PGDAMS - Post Grad. Diploma in Advanced Mechanical Systems

M01 – Pumps - Theory, Practice and Maintenance

Defining pumping systems

• Characteristics
• Positive Displacement family, Centrifugal pumps, Rotary pumps
• Pump Fundamentals, Pump Performance parameters and curves
• Parallel pumps
• Series pumping
• Pump vibration
• How pumps get damaged – 10 Ways
• Monitoring and Predicting Centrifugal Pump performance
• Predicting pump performance
• Preventive maintenance
  • Preventing bearing and seal failures
• Trouble shooting of centrifugal pumps
  • Centrifugal pumps – Troubleshooting guide
    
• Trouble shooting of Reciprocating Pumps
  
• Alignments Techniques

• Types of Misalignment
• Measurement Conventions
• Pre-alignment Steps
• 4 steps of alignment
• Things to watch if alignment still does not happen
• A few helpful tips

• Pump mounting
  
• How to start a pump
  
• Checklist

M02 –Compressors -– Theory, Practice and Maintenance

• 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
  • Lefining 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

M03 –Gear Box Systems– Theory, Practice and Maintenance

• 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

• 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

• 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

• Why alignment
• What is shaft alignment
• Types of couplings
• Types of misalignment
• Signs of misalignment
• Measuring misalignment
• Pre-alignment steps
• Alignment targets
• Alignment tolerances
• Soft foot
• Usage of shims
• Alignment of shafts
• Alignment of belt driven system
• Rules of thumb and tips

• 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

• Fundamentals of hydraulics: Basics of water  and oil hydraulics
• Hydraulic system accessories: Reservoirs, filters, coolers, Instrumentation and accumulators
• Principle construction and working of components
• Hydraulic pumps: Pump basics positive  & non-positive displacement pumps
• Pressure control: relief, reducing, regulating valves
• Flow control: FCV,  non-return valves
• Actuators: Linear actuators, hydraulic motors, Hydraulic drives.
• Direction control valves: Direct operated, pilot operated
• ISO symbol and hydraulic circuit reading
• Performance evaluation and testing of Hydraulic pumps, Relief & DC valves
• Principle of solenoid valves
• Working principles of proportional valves and servo valves
• Interpretation and discussions of electro-hydraulic circuits in plant machinery
• Material handling system
• Proportional variable pump control system
• General troubleshooting and maintenance

• Introduction to Industrial Automation
• Role of PLC in automation
• Various systems used in automation
• Comparison between various automation system
• Introduction to PLC hardware,
• Architectural Evolution of PLC,
• PLC Fundamentals - (Block diagram of PLC's),
• Information about various PLC components

• Power supply, CPU, I/O modules and
• Communication bus

• Introduction to Allen Bradley PLC system
• Various ranges available in Allen Bradley PLC system
• Detailed information about the CPUs, I/O modules and communication techniques used in Allen Bradley
• Connection of field inputs to PLCs
• Source and Sink concepts in PLCs
• Introduction to RS Logix PLC Programming S/W

• Addressing Concepts in AB PLC
• Introduction to Bit Byte and Word Concept
• Concept of flags,
• Scan cycle execution
• Various commands used in PLC programming

• Programming instructions arithmetic and logical

• Load /and /or/out / and Read / Write
• Compare / Add / Sub /And /Or – Blocks
• Leading edge / trailing edge instructions
• MOVE block application

• Programming instructions arithmetic and logical

• Timer Blocks programming
• Counter Block programming
• File handling
• Comment functions

• Upload, download, Monitoring of programs
• Programming instructions arithmetic and logical

• Advanced instructions

• Documenting the projects
• Forcing I/P & O/P,
• Monitoring / Modifying data table values
• Troubleshooting and fault diagnostics of PLC

• Hardware fault detection
• Replacing the faulty modules
• Fault detection using RS Logix

• What is SCADA / HMI?
• Applications of SCADA / HMI
• Info about leading SCADA companies
• Types of SCADA packages
• Licensing pattern
• Creating a new SCADA application development

• Creating Database of Tags
• Creating Windows / Mimic pages
• Creating and Editing graphic display
• Animating the objects

• Creating Real-time and Historical Trends
• Creating Alarm and Events
• Writing scripts
• Securities
• Communication technique used with SCADA / HMI system
• Communication with hardware
• Working On Line / Off Line
• Troubleshooting the application

• General

• Purpose of instrumentation
• Basic measurement concepts
• Measurement Practices
• Sensors- Inductive / Capacitive, Proximity, Ultrasonic
• Introduction to various sensors used in the industry

• Introduction to Temperature, Pressure and Flow measurement
• Selection, Installation and Commissioning guidelines
• Troubleshooting and Maintenance Guidelines