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ASIANS ACADEMY OF PROFESSIONAL TRAINING

2nd floor, Adinath Shopping Complex,Pune Satara Road, Pune 411 037.
Website -: www.asianacademy.org.in Email -: mrjoshi.piping@yahoo.com

POST GRADUATE DIPLOMA IN


BOILER & PLANT EQUIPMENT DESIGN & ENGINEERING
(Autonomous)

Course Structure & Examination Scheme


Sr.
No.

1.
2.
3.
4.
5.

6.
7.
8.
9.

Subject

SEMESTER I
Instructional Hours
Theory

Practical/
Drawing

Coded design of
pressure vessels &
design of storage tanks
Heat exchanger design
Equipment design for
unit operations
Fabrication of Process
equipment
Materials of
construction and
corrosion

40

10

40
40

70
70

20

20

Statutory regulations
and safety code rules
Inspection and quality
control of process
equipments
System engineering &
detailed eng..
Project work

20

Examination

Theory Marks
Theory Internal
Exam
Assessment
70
30

Total
Marks

Term
Work
Marks
25

Oral
Exami
nation
25

150

30
30

100
100

35

15

50

35

15

50

SEMESTER II
35

15

50

20

16

35

15

25

25

100

40

20

35

15

25

25

100

30

100

50

150

1.

CODED DEIGN OF PRESSURE VESSELS & DESIGN OF


STORAGE TANKS Theory-40
Hrs
Practical 10 Hrs
Theory Exam.- 70 Marks
Oral Examination- 25
Term work Marks 25
Marks Internal
Assessment- 30 Marks
Review of design principles form strength of materials. Deign principles
adopted in ASME and IS codes. Code philosophy. Understanding the
stated and implied requirements of the design codes.
Pressure vessels categories and classification, loading to be considered.
Concept of MAP, MAWP and DP code rules for design of cylindrical
vessels, spherical vessels, dished heads, flat heads. Nozzle opening
reinforcement, welded joint permitted as per code.
Design of jacketed vessels limpet coils, design of tall towers consideration
of wind load and seismic loads.
Design of leg support, saddle supports and skirt supports.
Working out and specifying the requirements for impact testing. PWHT
temperature heating and cooling rates, hydrotest pressure. Manufacturer's
data reports, stamping of vessels.
Design of Storage Tank
Classification of storage tanks bulk storage and day storage. Sizing and
optimizing of storage tanks. Design of storage tanks according to API 650
and IS 803 codes. Design of bottom plate layout, shell layout roof layout.
Shell design by one foot method, design of conical roof and dome roof.
Basic consideration in design of floating roofs, design of wind, girders and

stiffening rings, nozzles, & appurtenances. Field installation, inspection and


testing of bulk storage tanks.
Design of underground storage tanks, venting of underground tanks.
Design of shop fabricated tanks as per API 12C. Design of mobile tanks
and tankers.
2.

HEAT EXCHANGER DESIGN


Theory-40
Hrs
Theory Exam.- 70 Marks
Internal Assessment- 30
Marks
Thermal / Process Design of Heat Exchangers
Heat exchanger types, classification, categories, and nomenclatures used in
TEMA codes, thermal design of heat exchangers, physical phenomena in
condenser, reboiler, exchanger condenser liquid (water) cooled, air cooled
film heat transfer coefficients equations for estimation, typical values, dirt
factors, LMTD and correction factors, pressure drop calculation criteria for
deciding shell / tube side fluids, criteria for no of passes software and its
validation, mechanical design of heat exchangers according to ASME &
TEMA codes, design of shell side components design of tube side
components, design of tube sheets under bending and shear loads, sizing of
non pressure parts, detailed case study on heat exchanger design.
Mechanical Design of Heat Exchangers
Heat exchanger types, classifications, categories, nomenclatures and
terminology.
Design of shell bonnet, channel, channel covers, selection of girth flanges.
Design of floating heads.
Design of stationary tube sheets, floating tube sheets, fixed tube sheets
design of tube bundles
(U tube and straight type)
Sizing and selection of non pressure part like baffles, spaces, bolting bars,
P.P. plates etc Testing of heat exchangers.

3 EQUIPMENT DESIGN FOR UNIT OPERATION


Theory-40 Hrs
Theory Exam.- 70 Marks
Internal Assessment- 30
Marks
Evaporators : Review of thermal design considerations, multiple effect
and optimization consideration, types of evaporators and selection brief
overview of vacuum devices, sizing of evaporators and further mechanical
design considerations, accessories for evaporators and their design.
Crystallizers : Basic principles of crystallization, types of crystallizers
sizing of crystallizers, mechanical design considerations.
Agitators : Basic principal of agitator design, impeller types and flow
patterns, estimating speed of revolution and power components of complete
agitator system, mechanical design considerations.
Filters : Classification of filtration equipment, sizing of filtration
equipment, mechanical considerations,
Dryers : Principals of drying, types and classification, sizing of drying
equipment, auxiliaries for drying equipment, mechanical design
considerations.
Columns / Towers
1.1
Types of internals
1.2
Brief overview of different internals
1.3
Mechanical design considerations for internals.
1.4
Typical specifications and performance parameters.
Optimization and standardization considerations application to various
process equipment.
Agitator shaft sealing systems.
Specific considerations of heat transfer and masses transfer applicable to
evaporators, crystallizes, agitators and dryers.

4 FABRICATION OF PROCESS EQUIPMENTS


Theory-20 Hrs
Theory Exam.- 35 Marks
Internal Assessment- 15
Marks

Study of fabrication drawings, fabrications sequence diagrams and


schedules.
Materials identification, cuttings plans fabrication tolerances, weld-edge
preparations, fitups, assembly welding sequences.
Welding processes (SMAW, GTAW, GMAW, SAW) selection of welding
processes, welding equipments, equipment calibrations.
Understanding welding symbols, preparation of weld joints pre & post
heating requirements. Full & partial penetration weld, welds with backing
strips.
Procedure and performance qualifications as applied to shop practice.
Use of welding jigs-fixtures, distortion control, PWHT, hydro & pneumatic
testing of pressure vessels.
Painting & protection methods of surface preparation, selection and
application of painting system DET measurements.

5 MATERIALS OF CONSTRUCTION AND CORROSION


Theory-20 Hrs
Theory Exam.- 35 Marks
Internal Assessment- 15
Marks
Brief review of metallurgy, Iron-carbon equilibrium diagram; Review of
engineering properties, stress strain diagrams.
Factors governing choice of materials, criteria for material selection for
process equipments.
Commonly used carbon steel, alloy steels, stainless steels.
Choice of materials for low temperatures, cryogenic services. Material for
high temperatures, material for corrosive services materials for petroleum
industries, NACE material.
Common ASTM specifications, selection of equivalent material from IS, BS,
JIS and DIN specs.
Non metallic materials, polymeric materials, HDPE, PP, PVC etc.
Selection of gasket materials.
Corrosion types and methods of preventing corrosion
Painting and coating for corrosion protection, surface preparation (Sand
blasting, gritblasting) and painting methods. DET measurements, Pickling
and passivation.

6.

STATUTORY REGULATIONS AND SAFETY CODE RULES

Theory-20 Hrs
Theory Exam.- 35 Marks
Internal Assessment- 15
Marks
Brief review of safety codes applicable to pressure vessels.
IBR regulations for boilers, stamping as regards the design, material
selection, weld joints and inspection, IBR documentation.
SMPV code rules their applications for process equipments.
Safety gadgets e.g. safety valves, flame arresters, vent valves, principles
governing selection and setting of safety valves.
Regulations for explosive vessels, specific precautions for handling
flammable and hazardous substances, liquefied gases.
Hazardous area classifications introduction to 'HAZOP' methodology.
Introduction to environmental protection and waster management.

7.

INSPECTION AND QUALITY CONTROL OF PROCESS EQUIPMENT


Theory-20 Hrs
Practical 16 Hrs
Theory Exam.- 35 Marks
Term work Marks 25
Marks
Internal Assessment- 15
Marks

A.

Quality Control System Requirement


Q. C. System outline
Authority and responsibility
Organization
Drawings and design calculations
Material control
Exam and inspection programme
Correction of NCR welding
NDT
Heat treatment
Calibration of measurement and test equipments
Records
Sample forms.
B.
Inspection Before, During and After Welding
C.
Destructive Testing
D.
Nondestructive Testing (RT, PT, UT, MT, LT, ET, VT)
E.
Acceptance Standard For Destructive & Nondestructive Testing.
F.
ASME Section IX Welding and Performance Qualification.
G.
Typical Q.C. Plan and Inspection Checks
H.
ASME Certification Schemes

8.

SYSTEM ENGINEERING AND DETAILED ENGINEERING


Theory-40
Hrs
Practical 20 Hrs
Theory Exam.- 35 Marks
Oral Exam- 25
Term work Marks 25
Marks
Internal Assessment- 15
Marks
Introduction to equipment sizing and equipment data sheet. Essential
elements of design drawings, preparation of design, drawing based on
thickness calculations, M.O.C. and nozzle schedules.
Details of the drawings incorporating details like manway devits lifting
lugs, detailing of saddle supports, skirt supports, platforms and ladders,
handrails. Detailing of internals like sparger pipes, internal coils, baffles,
demister supports, tray support rings etc. Preparation of fabrication
drawings detailing of hear exchanger drawings.
Preparation of MR/MS documents (material requisition and material
specification documents) for procurement purpose Understand MTO, BOQ,
BOM etc. Use of CAD system in generation of vessel drawings.
Preparation of cutting plans for material, obtaining plate economy.
Calculation of load data (test weight, empty, weight, operating weight) and
other information to be shown on the vessel drawings.
Transportation drawings
Preparations of as built drawings

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