1.

Practical Boiler Plant Operation and Management for Engineers

This intensive and highly practical program will give you the most up-to-date information
and practical understanding of the installation, operation, maintenance and management of
boiler. After this program you will be able to recognize and solve boiler problems simply and
with confidence.
At the end of this program participants will be able to:
 Identify the various types of boilers
 Use essential terms and understand their key applications
 Describe the typical characteristics of fuels fired
 Perform basic combustion and process calculations
 Recognize the impact fuels have on the boiler heat transfer surfaces
 Describe the ancillary equipment associated with steam boiler plants and their integral
role in the safety of the boiler
 Discuss the correct operation, control sequences and procedures for the safe operation of
a typical fire-tube boiler plant
 Outline the applicable pressure part design codes and explain their influence on boiler
pressure parts sizing, inspection and non-destructive examination
 Initiate an effective inspection and maintenance program
 Minimize forced outages and prevent serious damage to boiler equipment
 Provide an overview of the legislative requirements plus the essential steps and
responsibilities for the repair of boilers
 Recognize the importance of and implement the procedures for the protection of a boiler
during cold storage
 Outline the technologies available for the reduction of emission levels and the applicable
international legislative controls
Practical Sessions
There are eight practical exercises and assignment sessions to give you the confidence
and experience to work on the installation, operation and maintenance of boiler plants.
The Program
Day 1
 Introduction
o Types of package boilers and their applications
o Boiler components, terminology and definitions
 Fuel Combustion And Steam Generation Process
o Overview of the boiler heating and steam generation process
o Influence of fuel types on boiler design and operation
o Basics to the theory of combustion and fundamentals of steam generation
o Thermal efficiency
o Fire-side deposits and their influences
 Boiler Auxiliary Plant
o Water treatment and dosing plant
o Feed water pumps, valves, steam traps, piping, fans, and dampers
o Firing systems
o Flue gas cleaning and dust removal
 o Soot blowers
 Practical Session and Questions
Day 2
 Operations and Controls
o Boiler instrumentation and its purpose
o Typical P&I diagrams for coal/oil fired package units
o Control systems or loops
o Operation and control philosophy, sequences and procedures
o Safety equipment and emergency procedures
o Typical operational problems, reasons for the problems
o Troubleshooting
o Operating records and logs
o The do's and don'ts of boiler operation and corrective action
 Practical Session and Questions.
Day 3
 Pressure Containing Components
o Overview of design parameters for shell, furnace, plates and tubing
o Importance of pressure part inspection
o Practical Session and Questions
 Planning and Managing Boiler Maintenance
o Critical importance of maintenance policies and programmes
o Manufacturers literature and requirements
o Regularity of inspections and maintenance
o Critical items for maintenance for safety, efficiency and reliability
o Practical Session and Questions
Day 4
 Managing Boiler Repairs And Modifications
o When does a boiler repair become a boiler modification?
o Importance of historical records
o Understanding the steps and requirements when undertaking modifications
o Boiler owner and contractor responsibilities
o Practical session and questions
 2. Fundamentals of Process Plant Layout
At the end of this program participants will be able to:
 Plant layout fundamentals and procedures
 Fundamental principles of chemical process technology
 Terminology and symbols used in plant layout
 Equipment used in process plants
 Piping design and engineering principles
 Terminology, symbols and abbreviations in piping design
 Documents (bill of materials, equipment specifications, etc) and drawings
 3D modeling of plants and piping systems
Process plants such as refineries and petrochemical plants are complex facilities
consisting of equipment, piping systems, instruments, electrical systems, electronics, computers,
and control systems. The design, engineering and construction of process plants involve
multidisciplinary team effort. Plant layout and design of piping systems constitute a major part of
the design and engineering effort. The objective is to design safe and dependable processing
facilities in a cost effective manner. The fact is that there are few formal training programs with a
focus on plant layout and design of piping systems, therefore most of the required skills are
acquired while on the job, reducing productivity and efficiency.
The Program
Day 1
 Introduction to Process Plant Layout and Piping Design
o Plant layout fundamentals
o Procedures and workflow methods
o Physical quantities and units
 Introduction to Chemical Processing Methods
o Basic principles of chemical technology - unit operations and unit processes.
o Process Flow Diagrams (PFDs).
o Process utilities
Day 2
 Equipment Used in Process Plants
o Process equipment - reactors, towers, exchangers and vessels
o Mechanical equipment - pumps, compressors and turbines
o Equipment drawings, nozzle specifications and vendor drawings
o Equipment foundations and supports
 Plant Layout and Plot Plans
o Plant layout specifications
o Guidelines and codes for plant layout
o Safety considerations
o Plot plans
o Equipment arrangement drawings
 Process and Instrumentation Diagrams (P&Ids)
Day 3
 Plant Layout and Piping Design Documentation and Tools
o Equipment arrangement drawings
 o Equipment lists
o Piping and Instrumentation Diagrams (P&IDs)
o Piping line lists
o Piping specifications and codes
o Piping isometrics
o Bill of materials
o 3D models
Day 4:
 Fundamentals of Pipe
o Piping materials
o Pipe dimensions and pipe data
o Pipe joining methods
o Pipe representation
o Common abbreviations
 Piping System Components
o Fittings - elbows, tees, reducers and end caps
o Fitting makeup and dimensions
o Flanges and flange ratings
o Valves
o Pipe racks, pipe supports and anchors and guides
 Pipe Routing
o Piping isometrics
o Piping plans, sections and elevations
o 3D representation
 3. Practical Lubrication Engineering for Engineers
Basic knowledge of lubricants and their applications are very important for maintenance
technicians and maintenance engineers. The variety of different lubricants increased
considerably over the last 10 years and if the right lubricant is used at the right time and in the
correct application, maintenance cost can be reduced and the life expectancy of equipment
increased. This outstanding workshop is a comprehensive, highly practical and interactive two-
day course. It will provide you with a collection of strategic knowledge from many practicing
professionals in this area. By the end of the workshop, you will have developed the skills and
ability to recognize and solve lubricant problems in a structured and confident manner.
At the end of this program participants will be able to:
 How to choose the best lubricant for your application
 How to better understand and manage lubricants
 How to use lubricants effectively in a proactive maintenance program
 When to select grease or oil as the lubricant of choice
 Best practices for oil draining, flushing and charging
 How to write equipment lubrication procedures
 How to handle lubricants in pumps and reservoirs
 The truth about aftermarket additives and oil conditioners
 How to best store lubricants and handle them effectively
 The latest techniques which are dramatically different to those of 10 years ago
 How to extend the life of your lubricants
 Troubleshooting techniques to deal with lubricants effectively in the future
The Program
Day 1
Discuss Briefly The Composition Of Lubricants And Synthetic Lubricants.
 Tribology
o The cause of friction, heat, the result of friction, what causes wear
o The types of lubrication:
 fluid and hydro-dynamic lubrication
 boundary lubrication
The characteristics of the lubricant under different operating conditions e.g. material
surfaces, temperature conditions, load and viscosity of the lubricant
o Different types of lubricants for different applications
 Tribology Root Causes of Failures
o Fluid contamination control
o Leakage stability
o Fluid chemical stability
o Temperature stability
o Wear stability
Day 2
 The Properties Of Lubricants
o Viscosity
o Flashpoint and Volatility
 o Oxidation and thermal stability
o Demulsibility
o Foaming and gas solubility
o Corrosion prevention
o Compatibility
Day 3
 Lubricating Oil Additives
o Oxidation inhibitors
o Rust and corrosion inhibitor
o Pour point depressants
o Viscosity inhibitor (VI) improvers
o Anti-wear additives
o Extreme pressure (EP) additives
o Anti-foam additives
o Detergents and dispersants additives
o Demulsifiers and Emulsifiers
o Tackiness additives
 Automotive Drive Line Lubrication
o Viscosity classifications
o Automatic transmission fluid
 Hydraulic Systems And Fluids
o Hydraulic systems
o Viscosity of the lubricant
o Chemical stability
o Fire resistance
o Anti-wear
o Anti-rust
o Anti-foam
 Miscellaneous Lubrication
o Steam Turbine Pumps and Motor Lubrication
o Air Compressor Lubrication
Day 4
 Types of Lubricants Greases and Grease Lubrication
o Grease characteristics
o Lubrication grease classification
o Choice of grease
o Grease types and performance
o Grease application and trouble-shooting
o Roller bearing lubrication
 Internal Combustion Lubricants
o Petrol and diesel engines
o The choice of lubricant by engine type
o Lubricant classification
o Plain bearing lubrication
 Lubrication Systems Filtration
o Contamination fundamentals
 o Contamination generation
o Cleanliness control
o Filter fundamentals
o Filter performance and testing
o Flashing
 Conditions Assessment Of Rotating Machinery
o Monitoring techniques
o Vibration analysis
o Oil analysis
 4. Pipeline Systems – Design, Construction, Maintenance and Asset
Management

At the end of this program participants will be able to:

The pipeline design standards
 Design and construction considerations
 Prediction, detection and treatment of corrosion
 Environmental and legal requirements
 How to meet and exceed key safety issues
 Optimum risk and financial considerations
You will learn about the practical aspects of pipeline design, integrity, maintenance and
repair mainly in a land based environment. You will gain an in-depth understanding of the
applicable codes and standards and the issues of mechanical and hydraulic design and
construction practices. The optimum routing and layout techniques will also be assessed.
You will be able to recognize causes of degradation in-service, whether mechanically induced
(pressure, fatigue, pressure transients, external damage or due to corrosion such as from wall
thinning, pitting andcracking). The focus of this program will be on consideration of internal,
external and pipeline corrosion. The program will assess the various inspection and repair
techniques from the most common to the most recent and the implementation of integrity
management programs, periodic inspections and evaluation of results. The program will
conclude with an evaluation of maintenance issues and asset management. The use of Key
performance indicators will be derived to measure the performance of your valuable asset - the
pipeline. Extensive use will be made of case studies and practical exercises to ensure the material
is covered as thoroughly as possible.
The Program
Day 1:
 Pipeline Design Standards
o Standards development
o International and local codes applicable to pipelines
o Changes to the regulations
o Steps in pipeline design
o Different materials transmitted: gas, steam and water
Day 2:
 Pipeline Design Considerations
o Compressible and non-compressible flow
o Discussion of steady state and transient analysis
o Examination of pumps and compressors
o Discussion of optimal pipeline construction material Practical Exercise
Day 3:
 Construction Process
o Examination of sequential spread
o Advice on making construction more efficient
o Examination of the hot-tap process
o Discussion of hydrotesting
o Examination of the strategic approach to pipeline construction and management
Day 4:
 Fitness-For-Purpose Analysis
o Examination of the principal kinds of damage that affects pipelines in service:
corrosion, mechanical damage, welds defects and ground movement
o Examination of assessment techniques with respect to these kinds of damage
o Strategies for pipeline management and maintenance
o Examination of the link between task importance and asset criticality
o Presentation of maintenance benchmarking techniques
 5. Metallic Corrosion and Methods of Protection
The Program
Day 1:
 Corrosion, Assessment and Repairs
o Introduction to Practical Corrosion
o Classification of Corrosion Mechanisms
o Internal Corrosion
 Predictions of corrosion rates
 Chemical treatments, inhibitors and biocides
o External Corrosion
 Coating applications
 Cathodic protection, design, operation and maintenance
 CP evaluation
Day 2:
 Forms of Corrosion
o Uniform corrosion
o Galvanic corrosion
o Crevice corrosion
o Pitting corrosion
o Intergranular corrosion
o Selective leaching
o Erosion corrosion
Day 4:
 Pipeline Corrosion
o CO2/Sweet
o Local and generalized corrosion
o Soils and microbiologically induced corrosion
 6. Cathodic Protection
The Program
Day 1:
 Cathodic protection [6]
Cathodic protection is defined as the reduction or prevention of corrosion by making it a
cathode in the electrolytic cell and can be classified into:
o Sacrificial anode method
o Impressed current method
Day 2
 Cathodic Protection Methods
o Sacrificial anodes method
o Impressed current method
Day 3
 Evaluation of Corrosion Rate
o From weight loss method
o From polarization method
Day 4
 Design
o Protection potential.
o Current density.
o Electrical resistivity of the environment
 ‫اﻟﺤﺮارﯾﺔ اﻟﻤﺒﺎدﻻت ﺷﺒﻜﺎت ﺗﺼﻤﯿﻢ ﻃﺮﯾﻖ ﻋﻦ اﻟﻄﺎﻗﺔ ﺗﺮﺷﯿﺪ‬
7. Energy Conservation through Heat Exchangers Networks
Synthesis

Day Title of Lecture

Energy problem- Importance & Methods of Energy Conservation , Energy
Conservation Through Heat Exchangers Networks Synthesis
‫ ﺗﺮﺷﯿﺪ اﻟﻄﺎﻗﺔ ﻋﻦ ﻃﺮﯾﻖ ﺗﺼﻤﯿﻢ ﺷﺒﻜﺎت اﻟﻤﺒﺎدﻻت اﻟﺤﺮارﯾﺔ‬، ‫ﻣﺸﻜﻠﺔ اﻟﻄﺎﻗﺔ – أھﻤﯿﺔ وﻃﺮق ﺗﺮﺷﯿﺪ اﻟﻄﺎﻗﺔ‬
1st Day Coffee Break
Basics of Pinch Design Technology for Heat Exchangers Networks' Synthesis
‫اﺳﺎﺳﯿﺎت ﻃﺮﯾﻘﺔ اﻟﻨﺪﺑﺔ ﻟﺘﺼﻤﯿﻢ ﺷﺒﻜﺎت اﻟﻤﺒﺎدﻻت اﻟﺤﺮارﯾﺔ‬

Steps for Designing Heat Exchangers' Networks Using Pinch Design Method
‫اﻟﺨﻄﻮات اﻟﺘﻔﺼﯿﻠﯿﺔ ﻟﺘﺼﻤﯿﻢ ﺷﺒﻜﺎت اﻟﻤﺒﺎدﻻت اﻟﺤﺮارﯾﺔ ﺑﺎﺳﺘﺨﺪام ﻃﺮﯾﻘﺔ اﻟﻨﺪﺑﺔ‬
Coffee Break
2nd Day
How to Design an optimum Heat Exchangers' Network
‫ﻛﯿﻔﯿﺔ اﻟﻮﺻﻮل ﻟﻠﺘﺼﻤﯿﻢ اﻷﻣﺜﻞ ﻟﺸﺒﻜﺔ اﻟﻤﺒﺎدﻻت اﻟﺤﺮارﯾﺔ‬

Data Extraction for Designing of Heat Exchangers' Networks by Using Process

Simulation Programs
‫اﻟﺤﺼﻮل ﻋﻠﻰ اﻟﺒﯿﺎﻧﺎت اﻟﻤﻄﻠﻮﺑﺔ ﻟﺘﺼﻤﯿﻢ ﺷﺒﻜﺎت اﻟﻤﺒﺎدﻻت اﻟﺤﺮارﯾﺔ ﺑﺎﺳﺘﺨﺪام ﺑﺮاﻣﺞ اﻟﻨﻤﺬﺟﺔ ﻟﻠﻌﻤﻠﯿﺎت‬
3rd Day Coffee Break
Applications of Heat Exchangers Networks Synthesis for Some Existing Plants
‫ﺗﻄﺒﯿﻘﺎت ﻟﻄﺮﯾﻘﺔ ﺗﺼﻤﯿﻢ ﺷﺒﻜﺎت اﻟﻤﺒﺎدﻻت اﻟﺤﺮارﯾﺔ ﻋﻠﻰ ﺑﻌﺾ اﻟﻮﺣﺪات اﻟﻘﺎﺋﻤﺔ اﻟﻔﻌﻠﯿﺔ‬

Recent Mathematical Formulation Methods used for Designing Heat of

Exchangers Networks
‫اﻟﻄﺮق اﻟﺮﯾﺎﺿﯿﺔ اﻟﺤﺪﯾﺜﺔ اﻟﻤﺴﺘﺨﺪﻣﺔ ﻟﺘﺼﻤﯿﻢ ﺷﺒﻜﺎت اﻟﻤﺒﺎدﻻت اﻟﺤﺮارﯾﺔ‬
4th Day
Coffee Break
Questions & Comments
‫ﻣﻨﺎﻗﺸﺔ‬
‫‪8. Fundamentals of Oil & Gas Facilities‬‬
‫اﻟﯿﻮم اﻷول‪:‬‬
‫‪ ‬أﺳﺎﺳﯿﺎت وﺗﺴﮭﯿﻼت إﻧﺘﺎج اﻟﺰﯾﺖ اﻟﺨﺎم ‪I‬‬
‫اﻟﯿﻮم اﻟﺜﺎﻧﻰ‪:‬‬
‫‪ ‬أﺳﺎﺳﯿﺎت وﺗﺴﮭﯿﻼت ﺗﺼﻨﯿﻊ اﻟﺰﯾﺖ اﻟﺨﺎم ‪II‬‬
‫اﻟﯿﻮم اﻟﺜﺎﻟﺚ‪:‬‬
‫‪ ‬ھﻨﺪﺳﺔ ﻋﻤﻠﯿﺎت اﻟﺘﻜﺮﯾﺮ‬
‫اﻟﯿﻮم اﻟﺮاﺑﻊ‪:‬‬
‫‪ ‬أﺳﺎﺳﯿﺎت وﺗﺴﮭﯿﻼت ﺗﺼﻨﯿﻊ اﻟﻐﺎز‬
 9. Corrosion Problems in The Petroleum Fields
The Program
Day 1:
 Acidizing oil and gas wells
Day 2:
 Scale remover treatment using acids
Day 3:
 Refinery units
 Oil storage tanks
Day 4:
 Protection against corrosion
o Methods based on design improvement
o Methods based on modification of the metal
o Methods based on modification of the environment
o Chang of the metal potential