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.

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:
•    Thermal energy and steam consumption
•    Air consumption
•    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


1.    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
2.    Boiler water treatment
•    Harmful effects from improper treatment.
•    Sizing and selection of water treatment plant
•    External and internal water treatment
•    Boiler deposits & blowdown control.
3.    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
4.    Steam distribution and condensate return
•    Steam traps and steam trapping
•    Pipeline ancillaries
•    Condensate removal
5.    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
6.    Rotating Equipment:
•    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
7.    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
8.    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
9.    Processes control
•    Basic Control Theory
•    Control Hardware: Electric/Pneumatic Actuation
•    Control Hardware: Self-acting Actuation
•    Control Application
•    Safety Valves
10.    Applying predictive maintenance regime
11.    Maintenance and Inspection
12.    Troubleshooting (case study)

Mechanical Engineers and Technicians in Process department.

  • Group Discussions
  • Group & Individual Exercises
  • Presentations
  • Games
  • Case Studies
  • Role Plays
  • Self-Assessment
  • Action Plan
  • Certificate,
  • Quality Training Kit (Pencil case: Erase, Bolpoint, Pencil, Tipe X, Stabillo, Flash Disk 8 GB),
  • Bag.
  • Training Material (HandOut & SoftCopy)
  • Convenient training facilities in stars hotel (Public Training)
  • Lunch and Coffee Breaks (Public Training)
  • Souvenir
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