Pgdams Course r2

8/13/2019 Pgdams Course r2

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Post Graduate Diploma in Advanced Mechanical Systems (PGDAMS)

Duration 3 months

Eligibility Degree / Diploma (Mechanical engineers, Production engineers)

PGDAM trans!orms Mechanical Engineers into Multi"s#illed $echnical Pro!essionals%

$his course is aimed at trans!orming Mechanical Engineers into Multi"s#illed $echnical Pro!essionals

ha&ing hands on e'perience on &arious aspects o! most idely used modern manu!acturing systems% The

course is a unique blend of Mechanical systems, Instrumentation systems, Control sytems (PLC and

SCADA), and ydraulic and Pnuematic systems!$he course content is de&eloped based on the strong

demand !rom the industry !or multi"s#illed mechanical engineers%

Generally college curriculum emphasies on theoretical aspects o! engineering sub*ects only% +or e&ery

theory there is a practical side% At proli!ic e impart training on the practical side% Acuiring practical

#noledge enhances *ob opportunities and chances o! higher emoluments than a person ithout practicalside #noledge%

A!ter completion o! the course, students ill be !amiliar ith modern mechanical euipment/systems

employed in the industry and ill ha&e strong demand !rom manu!acturing companies !or enhancing

producti&ity and e!!iciency o! their plant operations%

tudents ill be pro&ided lucrati&e placement in &arious -EMs/er&ice pro&iders and manu!acturing

companies in &arious sectors% $hey ill rise !ast in the hierarchy due to superior multi disciplinary

s#ills% $hey can then mo&e abroad or shi!t into senior le&el positions in maintenance, production or

uality !unctions o! &arious organiations%

Thanks & Regards

!ounsellor

Proli"ic Systems and Technologies Pvt #td

An Altanmiya Group ($u%ait) !ompany

o'* Ground +loorMadavanaPanangad

$ochi,-./ *-

Ph0 *.,/1**.21345.11.***

PGDAMS Program 6ighlight 72** 8 placement'

!ourse Modules0


2/20

Pumps .entri!ugal

.ompressor eciprocating and cre

DG et

Gear 0o'es

+ans and 0loers

0earings

Alignment o! sha!ts $heory and practice

1ydraulic and Pneumatic systems

Ad&anced Mechatronic ystems

2nstrumentation basics

3 hours a day , Monday thro +riday ($imings4 0atch 5 4 56%36 am to 5%36 pm7 0atch 8 4

8%36 pm to 9%36 pm7 0atch 3 4 :%66 pm to ;%36 pm)


3/20

Syllabus

Pumps

Defining pumping systems

Most important characteristics of a pumping system

Types of pumps

Positive Displacement family tree

asic !ifference "et#een Centrifugal an! PD pumps

$otary pumps

Maret applications an! &election of Pumps

Applications of PD pumps

'eneral gui!elines for pump selection

Pump characteristics v(s maret applications

Application ) *igh +iscosity, Lo# an! varia"le viscosity

Application ) Lo# shear pumping, &oli!s han!ling capa"ility

Application ) Multi-phase flo#

Process Con!ition ) *igh pressure

Process Con!ition ) Lo# flo#, Efficiency

Process Con!ition- Com"ination of high pressure ( lo# flo# an! efficiency

Process Con!ition - .lo# control

Environmental system re/uirements

Centrifugal Pump


4/20

asics

Types Construction "ase!2

Construction of an impeller

Types of impellersan! #earing rings

&eal cham"er an! stuffing "o3es

A3ial thrust in single an! multi stage pumps

*y!raulic "alancing !evices

&hafts an! shaft sleeves

earings

Couplings

e!plates an! other pump supports

Defining &uction *ea!

Capacity, 4nput horsepo#er, output horsepo#er, Efficiency

Pressure

*ea! v(s Pressure

Effect of specific gravity on *ea!

5inetic energy

&pecific gravity an! pump performance

Effect of flui! velocity

'auge height correction

6hat is TD* an! T*

Pump Performance parameters


5/20

*ea!-.lo# characteristics

Po#er-.lo# characteristics

Pump Efficiency

Efficiency v(s .lo#

Net Positive &uction *ea! NP&*2 an! its Characteristics

NP&* an! Cavitation

Cavitation process

Cavitation !amage

Preferre! operating range of a centrifugal pump

Allo#a"le operating range

Pump characteristic curves

Effect of $PM

&ystem curves

&ystem *ea!

Energy re/uirements to lift the flui!

Po#er re/uire! to lift the flui!

&ources of .riction

Parameters influencing frictional losses

&tan!ar! Pipe *ea! Loss Ta"les

Calculating frictional losses

.rictional loss coefficients

Pipe lengths an! associate! *ea!s


6/20


7/20

'oo! maintenance practices for seals an! "earings

$ecommen!e! !aily preventive maintenance checs for centrifugal

pumps an! !rives

$ecommen!e! monthly an! 7 monthly preventive maintenance checsfor centrifugal pumps an! !rives

$ecommen!e! yearly preventive maintenance checs for centrifugal

pumps an! !rives

Trou"le shooting of centrifugal pumps

The pump is hooe! up to the piping an! it is running

The pump is still hooe! up to the piping, "ut it is not running

The pump has "een taen into the #orshop, "ut has not yet "een

!isassem"le! an! you #ill "e present at the !isassem"ly

The pump has "een !isassem"le! 8ou #ere not present, "ut the parts

are availa"le for your inspection

Trou"leshooting four possi"ilities of ru" or #ear mars

Centrifugal pumps ) Trou"leshooting gui!e

Trou"le shooting of $eciprocating Pumps

Pump storage tips

Alignments Techni/ues

6hat is coupling alignment9

Types of coupling

Co-linearity

Types of Misalignment :ffset, or Parallel

Angular

Measurement Conventions

Pre-alignment &teps

Alignment Tolerances


8/20

Thermal 'ro#th Targets

Not correcting for soft foot

Not roughing in

;sage of shims

Not controlling "aclash or un#ante! movement

4ncorrect se/uence of moves

< steps of alignment

Angular misalignment in the +ertical Plane

Parallel :ffset in the +ertical Plane

Angular misalignment in the *ori=ontal Plane

Parallel :ffset in the *ori=ontal Plane

Things to #atch if alignment still !oes not happen

A fe# helpful tips

Pump mounting

.oun!ations

*ouseeeping pa!s

4nertia "ases

ase plate selection

.oun!ation preparation

ase plate installation

'routing

Pump an! Motor 4nstallation

Pipe 4nstallation

Pipe strain


9/20

*o# to start a pump

Pump rotation

Motor &olo

Couplings

:ther &tartup Consi!erations

Pump &tart up

.inal +i"ration Acceptance

Checlist

Compressors

> gol!en rules of Compresse! Air usage

Compresse! air system ) &upply si!e an! Deman! si!e

Compresse! air ) :ne of the most e3pensive utilities on the shop floor

4nappropriate use of compresse! air

:pen "lo#ing

&parging, Aspirating, Atomi=ing

Pa!!ing

+acuum generation

*an! "lo#ing

;nregulate! En! use

A"an!one! e/uipment

Potential for energy saving

:vervie# of su"-systems an! su"-components of a compressor system

4ntae Air .ilters


10/20

Compresse! Air .ilters

6hy compressor cooling is re/uire!

4nter stage coolers

After coolers

&eparators

6hy air !rying is essential

Air Dryers

Deli/uescent air !ryers

$efrigerate! Air Dryers

Moisture !rain traps

Air receiver

Lu"rication

*eat recovery

Air !istri"ution system

Types of compressors

Choice of compressors

$eciprocating compressor

&ingle acting air coole!

Dou"le acting #ater coole!

$otary compressor

&ingle stage

? stage


11/20

&cre# Compressors

Lu"ricant in@ecte!

:il free

Centrifugal air compressors

Compressor Prime Movers

Comparison of compressors

Capacity of a compressor

Calculating compressor efficiency

4sothermal efficiency

+olumetric efficiency

Leas

Defining an! uantifying leaage

ho# to calculate leaage

Cost of leaage

Lea !etection

;ltrasonic lea !etection

*o# to stop leas

Compresse! air system performance opportunity roa!map

Air /uality

Air /uantity

Loa! profile

&ystem pressure


12/20

Pressure !rop an! controlling system pressure

6hat causes pressure !rop 9

Minimi=ing pressure !rop

Measurements necessary for pressure profiling a compresse! air system

&ta"ili=ing system pressure

4mportance of Primary an! &econ!ary &torage

De!icate! compressors

Control strategy

Matching Deman! an! &upply

&ystem controls

Multiple compressor controls

Pressure(.lo# controllers

+aria"le loa!s

Ensuring efficiency of compresse! air en!-use applications

*eat recovery an! compresse! air systems

Air coole!, rotary scre# compressors

6ater coole! compressors

Calculating cost of compresse! po#er

The B step action plan to analyse an! improve compresse! air system

Tools nee!e! for monitoring an! "ase-lining compresse! air system

;sing Po#er, Pressure, an! .lo# to "ase-line &ystem Performance an! Energy

Consumption

Maintaining air compressors


13/20

Lu"rication

Cleaning

elts

Air treatment e/uipment

Automatic traps

Point-of-use filters, regulators, lu"ricators

&hutting !o#n for maintenance

$outine maintenance practices for various perio!ic fre/uency

Energy saving i!eas for compressor air system

Energy saving concept ) ;sage of +.D

$ea!ing nomenclature of compressors

Types of valves

Plate type

.inger type

Loa!ing an! ;nloa!ing characteristics of compressors

Types of unloa!ing !evices

Types of Drainage systems

Mounting

*ori=ontal

+ertical

Type of lu"rication

&oft

:utsi!e

Non lu"ricate! compressor

.oun!ation

Con!ition monitoring

Temp analysis

+i"ration analysis

Alignment analysis ) a3ial an! ra!ial laser "ase!2


14/20

Preventive ( Pre!ictive maintenance

rea!o#n maintenance

Trou"le shooting

Checlist

Gear Box Systems

Type of gear "o3

&election of gear "o3es

Comparison of gears an! their applications

4nstallation gear "o3 system

Alignment

ac lash use of filler gaugaes2

&tarting of gear "o3 system

Analysing gear "o3 failure

Lu"rication #ith various oils

Maintenance sche!ules of gear "o3es

Con!ition monitoring

earing temp

+i"ration

ac lash checing

Amps current to chec loa! on the motor

Thermography

Industrial Fans and Blowers

Types of in!ustrial fans an! "lo#ers

Comparison an! their applications

&election criteria

.an system characteristics

.an performance evaluation

Air flo# measurement an! calculation


15/20

Metho!s to re!uce air flo#

Pre!ictive an! preventive maintenance

Con!ition monitoring techni/ues

Bearings

Types of "earings

&election of "earings

earing nomenclature an! terminology

Types an! techni/ues use! for Mounting an! !ismounting of "earings

4n!ustrial practices for earing Care

&afety !uring "earing mounting

Dos an! Donts of "earing usage an! han!ling

Lu"rication of "earings

earing life cycle

Alignment theory and practice

6hy alignment

6hat is shaft alignment

Types of couplings

Types of misalignment

&igns of misalignment

Measuring misalignment

Pre-alignment steps

Alignment targets

Alignment tolerances

&oft foot

;sage of shims


16/20

Alignment of shafts

Alignment of "elt !riven system

$ules of thum" an! tips

D G Set

4ntro!uction

6hy Diesel 'enerator is re/uire!

Type of !iesel generator

Parts of !iesel generators

&tarting proce!ure of a !iesel generator

Pre-starting checs

*o# to start D' set

After starting checs

$unning parameters &topping

Protection !evices

&topping proce!ure for a D' set

Trou"le !etection an! trou"le shooting

6hy maintenance routine is re/uire!

Maintenance routine of !iesel generator set

4ll effects of un!er loa! running of a Diesel generator

'enerator glossary

Preventive maintenance, shut !o#n maintenance of D' sets

Con!ition monitoring of D' sets

Hydraulic and Pneumatic systems


17/20

Hydraulic systems

.un!amentals of hy!raulics asics of #ater an! oil hy!raulics

*y!raulic system accessories $eservoirs, filters, coolers, 4nstrumentation an!accumulators

Principle construction an! #oring of components

*y!raulic pumps Pump "asics, centrifugal positive !isplacement pumps

Pressure control relief, re!ucing, regulating valves

.lo# control .C+, .lo# !ivi!ers, non-return valves

Actuators Linear actuators, hy!raulic motors, *y!raulic !rives

Direction control valves Direct operate!, pilot operate!

4&: sym"ol, circuit !esign an! hy!raulic circuit rea!ing

Performance evaluation an! testing of *y!raulic pumps, $elief DC valves

Principle of solenoi! valves

6oring principles of proportional valves an! servo valves

4ntro!uction of cartri!ge valves if re/uire!2 4nterpretation an! !iscussions of electro-hy!raulic circuits in plant machinery

Mill hy!raulic systems

Material han!ling system

Proportional varia"le pump control system

*y!raulic !rives controls

'eneral trou"leshooting an! maintenance

Pneumatic systems

Theories of compresse! air

:peration function of air components

Design !ra#ing of air sym"ols

&imulation of movement phases function phases

Dra#ing air circuits accor!ing to stan!ar!s


18/20

Pneumatic logic

Dryers, air receivers

Compressors

Pneumatic actuators

Air !istri"ution systems

Directional valves

.lo# valves

Control systems #ith vacuum component

.ault-fin!ing trou"le shooting of compresse! air control circuits

'ui!elines for in!ustrial safety

Adanced !echatronic systems

Programmable "ogic Controller #P"C$ % Allen Bradley P"C

4ntro!uction to 4n!ustrial Automation

$ole of PLC in automation

+arious systems use! in automation

Comparison "et#een various automation system

4ntro!uction to PLC har!#are,

Architectural Evolution of PLC,

PLC .un!amentals - loc !iagram of PLCFs2,

4nformation a"out various PLC components

Po#er supply, CP;, 4(: mo!ules an!

Communication "us

4ntro!uction to Allen ra!ley PLC system

+arious ranges availa"le in Allen ra!ley PLC system

Detaile! information a"out the CP;s, 4(: mo!ules an! communication techni/uesuse! in Allen ra!ley

Connection of fiel! inputs to PLCs

&ource an! &in concepts in PLCs

4ntro!uction to $& Logi3 PLC Programming &(6

A!!ressing Concepts in A PLC 4ntro!uction to it yte an! 6or! Concept

Concept of flags,

&can cycle e3ecution

+arious comman!s use! in PLC programming

Programming instructions arithmetic an! logical

Loa! (an! (or(out ( an! $ea! ( 6rite

Compare ( A!! ( &u" (An! (:r ) locs

Lea!ing e!ge ( trailing e!ge instructions


19/20

M:+E "loc application


Timer locs programming

Counter loc programming

.ile han!ling

Comment functions

;ploa!, !o#nloa!, Monitoring of programs


A!vance! instructions

Documenting the pro@ects

.orcing 4(P :(P,

Monitoring ( Mo!ifying !ata ta"le values

Trou"leshooting an! fault !iagnostics of PLC

*ar!#are fault !etection

$eplacing the faulty mo!ules

.ault !etection using $& Logi3

SCADA So&tware

6hat is &CADA ( *M4

Applications of &CADA ( *M4

4nfo a"out lea!ing &CADA companies

Types of &CADA pacages

Licensing pattern

Creating a ne# &CADA application !evelopment

Creating Data"ase of Tags

Creating 6in!o#s ( Mimic pages

Creating an! E!iting graphic !isplay

Animating the o"@ects

Creating $eal-time an! *istorical Tren!s

Creating Alarm an! Events

6riting scripts

&ecurities

Communication techni/ue use! #ith &CADA ( *M4 system

Communication #ith har!#are

6oring :n Line ( :ff Line

Trou"leshooting the application

Instrumentation basics

'eneral

Purpose of instrumentation

asic measurement concepts


20/20

Documents

Pgdams Course r2