General Introduction

1. Introduction about Process Industry and EPC.

2. List of Equipment’s used in Industries, their Introduction & Applications.

3. Relevant Codes and Standards used in Industry.

Module 1

General Concepts and Methods of Mechanical Design of Pressure Equipments

1. Pressure Equipment Design in Accordance with ASME and in Accordance with PED.

2. Stress Strain Diagram.

3. Material Selection for Different Temperature & Service.

4. Design Methods: DBF, DBA and Design by Experiment.

5. Loads and Stresses: Elements of Stress Analysis, Stress Categorization.

6. Load Conditions & Failure Modes.

Module 2

ASME Codes and its Relation to Pressure Vessel Design

1. Introduction to Engineering Standards used in Design of Process Equipment's.

2. ASME Sec. VIII Div.1 & 2 [Latest Issue], TEMA , API 650 etc.

3. Conditions/Clauses Governing Pressure Vessel Design under ASME Sec VIII Div. 1.

Module 3

Mechanical Design of Pressure Vessels

1. Design and Analysis of Pressure Vessels & Component (ASME Section VIII Division.

2. Design of Pressure Vessel for Internal & External Pressure.

3. Design of Cylindrical Vessels & types of Dishend.

4. Design of Jacketed Vessels, Limpet Coils, Horizontal Equipments with saddle support.

5. Various Types of Supports & Attachments [Leg, Skirt, Bracket Supports].

6. Lifting attachments, Design of Anchor Bolts, Safe Loads for Ropes and Chains.

7. Nozzle Openings and Reinforcements [Nozzle Local Load Analysis].

8. Welded Joints, Butt Welded Joints of unequal Thicknesses & Welding Symbols.

9. Role of MAP, MAWP, Design Pressure & Design Temperatures.

10. Allowable Stresses, Corrosion Allowance and Loadings as per ASME in PV Design.

11. Impact Testing, PWHT along with Heating Rates and Cooling Rates.

12. Hydro Test Pressure & Stamping of Vessels.

Module 4

Pressure Vessel/Column/Reactor Design Calculation: (ASME SEC VIII, DIV.1)

1. Maximum Allowable Stress Values (UG-23).

2. Shell Design for Internal Pressure (UG-16, UG-27,Appendix 1-2).

3. Dished End Design For Internal Pressure (UG-32).

4. Shell Design for External Pressure (UG-28, UG-29,UG-30).

5. Dished End Design For External Pressure (UG-33).

6. Hydro test Pressure/Pneumatic Test (UG-99,UG-100).

7. Wind Load (IS-875, Pt-3) & Seismic Load (IS-1893, Pt-1 & 4).

8. Combined Loading Effect.

9. Conical & Tori-conical Section Analysis (UG-32,33, Appendix 1-5 & 1-8).

10. Weight Calculation.

11. Opening (Nozzles) (UG-36 ~ UG-45).

12. Local Load (WRC 107 & 297).

13. MDMT & Impact Test Enigma (UCS-66).

14. Lifting & Tailing Lug analysis.

15. Support Analysis (Skirt, Leg, Saddle ,Lug) & Anchor Bolt Design.

16. Joint Efficiency, MAWP, MAP, SR of DE for Forming Operation.

17. PWHT (UCS-56).

18. Types of Gaskets, Gasket material selection, Role of gaskets in Pressure Vessel Design.

19. Mechanical Design of Non Standard Flanges as per Appendix 2.

Module 5

Fabrication of Pressure Vessels

1. Plate rolling, Plate Bending, Welding Methodologies (STAW, GTAW, GMAW, SMAW).

2. Fabrication Sequences , Fabrication Schedules, Plate Forming, Cutting etc.

3. Testing of Pressure Vessel, Painting and Coating for Corrosion Protection.

Module 6

Column & Tower Internals

1. Types & Functions of Internals.

2. Process aspect of these Internals.

3. Specialized manufacturers of Internals.

4. Scope and design of the Internals.

Module 7

Design & Analysis of Heat Exchangers

1. Heat Exchanger types , Classifications & TEMA Standard.

2. Design of Shell, Channel, Shell Bonnet, Channel Cover, Selection of Girth Flanges.

3. Limitations in the use of Heat Exchangers.

4. Components of Heat Exchangers.

5. Design aspects of Heat Exchangers.

6. Tube sheet Design: Fixed Tube sheet , Floating Tube sheet , U – Tube sheet.

7. Design of Tube Sheet as per TEMA as per Bending and Shear Loading.

8. Limiting Cases in the Design of Heat Exchangers.

9. Testing of Heat Exchangers.

10. Types of HE : Condensers | Evaporators | Reboilers | Plate Heat Exchangers.

Module 8

Detail Engineering Aspects of Process Equipment’s

1. Understanding the Basic Engineering Package.

2. Tender requirements of Clients & Engineering Design Basis.

3. Technical Specifications: Process Data Sheets and Mechanical Data Sheets.

4. Data Exchange between Process and Mechanical to prepare the Technical Specification.

5. Understanding the Scope of Supply between Mechanical, Civil & Process.

6. Enquiry Stage Design , Drawings and Other Relevant Calculations.

7. Preparation of GAD & Fabrication Drawings of Process Equipment’s.

8. Evaluation of Vendor Offers, Preparation of Technical Queries.

9. Technical Bid Evaluation, Technical Recommendation to be given to the Client.

Module 9