. Protection against column plugging

VII. Entrainment Distillation control

I. Distillation principles

II. Temperature profile

III. Pressure profile

IV. Multi component distillation

V. Level / volume / flow controls

VI. Vacuum distillation

VII. Fractionator efficiency

Depropanizer Example

I. Equilibrium diagram

II. Raolt’s law

III. Vapor-liquid equilibrium concept

IV. Depropanizer example

V. Impact of feed temperature

VI. Debutanizer

VII. Gasoline stabilizer

VIII. L/V ratio

IX. Theoretical stages

X. Vacuum distillation.

Distillation Control II

I. Control principles

II. Feed temperature control

III. Top temperature control

IV. Bottom temperature control

V. Column pressure control

VI. Controlling tower operation

VII. Energy balance of a Distillation tower

VIII. Tower capacity

IX. Type of towers / contact mediums

Economics of tower operation

I. Coil outlet temperature control in multi pass heaters

II. Tube coking

III. Radiant heat transfer impact

Process Control Systems

I. Advanced Process control

II. Multi functional Adaptive Control – Example Furnace Operation

Trouble shooting Distillation Problems

I. Flooded trays

II. Hydrostatic head in trays

III. Bottom level control

IV. Dry trays

V. Upset trays

VI. Loss of fractionation

VII. Case studies

Distillation Operation and Control 5-day course (Distillation Systems / Advanced Controls)

Course Objective

The objective of this training program of 5 days duration is to

impart Basic Distillation and Control Principles and its practical

applications. This also covers the basics of Petroleum Chemistry, so that

the Distillation Principles may be well understood. This training is

designed for engineers and operations personnel of process plants,

petroleum refineries and petrochemical plants , involved in operation,

design, control and trouble shooting distillation units .

This program covers the principles of

Petroleum chemistry and their properties

Distillation basics

Parameters involved in distillation operation

Distillation control basics

Basics of Advanced control systems.

Instrumentation features in Distillation.

Trouble shooting distillation problems and

Case studies.

This also explains methods of analyzing the performance of

distillation units from the distillation data for possible process problems

related to the distillation / stripper columns. Techniques of minimizing

operating cost through optimal reflux ratio and feed temperature control is

also covered. This also covers tray fouling and capacity expansion

techniques.

The discussions are more operation and practice oriented and after the

training program, participants shall be able to understand the distillation

operation and control in a better way.

This program is more of an education in distillation basics and

control , which will give an all-round understanding of various features of

distillation control and operating issues, irrespective of the industry.

Problems related to poor distillation efficiency due to flooding, dry

trays, upset trays, collapsed trays, improper temperature control, leaks

are also covered in trouble shooting section of the program.

Dr.G.G.Rajan

TRAINING PROGRAMME ON

HEAT EXCHANGERS – OPERATION MAINTENANCE AND TROUBLESHOOTING

Faculty: Dr.G.G.Rajan

Cochin – India

Heat Exchangers Operation/ Maintenance and Trouble Shooting

4-day training program for plant personnel

Introduction

The objective of this training program of 4 days duration is to impart

Training on Operation / Maintenance and Trouble Shooting Heat

Exchanger problems related to the petroleum / petrochemical / fertilizer

and power generation plants.

The training covers the basics of

Heat Transfer

Fluid flow

Types of Heat Transfer

Heat transfer coefficient / it’s importance

Evaluating Heat Exchanger Performance

Coolers / condensers

Fouling / corrosion in heat exchange equipments

Design of heat exchangers – basics

Liquid – liquid heat transfer

Air pre heaters

Fin fan coolers

Performance monitoring of exchangers

Economics of heat exchanger design

Approach temperature

Logarithmic mean temperature calculation

Heat train concept

Commissioning / de commissioning of heat exchangers

Emergencies in heat exchanger operation

Surface condensers

This training is designed for engineers and operations personnel of

process plants, refineries and power plants, involved in operation ,

maintenance and performance monitoring of these equipments.This also

covers theory , practice and trouble-shooting of heat exchger based unit

operations such as :

Distillation

Absorption

Stripping

Extraction

Heat transfer operations

Evaporation

Fluid transfer

Gas Handling / transportation etc.

Specific unit processes included in the program include

Ammonia plant

Urea plant

Aromatics plant

Gas processing etc.

This explains methods of analyzing the field data for possible process

problems related to the above processes and equipments and taking

appropriate actions to overcome them.

This also covers fouling and corrosion problems related to various type of

equipments and tackling them .

The discussions are more process and operation oriented. After the

training program, participants shall be able to understand the process

problems and take appropriate actions to overcome them effectively. This

program is more of theory / operation and Trouble-shooting operational

problems. A number cases studies are covered in this program, with

appropriate clip shows.

Dr.G.G.Rajan

CONTENTS 1. Fluid Mechanics for Heat Transfer. 2. Basic Heat Transfer Theory. 3. Types of Heat Exchangers: − Shell and Tube heat exchanger

− Tube in tube heat exchanger

- Pipe exchangers

4. International Standards of Heat Exchangers:

−DEP 31.22.10.32 – Gen (pressure vessel)

−DEP 31.38.01.00 – Gen (piping general requirements)

−API 660 (shell and tube heat exchangers for general refinery services)

5. Shell and Tube Heat Exchanger Design. 6. Mechanical Design. 7. Materials of construction / metallurgy for heat exchangers. 8. Preliminary Activity Prior Heat Exchanger Inspection:

− Isolating and draining procedures

− Emptying circuits and isolating them

9. Installation, Dismantle and Assembly Principles:

− Removing the tube bundle

− Devices for removing the tube bundle

− Hydraulic bundle remover

10. Heat Exchanger Inspection and Maintenance:

− Clearances around the heat exchangers

− Removing, cleaning and repairing the complete unit

− Removing the tube bundle for cleaning and repair

− Cleaning the shell

11. Various Cleaning Methods for the Heat Exchangers: − Conventional (mechanical) cleaning

− High – pressure water jet cleaning

− Chemical cleaning

− Cleaning in a central yard

− Cleaning in a yard

12. The Inspection Techniques for Heat Exchangers:

− Visual

− Ultrasonic

− Eddy current

− Magnetic particles

− Liquid penertrant

14. Extended Surface Heat Transfer. 15. Vibration in exchangers 16. Troubleshooting of Heat Exchangers:

− Measuring flow temperatures and pressure drops

− Methods to lower pressure drop

− Shell Side Pressure Drop

− Bundle Sealing

− High pressure drop

− Problems: Venting, debris, slug for two phase stream.

- Scaling , corrosion in exchangers .

BASIC HEAT TRANSFER (INDUSTRIAL APPLICATIONS)

Faculty : Dr.G.G.Rajan

Cochin - India

Basic Heat Transfer 3-day course (Industrial Boilers & HRSGs)

Introduction

The objective of this training program of 3 days duration is to impart Basic

Heat Transfer Principles and its industrial applications. This training is

designed for engineers and operations personnel of process plants,

refineries and power plants, involved in operation , maintenance and

performance monitoring of oil / gas fired

Steam generators

Waste heat boilers

HRSGs and

Fired heaters.

This program covers the principles of

Process heat transfer

Boiler / heater features

Modern trends

Identify poor performance

Appreciation of operating parameters and

This covers critical issues such as:

Boiler tube wall temperatures

Efficiency

Steam temperatures

Heat flux

Effect of fuels

Deviations from design operating point

Economizer steaming

This explains methods of analyzing the field data for possible process

problems related to boilers and accessories such as super heaters ,

evaporators or economizers and techniques of minimizing operating cost

through proper evaluation of various alternates and Pollution control

issues.

This also covers fouling and corrosion issues related to various type of

boiler sections. Techniques of Efficiency improvement and Modifying

existing equipment for better performance will also be discussed with

relevant examples.

The discussions are more process and thermal design oriented and not

on mere operating issues alone. After the training program, participants

shall be able to understand the process aspects of various alternates and

select the best process and implement parametric changes for achieving

the best performance. This program is more of an education in thermal

process behind these boilers / heater / heat transfer equipment, which will

give an all-round understanding of various design and operating issues.

Problems related to poor boiler feed water quality such as fouling, Tube

failures, Steam purity ,Carry over, Super heater failures, Steam

temperature variations etc are also covered.

Dr.G.G.Rajan

Basic Heat Transfer

Chapter 1 - Applied Heat Transfer 1. Modes of heat transfer

2. Conduction / Convection / Radiation Heat Transferr

3. Overall Heat Transfer Coefficient

4. Mean / Log mean temperature difference / Economic approach

temperature

5. Extended surfaces

Chapter 2. Boilers

1. Shell Boilers / Advantages of shell boilers

2. Water tube boilers and sections

3. Volumetric heat release / Steam release rate

4. Pressure / Output limitations

5. Economizer / Super heaters

Chapter 3 – Energy Efficiency of Boilers

1. Boiler theory and operating principles

2. Energy / Material balance approach

3. Theoretical air / Excess air evaluation from flue gas analysis

4. Optimum excess air – concept

5. Air leaks / Convection and Radiation losses

6. Heat losses

7. Blow down loses / Blow down rate – estimate

8. Boiler efficiency general

9. Boiler efficiency determination – direct method

10. Boiler efficiency – indirect method

11. Oil burners for boilers / Pressure jet burners for boilers Burners /

Gas Burners / Rotary cup burners Turn down ratio of burners

12. Boiler loading/ Boiler load % vs Efficiency

13. Boiler performance analysis

14. Efficiency of heat transfer devices.

15. Efficiency of Economizers / Super heaters.

16. Flash steam recovery / Condensate recovery.

Chapter 4 – Combined Heat and power 1. Characteristics of prime movers. / Cogeneration of Heat and power

2. Economics of CHP system

3. Power Generation using CHP cycle / Benefits of CHP system

4. Typical cogeneration methods / Combining turbine exhaust to fired heaters

5. Waste heat recovery option / Calculating steam generation potential

6. HRSG efficiency

Chapter 5. - Fired Heaters.

1. Types of Heaters / Reaction type / Other types

2. Heater Section/ Fire Box / Burner Assembly / stack

3. High efficiency heaters

4. Combustion theory / Optimum excess air

5. Pass flow balancing in a heater

6. Convection & Radiation Losses

7. Thermal Efficiency of heaters

8. Losses through heated walls / Insulation Efficiency

Chapter 6. Heater Auxiliaries 1 Air pre heater types ./ problems

2 Cold End corrosion / Dew Point

3 Finned / Studded tubes

4 Soot Blowers

5 Combustion Analyzer and control 6 Auto Damper Control

7 Emissivity coatings

8 Ceramic coating on heater coils

9 Hot tube descaling

10 Fired heater – check list for trouble free operation Final Session: Discussion on topics presented

TROUBLE SHOOTING CHEMICAL PLANT PROBLEMS

Faculty : Dr.G.G.Rajan

Cochin - India

Trouble Shooting Chemical Plant

Problems 5-day training program for plant personnel

Introduction

The objective of this training program of 5 days duration is to impart

Training on Trouble Shooting Chemical Plant Problems related to the

petroleum / petrochemical / fertilizer and power generation plants. The

training covers the basics of common chemical plant equipment such as

Pumps, Compressors, Turbines, Heat exchangers , coolers, Distillation

columns, static vessels, pipe lines , motors etc and trouble shooting

various problems associated with them. This training is designed for

engineers and operations personnel of process plants, refineries and

power plants, involved in operation , maintenance and performance

monitoring of these equipments.

This program covers the theory , operation and trouble shooting problems

related to

Process heaters

Boilers

Pumps

Compressors

Turbines ( Steam / Gas Turbines )

Motors

Columns

Vessels

Heat exchangers

Coolers /Condensers

Reboilers etc

This also covers theory , practice and trouble-shooting of unit operations

such as :

Distillation

Absorption

Stripping

Extraction

Heat transfer operations

Evaporation

Fluid transfer

Gas Handling / transportation etc.

Specific unit processes included in the program include

Ammonia plant

Urea plant

Aromatics plant

Gas processing etc.

This explains methods of analyzing the field data for possible process

problems related to the above processes and equipments and taking

appropriate actions to overcome them.

This also covers fouling and corrosion problems related to various type of

equipments and tackling them .

The discussions are more process and operation oriented. After the

training program, participants shall be able to understand the process

problems and take appropriate actions to overcome them effectively. This

program is more of theory / operation and Trouble-shooting operational

problems. A number cases studies are covered in this program, with

appropriate clip shows.

Dr.G.G.Rajan

CONTENTS

APPLIED FLUID DYNAMICS

I. Flow laws

i. Mass conservation

ii. Energy in fluid and energy balance

iii. Bemoulli’s law.

iv. Friction losses for Newtonian fluids:

v. Viscosity

vi. Reynolds number

vii. Types of flow and friction losses.

II. Application to liquids

i. Non vaporization conditions in a system:

ii. vapor pressure

iii. Cavitation, and use of piezometric lines

III. Pumps

i. General aspects of pumping in process plants in terms of flow, pressure increase

specific gravity, viscosity, and temperature.

ii. General aspects of the pumps in process plants: main types of pumps

(centrifugal, reciprocating, rotary, etc.) investment, reliability, costs (maintenance

and operating)

iii. System characteristic: head, system curve, influence of the control valve, of the

static conditions, combination of systems: parallel and series.

iv. Characteristic curves: head efficiency, power versus capacity; shapes of curves

in relation to the type of pipe.

v. Change in Characteristics: capacity regulations, parallel or series operations,

and cavitation, NPSHa.

IV. Operation & Troubleshooting

i. Start-up, priming, shut down

ii. Survey: vibration level and noises, chain cause, bearing housing temperatures;

motor intensity; incidence on pressure changes

iii. Parallel and series operations

iv. Application:

v. Hydraulic study of a reflux line; friction losses, study of several kinds of

centrifugal pump and several auxiliary arrangements

V. Gas Laws & Compression

i. Ideal gas compression law

ii. Density

iii. Volume

iv. Mass flow

v. Perfect machine application: discharge temperature, theoretical power

vi. Use of thermodynamics diagrams: application to steam, to coolant gases, to air vii. System characteristics for gas, viscosity losses, application to typical processes (recycling, transfer, etc.)

VI. Dynamic Compressors

i. General aspects of gas transfer in process plants: capacity and pressure rate, types

of compressors, operating cost, reliability.

A. Centrifugal compressors

i. Main types, applications in process plants

ii. Design: casing, rotor journal and thrust bearings, internal and shaft seals,

auxiliaries; typical failures.

iii. Polytropic efficiency: effect on discharge temperature and indicated power

iv. Relation between head, power and capacity, invariant representations

v. Sound velocity in gas, stonewall and surge effect

vi. Operation: capacity control, start-up, critical speed and vibration

B. Troubleshooting and Case Studies

i. Applications

ii. Short exercises on reciprocating and centrifugal compressors: discharge

temperature calculation. Indicated power, use of invariant in characteristic

curves Technology; study of auxiliary system of a centrifugal compressor and

safety device.

VII. Turbines

A. Steam Turbines

i. Main types

ii. Design: main parts, rotor and blades, journal and thrust bearings, seals, typical

failures

iii. Performance: ideal and real expansion, expansion mechanism

iv. Control system: speed control system, safety devices

v. Operation: preheating, start-up, critical speeds and vibrations

B. Gas Turbines

i. Cycle of operation

ii. Design, Main Parts, Rotor, Stator, Blades, Bearings and Seals

iii. Simple cycle, Cogeneration & Double cycle

iv. Significance of E.G.T.(exhaust/ energy recovery gas turbine)

v. Factors affecting the life

vi. Arial compressors

vii. Application, Parts and Function

VII. Troubleshooting and Case Studies

VIII. Distillation – basics

IX. Trouble shooting Distillation Problems

INTRODUCTION TO METALLURGYTraining Program

FACULTY Dr.G.G.Rajan,Cochin,India

Introduction to Metallurgy & Trouble Shooting metallurgical problems 5-day training program for plant personnel

Introduction

The objective of this training program of 5 days duration is to impart

Training on Basics of Metallurgy and Trouble Shooting Metallurgical

problems related to the petroleum / petrochemical / fertilizer and power

generation plants.

The training covers the basics of

Elements

Atoms / Molecules / Molecular structure

Molecular structure of common metals

Properties of metals

Theory of crystals / crystallography

Chemical equilibrium

Elements of extractive metallurgy

Metal production methods / refining

Solid solutions

Metal solidification and properties

Heat treatment of metals

Heat treatment of steel

Metal treatment methods and their objectives

Metal failure and measures to avert failures

Metal forming

Metal testing and inspection methods

This training is designed for engineers and operations personnel of

process plants, refineries and power plants, involved in operation ,

maintenance, inspection and safety management.

This also covers theory, practice and trouble-shooting of metallurgical

problems faced by the industries.

This explains methods of analyzing the field data for possible

metallurgical problems and averting costly failures by appropriate actions

to overcome them.

This also covers fouling and corrosion problems related to various type of

equipments and tackling them .

The discussions are more practical metallurgy oriented. After the training

program, participants shall be able to understand the metallurgical

problems and take appropriate actions to overcome them effectively.

A number cases studies shall be covered in this program, with

appropriate clip shows.

Dr.G.G.Rajan

Contents 1. Basics of Physical Chemistry

I. Atoms, Molecules and Crystals

II. Common elements

III. Atomic structure

IV. Periodic table

V. How atoms combine

VI. Crystals and crystalline materials

2. The Physics and Chemistry of Metals I. Physical quantities and their measurement

II. Conservation of mass and energy

III. Chemical solutions, formulas and equations

IV. Acids, bases and salts

3. Chemical Equilibrium I. Heat and Temperature

II. Compound formation

III. Types of reactions - effects of heat

IV. Instruments for measuring temperature

4. Elements of Extractive Metallurgy I. Steps in processing common ores to metals

II. Beneficiating and reducing methods

III. Types of furnaces

IV. Refractory

5. Metal Refining I. Primary methods for refining steel

II. Basic-oxygen and electric-furnace processes

III. Ladle metallurgy; electrolytic refining of non-ferrous metals

6. Solidification of Metals I. Patterns of atoms in solid metals

II. Stages of crystal growth

III. Formation of grain boundaries

IV. Phase diagrams

V. Ingot casting and continuous casting

7. Solid Solutions:

I. Effects of alloy additions

II. sub-situational and interstitial solid solutions

III. Movement of atoms in solid solutions

IV. Diffusion

V. Important commercial alloys

8. Heat Treatment of Steel I. Fundamentals: types of steel

II. Structure of iron; relation between carbon content and microstructure

III. Austenite, bainite and martensite

IV. Hardness and hardenability

9. Heat Treatment of Steel I. Equipment and Processes

II. Main types of heat treating furnaces

III. Atmospheres and quenching media

IV. Temperature control systems

V. Case hardening and

VI. localized hardening processes

10. Precipitation Hardening Heat Treatments

I. Solution annealing and precipitation hardening;

II. Coherency theory

III. Effects of aging on properties of alloys

IV. Requirements for hardening by precipitation

11. Failure of Metals Under Service Conditions I. Major causes of metal failure during service

II. Major methods of preventing corrosion

III. Factors that cause metal failure due to rupture and wear

IV. Effects of high and low temperatures

12. Forming of Metals - Part I:

I. Primary Forming Processes: plastic and elastic deformation

II. Effects on grain structure

III. Forging operations and machining

IV. Rolling, extruding and wire drawing;

V. Lubricants and coolants

13. Forming of Metals - Part II:

I. Secondary Forming Processes

II. Casting methods and molds;

III. Mechanical forming; welding, soldering and brazing

IV. Powder metallurgy

V. Hot isostatic pressing

14. Metallurgical Testing and Inspection

I. Techniques and instruments for mechanical and

II. nondestructive testing and Metallographic examination

III. Metal properties determined by testing

Training Program on Reliability Centered Maintenance

Dr.G.G.Rajan / Kochi / India

5 Day Training Program on

Reliability Centered Maintenance Day 1 Introduction · Learning Objectives Introduction To RCM · What is RCM

· Brief History of RCM

· RCM Case Studies

Introduction of Planned Maintenance · Overview of planned maintenance principles

· Characteristics of world-class planned maintenance

· Basic concepts of equipment Failures

Day 2 Overview of RCM Analysis Steps and Tools · Measures of Equipment performance

· Workshop: Estimating MTTF and equipment failure pattern

· Types of Maintenance Tasks

· Workshop: Identify different appropriate maintenance action

· Overview of six-step RCM analysis approach

· Overview of RCM Analysis Tools.

Day 3 Traditional RCM Analysis Steps · Pareto Analysis

· Failure Modes and Effect analysis(FMEA)

· Logic Tree Analysis (LTA)

· System Definition and selection using Pareto Analysis

· System Function and Failure Analysis

· Equipment failure mode identification

· Equipment Failure Mode Categorization Day 4 Applying Risk-based Tools in RCM · Overview of risk

· Risk-based system selection

· Risk based maintenance Task

· Risked –based task selection guides

· Managing an RCM project

· Resources needed

· Workshop: Scoping an RCM Analysis

Day 5 Predictive maintenance and Reliability centered maintenance

Advantages of predictive maintenance

What to maintain and how to maintain.

Learning objectives :

This program covers the basics of

Reliability Centered Maintenance

Reliability theory

Preventive and Predictive Maintenance

Evaluation of failure rates

Fault tree analysis and

Application of these concepts in actual operation and maintenance practices.

This program is intended for all operations / maintenance / production planning /

inspection and safety and project personnel from petroleum , petrochemical, fertilizer,

power plants and equipment intensive industries.

The specific advantage of this training programme is the hands-on training with group

exercises and case studies.

After participation in this programme, candidates shall be able to assess the reliability of

their industries and carry out predictive maintenance of their plant, which could save

substantial maintenance costs and avert costly equipment failures.