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
COOLING TOWERS - OPERATION,
MAINTENANCE AND TROUBLE
SHOOTING
5 Day Training Program
Faculty. Dr.G.G.Rajan / Cochin / India
 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
DISTILLATION OPERATION , CONTROL
& TROUBLE SHOOTING
(5 DAY TRAINING PROGRAM)

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

FEBRUARY 2005
 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 METALLURGY
Training 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.