JA Alpha
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Examining Engineer Qualification Requirements:
--> Member, National Board of Directors, or
--> Independent Examining Engineer Examination
- Education Required - Bachelor's Degree or Equivalent
- Experience Required - Twelve years as a Qualified Power Engineer
- Prerequisite - Chief Engineer's License
- Examination Formats - Written
Technical Instructor Qualification Requirements:
--> Examination Route
- Education Required - Bachelor's Degree or Equivalent
- Minimum Operating Experience Required - Twelve years Power Engineering Qualification
- Prerequisite - Chief Engineer's License
- Examination Formats – Written
--> Third Party Training Route
- Currently Registered as a Power Engineer at least one Class above the Level Approved for Instruction
- NIULPE Approved Third Party Technical Instructor Training Program
Approved Educator Qualification Requirements:
--> Appointment by NIULPE National Board of Directors
--> Instructor’s Minimum Qualifying Requirements for approved Program Delivery:
Delivery of National/International Standards:
- NIULPE Technical Instructor Qualification, or
- A NIULPE Power Engineering Qualification at least one Class above the National Program (Class) Delivered
- NIULPE Approved Third Party Technical Instructor Training Program
- Minimum Operating Experience Required - Twelve years Power Engineering Qualification
- Prerequisite - Chief Engineer's License
- Examination Formats – Written
Delivery of Extracted and Technology Standards:
- Proven experience in delivering the Program Subject Matter, and
- NIULPE Technical Instructor Qualification, or
- A NIULPE Power Engineering Qualification at least one Class above the National Program (Class) Delivered
- NIULPE Approved Third Party Technical Instructor Training Program
- Details
NIULPE and our partners offer content and training in a wide range of trades and technology focused areas to help supplement occupation specific knowledge requirements. Our portfolio emphasizes but is not limited to Jobsite Planning and Plant Safety, Buildings and Facilities, Commercial Facility Construction Maintenance, Plant Processes and Control, Mechanical Technologies, Heat and Pressure, Rig Technologies.
- Details
Learning Outcome
Describe the design, components, and implementation of a loss control program.
Learning Objectives
- Explain the purpose, benefits, and typical components of a loss control program.
- Explain the process of developing a comprehensive loss control program including the typical responsibilities and accountabilities of the program.
- Describe the factors affecting insurance rates and the authority, role, and interaction of insurance inspectors with plant staff.
- Describe the tools and techniques used to develop a positive attitude towards the components of a loss control program.
- Describe the tools and techniques used to develop safety awareness in consumers.
Learning Outcome
Identify the authority and application of federal and state safety legislation to the work place.
Learning Objectives
- Explain the ultimate responsibility and requirement, in the work place, to enforce all relevant safety legislation and regulations and to respond to regulatory directives.
- Describe the legal and ethical obligations of managers, supervisors, and employees to personnel safety.
- Explain the significance, components, and applications of Canada Labor Occupational Health and Safety legislation.
- Explain the authority, significance, components, and applications of provincial safety regulations, including the role and interactions of the provincial safety inspectors with plant staff.
- Explain the requirements for safety compliance training.
- Explain right to refuse work legislation and its legal implications.
- Explain the authority, significance, and applications of the Workers’ Compensation Board regulations, including the role and interactions of the Board with plant staff.
- Describe the function of, and roles and responsibilities for, a worksite health and safety committee.
Learning Outcome
Describe comprehensive safe work programs.
Learning Objectives
- Identify the components and explain the management of a comprehensive safe work program.
- Explain the components and management of a safety training program.
- Explain the process of hazard identification, risk assessment and mitigation.
- Explain the significance and procedure for safe work planning.
- Explain the significance and procedure for safe work permits, including lockouts.
- Explain the significance and procedure for confined space entry.
- Explain the significance and procedure for hot work.
- Explain the significance and procedure for excavations.
- Explain the significance and procedure for working at heights.
- Explain the significance and components of a contractor safety program.
- Explain the components and management of a safety audit program, including roles and responsibilities.
- Explain the purpose, components, and procedure for a hazard and operability study.
Topic 4 Emergency Response and Incident Investigation
Learning Outcome
Describe emergency response and incident investigation programs.
Learning Objectives
- Identify the benefits and typical stakeholders of an emergency response program.
- Explain the typical components of an emergency response program.
- Explain the process of developing and maintaining an emergency response program, including typical responsibilities and accountabilities.
- Explain the procedure for emergency response testing.
- Explain the typical components of an incident reporting and investigation program.
- Define categories of incidents.
- Describe roles and responsibilities for incident initial reporting, investigation, final reporting, and corrective actions.
- Explain the significance off and steps required in incident investigation.
- Describe a system for managing incident report data, including the communication process and its significance.
- Apply an incident reporting and investigation procedure to a case study.
Topic 5 Environmental Legislation
Learning Outcome
Identify the authority and application of federal and provincial safety legislation and permits.
Learning Objectives
- Explain the ultimate responsibility and requirements to enforce all relevant environmental legislation and regulations and to respond to regulatory directives.
- Explain the authority, significance, components, and applications of provincial environmental legislation and regulations, including the role and interactions of the provincial inspectors with plant staff.
- Explain the authority, significance, components, and applications of federal environmental legislation and regulations, including the role and interactions of the federal environmental inspectors with plant staff.
- Explain the significance and process of identifying and working with typical stakeholders for environmental programs – the Environmental Impact Assessment (EIA) process.
- Explain typical compliance requirements for an environmental monitoring program, including equipment calibration and uptime requirements.
Topic 6 Environmental Management
Learning Outcome
Explain environmental management programs, including reporting, clean‐up, disposal, and reclamation.
Learning Objectives
- Explain the purpose, significance and components of an Environmental Management System.
- Describe the ISO 14000 ‐ 14002 standards for an Environmental Management System.
- Describe requirements for environmental routine, excursion and exceedance reporting.
- Explain the compliance tests for Continuous Emission Monitoring Systems (CEMS) and the significance and procedures for Relative Accuracy Test Audits (RATA).
- Explain the responsibilities and procedures for spill containment and cleanup.
- Explain the components and development of an environmental audit program.
- Explain the procedure for an environmental audit, including the roles and responsibilities for performing and responding to the audit.
- Explain the significance, procedures, and regulatory requirements of waste segregation and disposal.
- Identify waste streams that require special disposal procedures, including recognition of hazardous wastes.
- Explain the significance and general components of Transportation of Dangerous Goods Acts.
- Explain the significance and general requirements of hazardous waste transportation.
- Describe the purpose, significance, requirements and general process of land reclamation.
Topic 1 Project Management
Learning Outcome
Demonstrate the application of project management practices.
Learning Objectives
- Define a project, the role of project management and the makeup of the project stakeholders.
- Identify the roles and responsibilities of a typical project team.
- Explain in detail the project planning step.
- Describe the common tools that are used for project planning and management, including Work Breakdown Structure (WBS), Critical Path Method (CPM) and Gantt charts.
- Explain in detail the project execution step, including control processes.
- Explain in detail the project completion step, including assessment and reporting.
Topic 2 Maintenance Management Practices
Learning Outcome
Explain management practices for typical maintenance programs.
Learning Objectives
- Describe how equipment is managed through the concept of asset management.
- Explain the purpose, components, and management of a maintenance program including preventive, predictive and corrective maintenance approaches.
- Explain the concepts and importance of reliability centred maintenance (RCM) in developing a maintenance program.
- Describe the major steps in performing an RCM analysis.
- Provide an example of how RCM is applied.
- Explain the purpose and process of root cause failure analysis (RCFA).
- Describe how maintenance can be optimized.
- Describe how a plant turnaround is planned and effectively executed.
- Explain the concept, process, and benefits of outsourcing maintenance.
- Explain the setting up and management of short‐term maintenance contracts and long‐term service agreements.
- Explain the purpose and process of maintenance planning and scheduling.
Learning Outcome
Explain quality control programs and specific boiler repair procedures.
Learning Objectives
- Explain the National Board of Boiler Inspectors (NBBI) requirements for owner inspection and quality control programs.
- Describe in detail the components of owner inspection and quality control programs, including roles and responsibilities, records and reporting procedures.
- Describe the roles, responsibilities, and personnel qualifications regarding repairs to boilers.
- Explain the detailed procedure for repairs to cracks in boiler parts, including drums and headers.
- Explain the detailed procedure for repairs to ruptured boiler tubes.
- Explain the management, responsibilities, and procedures for safety valve repairs.
Topic 4 Pressure Vessel and Piping Repairs
Learning Outcome
Explain specific pressure vessel and piping inspection and repair procedures.
Learning Objectives
- Describe the management roles, responsibilities, and qualifications regarding repairs to pressure vessels and pressure piping.
- Explain the concept for fitness for service.
- Describe in detail a typical pressure vessel inspection, identifying typical problem areas.
- Describe in detail a typical pressure piping inspection identifying common problem areas.
- Explain the detailed procedure for typical repairs to cracks in pressure vessels.
- Explain the methods and detailed procedures for typical repairs to corrosion in pressure vessels.
- Explain the detailed procedure for typical repairs to cracks in pressure piping.
- Explain the methods and detailed procedures for typical repairs to corrosion in pressure piping.
Topic 5 Non-Destructive Examination
Learning Outcome
Explain the methods, applications, and control of non‐destructive examination.
Learning Objectives
- Explain the significance and application of ASME Section V.
- Describe radiographic examination.
- Describe the process of ultrasonic examination.
- Describe the process of dye penetrant examination.
- Describe the process of magnetic particle examination.
- Describe the process of eddy current examination.
- Describe the process of acoustic emission examination.
- Explain the selection, management, and control of a non‐destructive examination contractor.
Topic 6 Rotating Equipment Maintenance
Learning Outcome
Explain specific maintenance procedures for, and typical maintenance problems of, rotating equipment.
Learning Objectives
- Explain the typical maintenance problems of a large steam turbine.
- Explain the procedures for inspection and overhaul of a large steam turbine.
- Explain the procedures for inspection and overhaul of a gas turbine.
- Explain the typical maintenance problems of a large multi‐stage pump.
- Explain the procedures for inspection and overhaul of a large multi‐stage pump.
- Explain the typical maintenance problems of a large generator.
- Explain the procedures for inspection and overhaul of a large generator.
Topic 7 Rotating Equipment Monitoring
Learning Outcome
Describe the parameters and methods of turbine monitoring and oil analysis.
Learning Objectives
- Describe the purpose, importance and types of rotating equipment monitoring.
- Explain the concept and significance of turbine thermal expansion, the general principles and placement of measuring devices and the procedures to control.
- Explain the concept and significance of turbine differential expansion, the general principle and placement of measuring devices and the procedures to control.
- Explain the concept and significance of turbine eccentricity, the general principle and placement of measuring devices and the procedures to control.
- Explain the concept of vibration, including typical causes, effects, and locations of vibration in rotating equipment and how it is measured.
- Explain the concept and significance of turbine critical speed.
- Explain the concept and significance of oil whirl, oil whip, and steam whirl and the design and operational considerations to counter oil whirl.
- Describe common oil problems and their effects on rotating equipment and a typical oil sampling and testing program.
Topic 1 Business Management
Learning Outcome
Explain general concepts in plant budgeting, finance, accounting, and inventory control.
Learning Objectives
- Explain the concept and significance of the following accounting terms: accounting cycle, dual entry accounting, debits and credits, accrual accounting, revenue and expenses, assets and liabilities, and debt and equity.
- Explain the concept and significance of financial statements, including Income Statement, Balance Sheet, Statement of Retained Earnings and Cash Flow Statement.
- Explain budget development, control and reporting processes.
- Explain typical types of budgets and their significance, including revenue, expense, capital expenditure and production budgets.
- Explain the components of plant department budgets.
- Explain the significance of a cost/benefit analysis.
- Explain the “time value of money” concept and calculate the Net Present Value (NPV) and Internal Rate of Return (IRR) of a proposed investment.
- Calculate the Return on Investment (ROI) of a proposed investment.
- Explain depreciation, including straight‐line and declining balance depreciation, and the concept and significance of Capital Cost Allowance (CCA).
- Describe the components and use of a typical automated inventory system.
- Explain the purpose and operation of typical inventory management systems, including fixed‐point, fixed‐interval, max/min, ABC, Just In Time (JIT) and Economic Order Quantity (EOQ).
- Explain the concepts and significance of periodic and perpetual inventory systems, Last In First Out (LIFO) and First In First Out (FIFO).
- Describe the role of a supplier and the use of strategic partnerships in an inventory management system.
Learning Outcome
Explain general concepts and management of contracts.
Learning Objectives
- Explain the content and significance of a typical code of ethics of a professional association.
- Explain the importance and application of ethical practices in the work place.
- Define and explain the legal significance of contract, offer and acceptance.
- Explain the significance of contract documentation, and the rights and obligations of a contactor and contractee.
- Compare contract types, including: fixed price; cost plus/shared risk; fixed price/cost plus incentive; bonus/penalty; time/material; product/service/resource; and enforceable/unenforceablecontracts.
- Describe methods of discharging a contract, including: agreement, performance, impossibility, operation of law, breach, failure to perform and specific performance.
- Explain tort and its legal significance; the three basic types of torts, including: intentional, fault‐based or negligent, and strict liability; the distinction between legal and ethical liability.
- Explain due diligence and its legal and ethical significance.
- Explain “force majeure” and its legal significance.
- Explain what is involved in issuing and then completing a tendering process.
Topic 3 Problem Solving and Decision Making
Learning Outcome
Explain techniques for structured problem solving and decision making.
Learning Objectives
- Explain the importance and application of a structured decision making process.
- Describe the eight steps in a rational decision making process.
- Compare analytic, conceptual, directive and behavioral decision making styles.
- Explain the advantages and disadvantages of group decision making.
- Describe the common methods of group decision making, including brainstorming, storyboarding, Nominal Group Technique (NGT) and the Delphi technique.
- Apply a problem solving and decision making approach to a typical plant case study.
Learning Outcome
Discuss models of leadership and motivation.
Learning Objectives
- Explain leadership responsibilities and the significance of an effective leadership style.
- Explain the Managerial Grid and its significance.
- Explain Situational Leadership and its significance.
- Compare the concept and significance of traditional objective setting and Management by Objectives (MBO).
- Compare methods of communicating goals and objectives.
- Explain the Motivation Process
- Compare the basic models of individual motivation, including the Hierarchy of Needs, Motivation‐ Hygiene Theory, Goal‐Setting Theory, Reinforcement Theory, Equity Theory, and Expectancy Theory.
- Explain the concept and significance of the Social Styles Matrix.
Topic 5 Communication and Conflict Resolution
Learning Outcome
Apply principles of communication and conflict resolution in the work place.
Learning Objectives
- Compare linear, interactive, and transactive communications and their significance.
- Explain the common communication shortcuts and their significance, including selectivity, assumed similarity, stereotyping, and the halo effect.
- Explain the significance and effects of conflict in an organization.
- Describe interpersonal and intergroup conflict.
- Explain the lose/lose, lose/win, win/lose and win/win outcomes of conflict.
- Explain assertiveness and cooperativeness and their significance.
- Compare avoiding, accommodating, forcing, collaborating and compromising as conflict resolution strategies.
- Explain the stages in assertive behavior for conflict resolution.
- Describe the concept, significance, responsibilities and typical steps and tactics of a grievance process.
- Explain the process of labor/management conflict resolution.
- Describe the typical public stakeholders for an organization’s business and the typical communication processes used in dealing with the public.
- Explain the public concerns that an organization must address and the appropriate communication methods used in addressing them.
Learning Outcome
Explain principles and models in the management of labor relations and change.
Learning Objectives
- Explain management’s right and responsibilities in the enforcement of federal and provincial labor legislation.
- Compare management interactions between union and non‐union work forces.
- Explain the concept, preparation, and tactics of collective bargaining, including the use of a problem‐ solving approach.
- Explain the concepts, significance, roles, and responsibilities during conciliation, arbitration, strike or lockout.
- Compare the benefits and significance of permanent and contingent employees.
- Explain the purpose and process of human resource planning and capacity planning.
- Explain the facilitation of labor relations with a contractor’s workforce.
- Describe the types of changes that occur in the workplace, the relationship between workplace change and employee attitude, the psychological costs and benefits of change, and management’s role and responsibilities.
- Explain the concept and significance of homeostasis.
- Describe the three types of resistance to change (logical, psychological, and sociological), the potential benefits of resistance to change, and the three basic steps to overcome resistance (unfreezing, changing, and refreezing).
- Explain the typical strategies used to build support for change, including: use of group forces, leadership for change, participation, shared rewards, negotiation, employee security, and communication.
- Explain the purposes and processes of benchmarking.
Topic 7 Recruitment and Employee Development
Learning Outcome
Explain principles and models in the management of employee recruitment and development.
Learning Objectives
- Explain the purpose and components of a human resource management process.
- Explain the legal and ethical constraints on recruitment and selection.
- Explain the types and processes of pre‐employment testing.
- Explain the purpose, procedure, and limitations of typical interviewing techniques, including behavioraldescriptive interviews.
- Explain the significance and components of a training and development program including trainingstandard, roles and responsibilities.
- Explain the significance and components of an orientation process.
- Explain the purpose and proceeds of a needs assessment and gap analysis
- Explain the purpose and process of competency profiling.
- Explain the significance and selections of typical training methods, and their relationship to learningstyles.
- Explain the significance and progression and cross‐training methods.
- Explain the purpose and components of a performance management program, including coaching.
- Explain typical models of performance reviews.
- Explain the process of corrective and progressive discipline.
Topic 8 Management Structures and Organization
Learning Outcome
Discuss principles of organizational structure and the application of work teams.
Learning Objectives
- Compare the design and benefits of typical organizational structures, including: scalar, functional, tall/flat and matrix.
- Explain the concept and significance of organizational culture.
- Explain the significance of a team‐based organizational structure and methods to develop and promoteteamwork.
- Compare the significance, benefits, and limitations of supervised and self‐directed work teams.
- Describe the characteristics and functioning of a successful work team.
- Explain the concept and significance of cross‐functional work teams.
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Topic 1 A.S.M.E. Code Calculations - Cylindrical Components
Learning Outcome
Apply the appropriate formulae from ASME Sections I and VIII to calculations involving cylindrical components, openings, and compensations in boilers and pressure vessels.
Learning Objectives
- Calculate the minimum required thickness or the maximum allowable working pressure of ferrous tubing, up to and including 125 mm O.D.
- Using ASME Sections I and VIII, calculate the required minimum thickness or the maximum allowable working pressure of ferrous piping, drums, and headers.
- Calculate the required thickness or maximum allowable working pressure of a seamless, unstayed dished head.
- Calculate the minimum required thickness or maximum allowable working pressure of unstayed flat heads and welded covers.
- Determine whether or not reinforcement is required for openings in a cylindrical shell, header, or head.
- Using the ligament efficiency method, calculate the minimum required thickness of a cylindrical drum with two or more openings in the pressure boundary.
Topic 2 ASME Code Calculations: Stayed Surfaces, Pressure Relief Valves and Furnaces
Learning Outcome
Apply the appropriate formulae from A.S.M.E. Sections 1 and 8 to calculations involving pressure vessel stayed surfaces, safety and safety relief valves, and firetube boilers.
Learning Objectives
- Calculate the required thickness and maximum allowable working pressure for braced and stayed surfaces in pressure vessels.
- Calculate the minimum required cross‐sectional area of stays and staybolts in firetube boilers, including diagonal stays.
- Calculate the required size and capacity of pressure relief valves.
- Explain design considerations for various circular furnaces and calculate the required thickness of corrugated furnaces.
Topic 3 Boiler and Pressure Vessel Legislation
Learning Outcome
Describe the components and application of boiler and pressure vessel legislation within Canadian jurisdictions.
Learning Objectives
- Identify the types and sources of Laws and the levels and scope of the Courts.
- Define Statutory Delegation of Powers as they apply to the Boilers and Pressure Vessels Act.
- Describe the authority that Safety Officers (Inspectors) have within their jurisdiction.
- Determine what are the offences and penalties under the Act and the appeal process.
- Describe the typical Regulations under the Boilers and Pressure Vessels Act.
- Describe the typical Codes and Standards referenced by the Boilers and Pressure Vessels Act.
Topic 4 Plant Design and Installation
Learning Outcome
Explain the codes and procedures involved in the design and construction of a new plant.
Learning Objectives
- State the codes and standards that must be followed when designing and building a new plant.
- Describe the steps involved in developing specifications and contracts for new installations and modifications.
- Explain the major steps involved in the design and construction of a new plant.
- Explain the roles and responsibilities in the design and construction of a new plant.
- Explain how the design and construction of a new plant are administered and controlled.
Topic 5 Management and Supervision
Learning Outcome
Describe the roles and basic competencies of a supervisor and manager.
Learning Objectives
- Define management and explain the general functions of management.
- Explain how management goals and objectives are developed through planning.
- Describe how business decisions are made.
- Describe methods of selecting new employees.
- Explain how employees are trained.
- Explain how to provide leadership and motivate employees.
- Explain how to manage employee performance and behaviors.
- Describe proper communication skills by writing a formal report.
Learning Outcome
Describe plant maintenance management systems.
Learning Objectives
- Describe the major aspects of managing maintenance activities including management of maintenance, maintenance program development, planning, scheduling, performing maintenance, assessment and improvement.
- Describe the different approaches to maintenance including preventive and corrective.
- Describe how routine maintenance activities are planned, scheduled, and controlled.
- Describe the use of Gantt and PERT charts and the critical path method to schedule major maintenance activities.
- Describe the steps involved in preparing for and conducting a pressure vessel inspection.
- Describe the use of computerized systems in managing maintenance, including a work order system.
- Describe various methods of monitoring equipment, including log sheets and trending.
- Describe the steps involved in developing a plant budget and controlling maintenance costs.
Learning Outcome
Explain the components and application of safety programs, safety audits, and safety training.
Learning Objectives
- Describe the elements of a comprehensive safety program for a power plant.
- Explain the purpose of and the process used for safety checklists, inspections, audits and reviews.
- Explain the purpose of and the process used for safety orientation, education, and training.
Learning Outcome
Apply the theory of applied mechanics to bodies at rest and in linear motion.
Learning Objectives
- Calculate the displacement, velocity, and acceleration of bodies moving in a straight line.
- Calculate the displacements and flight times of projectiles.
- Describe the relationship between mass, force, acceleration and weight.
- Explain inertia, momentum, and conservation of momentum and perform related calculations.
- Demonstrate graphically the relationship between work, force, and distance.
- Define and calculate the kinetic energy of moving objects.
- Define and calculate the potential energy of stationary objects.
- Explain the Law of Conservation of Energy.
- Define and calculate indicated power and power cylinder dimensions.
Learning Outcome
Apply the theory of applied mechanics to bodies in angular motion.
Learning Objectives
- Define and calculate angular displacement, angular velocity, and angular acceleration.
- Define and calculate moment of inertia, radius of gyration and torque.
- Define and calculate the kinetic energy of rotating masses, including flywheels.
- Define rotational work and power. Calculate brake power and mechanical efficiency of a reciprocating engine.
- Calculate the power transmitted by a belt drive.
- Define centrifugal and centripetal force, centripetal acceleration, and perform calculations involving them.
- Calculate the distance of movement of a governor due to centrifugal force.
- Explain the balancing of masses about a center of rotation and perform simple balancing calculations for single and multiple masses.
Learning Outcome
Perform calculations related to frictional force.
Learning Objectives
- Describe the concept, types, and laws of friction.
- Define and calculate the coefficient of friction and applied forces for objects moved on a horizontal surface by forces parallel to the surface.
- Define and calculate the applied forces for objects moved on a horizontal surface by forces not parallel to the surface.
- Define and calculate the applied forces for objects moved on an inclined plane.
- Define and calculate the frictional forces on a screw jack.
- Define and calculate maximum torque on a belt drive.
Topic 11 Static and Dynamic Forces
Learning Outcome
Perform calculations related to static and dynamic forces acting on a body.
Learning Objectives
- Define and evaluate forces in terms of moments and couples.
- Define and calculate centroids and first and second moments of areas.
- Define and calculate the different types of stress.
- Define strain, modulus of elasticity, Poisson’s ratio and perform calculations.
5 Define the thermal expansion of bars, including reactions, under conditions of restricted expansion and reactions of bars composed of dissimilar metals.
- Define and calculate shear forces and bending moments for simply supported beams and cantilevers.
- Perform calculations involving the fundamental torsion equation and explain the relationship between torque and stress.
- Explain the relationship between torque and power, and calculate maximum and mean torque for solid shafts of circular cross section.
- Calculate stress in coupling bolts due to torque.
Learning Outcome
Perform calculations related to fluid flows and pressure.
Learning Objectives
- Describe the basics of fluid mechanics.
- Perform calculations related to pressure in a fluid, including center of pressure.
- Explain buoyancy and perform calculations involving buoyancy principles.
4 Define and calculate thermal expansion of a vessel and its liquid contents.
- Describe flow in open channels and calculate fluid flow through a weir.
- Describe liquid flow in a pipe using the continuity equation.
- Apply the law of conservation of energy to fluid flow and define Bernoulli’s equation.
- Calculate fluid flow from a vessel orifice.
- Calculate flow using a venturi meter.
Topic 1 Heat, Expansion of Solids, and Heat Transfer
Learning Outcome
Perform calculations to determine the thermal expansion of solids and basic heat transfer properties.
Learning Objectives
- Perform heat calculations on solids, liquids, and vapors.
- Explain the theory of thermal expansion and solve problems using the formula for linear thermal expansion.
- Calculate the change in the area of an object, including holes, due to a temperature change.
- Describe the principle of volumetric expansion and perform calculations involving the change in volume of solids, due to a change in temperature.
- Describe the three basic modes of heat transfer (convection, conduction, and radiation) and perform simple calculations.
- Perform calculations involving heat transfer at a surface.
Topic 2 Thermodynamics of Gases
Learning Outcome
Perform calculations related to expansion and compression of perfect gases.
Learning Objectives
- Explain the behaviors of a perfect gas and the laws that govern gas behavior, including Boyle’s Law, Gay‐ Lussac’s Law, Charles Law, the General Gas Law, and the Ideal Gas Law.
- Explain Dalton’s Law of Partial Pressures.
- Define and calculate specific heats under constant volume and constant pressure conditions.
- Explain the relationship between work and heat as expressed in the First and Second Laws of Thermodynamics.
- Calculate the work done during expansion and compression under constant pressure and isothermal conditions.
- Calculate the work done during adiabatic expansion and compression.
- Calculate the work done during polytropic expansion and compression.
Topic 3 Thermodynamics of Steam
Learning Outcome
Perform calculations related to properties of steam.
Learning Objectives
- Describe the basic properties of water and steam.
- Perform calculations involving specific enthalpy, dryness fraction, specific heat, and specific volume using steam tables.
- Explain the principles and use of calorimeters to measure the dryness fraction of wet steam.
- Calculate the dryness fraction of steam based on calorimeter data.
- Calculate the internal energy of steam under given conditions.
- Explain entropy and calculate the change in entropy for a particular water/steam process.
- Determine steam properties using a Mollier Chart.
- Calculate boiler thermal efficiency using test data.
Topic 4 Practical Thermodynamic Cycles
Learning Outcome
Explain the concepts and use of common thermodynamic cycles, using pressure‐volume and temperature‐ entropy diagrams.
Learning Objectives
- Explain the concept of a heat engine and describe the different types of heat engines.
- Describe the Carnot cycle and calculate Carnot cycle efficiency.
- Explain the Rankine cycle using pressure‐volume and temperature‐entropy diagrams and calculate Rankine cycle efficiency.
- Explain the Otto cycle using pressure‐volume and temperature‐entropy diagrams and calculate Otto cycle efficiency.
- Explain the Diesel cycle using pressure‐volume and temperature‐entropy diagrams and calculate Diesel cycle efficiency.
- Explain the Brayton cycle using pressure‐volume and temperature‐entropy diagrams and calculate Brayton cycle efficiency.
- Calculate the heat balance at different points in a Rankine cycle system using test data provided.
Learning Outcome
Discuss the uses and structure of common metals.
Learning Objectives
- Explain the study of metallurgy and the atomic and crystalline structure of metals.
- Explain the significance of the iron‐carbon equilibrium diagram.
- Explain the purposes of, and processes used, in the heat treatment of steels.
- Explain how to interpret metal specifications.
- Explain typical selection of metals for process plant applications (what is selected and why).
- Describe the composition, physical properties, and uses of copper, lead, and tin.
- Describe the composition, physical properties, and uses of aluminum and aluminum alloys.
Learning Outcome
Discuss the common procedures and parameters for testing of metals.
Learning Objectives
- Differentiate between destructive and non‐destructive testing and explain the procedures and interpretation of tensile, hardness, and impact tests.
- Explain the purpose and procedure of a Proof (Hydrostatic Deformation) Test.
- Explain the causes and significances of welding discontinuities.
- Explain Non‐Destructive Examination, along with its applications and benefits.
- Explain visual inspection and the procedures used.
- Explain magnetic particle inspection and the procedures used.
- Explain liquid penetrant testing and the procedures used.
- Explain ultrasonic testing and the procedures used.
- Explain radiographic testing, including interpretation of results.
- Explain acoustic emission testing and the procedures used.
- Explain leak and pressure testing.
- Explain how to monitor and test metals for creep, fatigue, and corrosion.
Learning Outcome
Discuss corrosion mechanisms and corrosion prevention methods.
Learning Objectives
- Define corrosion and explain the electrochemical principles involved.
- Explain how the environment can affect corrosion.
- Explain the most common corrosion mechanisms.
- Describe the predominant corrosion mechanisms that potentially affect various power plant systems and equipment.
- Explain methods used to monitor and test for corrosion during plant operation.
- Explain the methods used to control and prevent corrosion at the design stages and during operation.
- Explain the main components of a corrosion failure analysis and a typical corrosion failure report.
Topic 8 Introduction to Welding Symbols
Learning Outcome
Describe how weld joints are constructed, using standard weld symbol terminology.
Learning Objectives
- Explain the purpose of welding symbols.
- Describe the common weld joints and weld types, including groove, fillet, plug and slot welds, with related weld terminology.
- Recognize and describe symbols that identify weld types.
- Identify and explain the meaning of the reference line, the arrow, and the tail in a welding symbol.
- Identify and explain the meaning of supplemental welding symbols, not specific to the weld itself.
- For groove and fillet welds, identify and explain welding symbols that relate to the weld configuration and joint preparation.
Topic 1 Boiler and Steam Generator Components and Design
Learning Outcome
Discuss the components and design considerations of a steam generator.
Learning Objectives
- Explain how the ratings of boilers and steam generators are calculated.
- Explain the factors to be considered in designing a steam generator.
- Contrast the influence of solid fuel, liquid fuel, and gas fuel on steam generator design.
- Explain the principles of natural water circulation in a steam generator. Explain why forced circulation is used in a steam generator and how it is attained.
- Explain the design, placement, and installation considerations for water walls, superheaters, desuperheaters, reheaters, economizers, and air heaters.
- Explain the purpose and placement of screen tubes, division walls, water‐cooled stringer tubes in superheaters, and wall‐mounted radiant superheaters.
- Describe top and bottom support systems for a steam generator.
- Describe furnace casing design considerations.
- Describe the purpose and use of specialized steam generator duct arrangements, including air heater bypass, economizer bypass, and air heater recirculation.
- Describe the methods used to insulate different parts of a steam generator.
- Explain the general steps used to construct a steam generator.
Topic 2 Specialized Boiler Designs
Learning Outcome
Identify and discuss common specialized boiler designs.
Learning Objectives
- Describe typical designs, components, and operating strategies for once‐through steam‐flood boilers.
- Describe typical designs, components, and operating strategies for fluidized bed boilers (bubbling bed and recirculating bed types).
- Describe typical designs, components, and operating strategies for heat recovery steam generators.
- Compare different designs of heat recovery steam generators (HRSG): natural circulation, controlled circulation and once‐through (OTSG).
- Describe typical designs, components, and operating strategies for supercritical steam generators.
- Describe typical designs, components, and operating strategies for black liquor recovery boilers.
- Describe typical designs, components, and operating strategies for refuse boilers used in waste disposal.
- Describe typical designs, components, and operating strategies for biomass boilers.
- Describe typical designs, components, and operating strategies for waste‐heat boilers (firetube and watertube types).
Topic 3 Boiler and Steam Generator Operation
Learning Outcome
Describe in detail the typical procedures for operation of a large steam generator.
Learning Objectives
- Describe the detailed hot and cold startup procedures for a steam generator including safety precautions.
- Describe the detailed shutdown procedure for a steam generator including safety precautions.
- Describe the detailed lay‐up procedures for a steam generator including safety precautions.
- Describe the detailed refractory dry out procedure for a new steam generator including safety precautions.
- Describe the detailed boil out procedure for a new steam generator including safety precautions.
Topic 4 Boiler and Steam Generator Maintenance and Inspection
Learning Outcome
Describe in detail the typical procedures for boiler maintenance and inspection.
Learning Objectives
- Describe the mechanical cleaning procedures for a boiler including safety precautions.
- Describe the detailed chemical cleaning procedures for a watertube boiler including safety precautions.
- Describe the detailed hydrostatic testing procedure for a boiler including safety precautions.
- Describe standard shutdown activities and preventive maintenance procedures required for a boiler.
- Describe the detailed procedure for complete inspection of a boiler including waterside, fireside, and auxiliary equipment.
- Describe boiler inspection techniques and equipment.
7 Describe the required inspection records and reporting procedures.
- Describe the roles and responsibilities for an inspection including engineering staff, operators, and boiler inspector.
- Describe the safety requirements during a boiler inspection.
Learning Outcome
Discuss the application of large centrifugal pumps.
Learning Objectives
- Explain selection criteria for pump applications.
- Interpret pump operating characteristics and performance curves.
- Describe the procedure for the installation of a large multi‐stage centrifugal pump.
- Describe the typical repairs and preventive maintenance procedures required for a multi‐stage centrifugal pump.
- Describe the methods of control for a multi‐stage centrifugal pump including recirculation control.
- Describe the selection criteria for seal types and materials in a centrifugal pump.
- Describe the methods of counteracting thrust in a large centrifugal pump.
Topic 6 Water Chemistry and Analysis
Learning Outcome
Discuss the significance of common water impurities, and the application of water analyses.
Learning Objectives
- Describe the sources of the impurities found in raw water.
- Describe the effect of the listed water impurities on power plant equipment and processes.
- Explain the significance and importance of standard methods of water analysis.
- Describe which analyses are appropriate at given sampling points including the significance of the sampling point locations.
- Interpret the results of a comprehensive standardized water analysis including the relationship of the various parameters.
- Explain the purposes and principles of testing instruments, including embrittlement detector, total solids meter, and pH meter.
- Explain the purpose of steam purity measurement and process of steam sampling.
Topic 7 Water Pre-Treatment I
Learning Outcome
Describe water pre‐treatment processes for removal of suspended solids, oil, and gases.
Learning Objectives
- Explain the purpose, equipment, operation, and limitations of sedimentation.
- Explain the purpose, equipment, operation, and limitations of coagulation and flocculation.
- Explain the purpose, equipment, operation, and limitations of filtration.
- Explain the purpose, principles, equipment, operation, and limitations of microfiltration.
- Describe how oil is removed from water.
- Explain the purpose, equipment, operation, and limitations of mechanical deaeration.
- Explain the purpose, equipment, operation, and limitations of evaporation.
Topic 8 Water Pre-Treatment II
Learning Outcome
Describe water pre‐treatment processes for ion removal.
Learning Objectives
- Explain the purpose, equipment, and operation of lime‐soda softening.
- Explain the purpose, equipment, operation, and limitations of hot process phosphate softening.
- Explain the purpose, equipment, operation, and limitations of sodium zeolite softening.
- Explain the purpose, equipment, and operation of hydrogen zeolite softening.
- Describe how silica is removed from water.
- Explain the purpose, equipment, and operation, of demineralization, including condensate polishing.
- Explain the purpose, equipment, and operation of electrodialysis (ED) and electrodeionization (EDI).
- Explain the purpose, equipment and operation of reverse osmosis (RO).
Topic 9 Internal Water Treatment
Learning Outcome
Describe boiler internal water treatment processes.
Learning Objectives
- Explain the causes, effects, and control of scale.
- Explain the causes, effects, and control of foam in boiler water.
- Explain the causes, effects, and control of caustic embrittlement.
- Explain the causes, effects, and control of return line corrosion.
- Explain the use of chelating agents in boiler water.
- Explain the use of sludge conditioning in boiler water.
- Explain the use of pH control in boiler water.
- Explain the use of chemical deaeration in boiler water.
- Explain the causes, effects, and control of carryover of boiler water.
- Explain the use of blowdown from boiler water.
- Explain the use and control of chemical feed systems for boiler water.
- Explain the control of silica to avoid turbine blade deposits.
Topic 10 Non-Boiler Water Treatment
Learning Outcome
Discuss water treatment applications for cooling water, wastewater, and potable water.
Learning Objectives
- List the water impurities of concern in a cooling water system and the effects caused by each one.
- Describe control methods for a cooling water system for control of corrosion, fouling, and microbiological attack including chloride corrosion, and delignification.
- Describe the potential effects of wastewater discharge.
- Compare and contrast mechanical, chemical, and biological methods of wastewater treatment including the advantages and disadvantages of each.
- Specify an appropriate method of wastewater treatment for a particular case study.
- Describe the methods used for potable water treatment and analysis.
Topic 1 Steam Turbine Theory and Construction
Learning Outcome
Explain the design and components of a large steam turbine, and perform nozzle and steam velocity calculations.
Learning Objectives
- Explain selection criteria for a turbine application.
- Describe the design and components of steam turbine casings and casing drains.
- Describe the design and components of steam turbine rotors, blading, and diaphragms.
- Describe shaft seal designs, including stuffing boxes, carbon rings, labyrinth, and water seals.
- Describe the design and components of steam turbine bearings.
- Describe the ways in which steam turbines are designed to counteract thrust.
- Describe the purpose and design of expansion and anchoring components.
- Explain the principles of steam turbine nozzle design.
- Explain a steam turbine blade velocity diagram.
- Calculate the steam velocity and angle of entry for impulse and reaction turbine blading.
- Calculate the work done on steam turbine blades and the resulting power developed.
- Calculate steam turbine Rankine cycle thermal efficiency.
Topic 2 Steam Turbine Auxiliaries and Control
Learning Outcome
Explain the purpose and design of steam turbine auxiliaries, control, and monitoring equipment.
Learning Objectives
- Describe the purpose, design and components of a turning gear.
- Describe the purpose, design and components of an adjusting gear.
- Explain critical speed.
- Describe the design and components of lubricating oil and jacking oil systems.
- Describe the design of speed reducing gears.
- Describe the design and components of flexible couplings.
- Describe the purpose and design of steam turbine governors and governor systems.
- Describe the purpose and design of steam turbine stop valves and control valves.
- Describe the purpose and design of steam turbine grid type extraction valves.
- Describe the purpose and design of steam turbine casing pressure relief systems including rupture diaphragms.
- Describe the purpose and design of steam turbine overspeed trips.
- Describe the purpose and design of steam turbine supervisory equipment.
Topic 3 Steam Turbine Operation and Maintenance
Learning Outcome
Discuss procedures for operation and maintenance of a large steam turbine.
Learning Objectives
- Describe the detailed hot and cold start‐up procedures for a large steam turbine, including safety precautions.
- Describe the detailed shutdown procedure for a large steam turbine including safety precautions.
- Explain what checks are performed on a large steam turbine during normal operation.
- Sketch the flow of steam and condensate through a condensing steam turbine and a non‐condensing steam turbine.
- Explain the preventive maintenance requirements for a large steam turbine. Include shaft alignment, bearings, clearances for thrust, blades, shaft seals, correction of blade fouling, erosion and cleaning.
- Describe the purpose of and procedure for static and dynamic balancing.
Learning Outcome
Discuss condenser principles, performance, operation and auxiliaries.
Learning Objectives
- Describe the principles and design of jet, air cooled, and surface condensers.
- Describe the purpose, principle and design of surface condenser support and expansion systems.
- Explain the significant parameters in condenser performance.
- Calculate condenser thermal efficiency from the test data.
- Explain the procedures used to troubleshoot condenser performance.
- Explain the procedures used to backwash and clean a condenser.
- Describe the purpose, principle and design of air ejectors and vacuum pumps.
- Describe the purpose and flow of cooling water systems.
- Describe the purpose, principle and design of cooling water intake screens, circulating pumps, cooling towers, and cooling ponds.
- Describe the purpose, principle and design of condenser atmospheric exhaust (relief) valves.
- Describe the purpose, principle and design of condensate pumps.
Topic 5 Internal Combustion Engines: Components and Auxiliaries
Learning Outcome
Explain the design, selection, and components of internal combustion engine installations, including auxiliaries.
Learning Objectives
- Explain design, applications, and selection criteria for the different types of reciprocating internal combustion engines.
- Explain fuels and combustion processes used by internal combustion engines.
- Describe the design of internal combustion engine scavenging and supercharging arrangements.
- Describe the design and components of internal combustion engine fuel conditioning systems, injection systems, and ignition systems.
- Describe the design and components of internal combustion engine cooling systems and cooling water conditioning systems.
- Describe the purpose, design and components of internal combustion engine lubricating oil systems.
- State the purpose and describe the control of a typical internal combustion engine including the operation of safety devices.
Topic 6 Internal Combustion Engines: Operation and Maintenance
Learning Outcome
Describe general maintenance requirements, and detailed operating and troubleshooting procedures for internal combustion engines.
Learning Objectives
- Describe the detailed startup procedures for an internal combustion engine.
- Describe the detailed shutdown procedures for an internal combustion engine.
- Explain the routine maintenance and monitoring requirements for an internal combustion engine.
- Explain the major maintenance and overhaul requirements for an internal combustion engine.
- Explain the troubleshooting of combustion and engine problems.
Topic 7 Gas Turbine Design and Auxiliaries
Learning Outcome
Explain the design and components of a large gas turbine and related auxiliaries.
Learning Objectives
- Explain applications and selection criteria for the different types of gas turbine engines.
- Describe the principles and design of open and closed cycle gas turbine systems.
- Describe the principles and design of combined cycle and cogeneration systems using gas turbines.
- Describe the principles and design of gas turbine regeneration, intercooling, and reheating.
- Describe the principles and design of gas turbine shaft arrangements.
- Describe the design and components of gas turbine compressors, combustors (combustion chambers) and turbines.
- Describe the design and operation of gas turbine air intake and exhaust systems.
- Describe the design and operation of a gas turbine lubricating oil system.
- Describe the design and operation of a gas turbine fuel system.
-
Describe the design and operation of a gas turbine steam or water injection system and a dry low NOX system.
Topic 8 Gas Turbine Operation and Control
Learning Outcome
Discuss operating procedures, and control and monitoring components of a large gas turbine.
Learning Objectives
- Describe the components and operation of gas turbine supervisory and control systems.
- Describe the principles and design of gas turbine protection devices.
- Describe the detailed hot and cold startup procedures for a gas turbine, including safety precautions.
- Describe the detailed shutdown procedure for a gas turbine, including safety precautions.
- Explain the routine maintenance and monitoring requirements for a gas turbine.
- Describe the major maintenance and overhaul requirements for a gas turbine.
- Explain the troubleshooting of gas turbine problems.
Learning Outcome
Explain the components of a lubrication application and maintenance program.
Learning Objectives
- Describe the methods of manufacture and the different classifications of lubricants.
- Describe the significance and measurement of lubricating oil characteristics, including viscosity, relative density, API (American Petroleum Institute) gravity, pour point, and dielectric strength.
- Explain the typical causes of lubricating oil deterioration.
- Describe the types of lubrication additives.
- Describe a typical power plant lubrication program, including a lubrication survey.
- Explain the different types of lubricating/governing/seal oil systems.
- Describe the components and operation of a typical lubricating oil purification system.
- Describe the various applications of ball‐and‐roller bearings and their lubrication, including bearing seals.
Learning Outcome
Explain piping system design, inspection, and maintenance.
Learning Objectives
- Explain selection criteria for piping materials.
- Calculate the required thickness and the internal design pressure of piping.
- Describe typical inspection procedures for piping installations and repairs.
- Describe a typical routine inspection procedure and schedule for high‐energy piping.
- Explain the effects of high temperature on piping strength.
- Describe the design and installation criteria for a piping system layout.
- Explain the theory and effects of water hammer.
Learning Outcome
Interpret construction and process drawings.
Learning Objectives
- Interpret the information provided in orthographic, isometric, and oblique projections.
- Interpret the information provided in construction drawings with sectioning and dimensioning.
- Interpret the information provided in Process Flow Diagrams.
- Interpret the information provided in Piping and Instrumentation Diagrams (P&IDs).
- Explain the use of isometric piping system and spool drawings in piping systems.
Topic 1 Power Plant Fuel Systems
Learning Outcome
Describe the design and operation of typical power plant systems.
Learning Objectives
- Describe, using a sketch, the design and operation of fuel oil supply systems.
- Describe, using a sketch, the design and operation of fuel gas supply systems.
- Describe, using a sketch, the design and operation of solid fuel supply systems.
Topic 2 Power Plant Water and Steam Systems
Learning Outcome
Describe the design and operation of power plant systems.
Learning Objectives
- Describe, using a sketch, the design and operation of feedwater systems.
- Describe, using a sketch, the design and operation of steam distribution systems.
- Describe, using a sketch, the design and operation of condensate systems.
- Describe, using a sketch, the design and operation of cooling water systems.
- Describe, using a sketch, the design and operation of waste handling systems.
- Explain how different power plant water systems interconnect and what parameters are significant to each.
Topic 3 Measurement and Control Components
Learning Outcome
Explain the design and application of measuring devices and final control elements.
Learning Objectives
- Describe the design, use, and placement of electrical and electronic pressure measuring devices.
- Describe the design, use, and placement of electrical and electronic temperature measuring devices.
- Describe the design, use, and placement of Venturi tubes, orifice plates, flow nozzles, and Pitot tubes.
- Describe the design and use of: manometers, ring balance, force balance, and electric flow indicating mechanisms.
- Describe the design, use, and placement of the following liquid level measurement devices: ball‐float, displacement‐type, hydrostatic head, electric and pneumatic level transmission, electric and magnetic type level‐limit devices, and remote water‐level indicators.
-
Describe the types, construction, and flow characteristics of control valves.
- Describe the design, operation, and application of the following valve operators: solenoid, pneumatic‐ diaphragm, power cylinder, and electric motor.
Topic 4 Control Instrumentation Systems
Learning Outcome
Explain and apply the theory of automatic boiler, distributed control, and programmable logic control systems.
Learning Objectives
- Describe the principle, design, application, and limitations of the following automatic control methods: proportional, proportional‐plus‐reset, and proportional‐plus‐reset‐plus‐rate.
- Describe the principle, design, application, and limitations of single, two, and three‐element boiler feedwater control systems.
- Describe the principle, design, application, and limitations of superheated and reheated steam temperature control systems.
- Describe the principle, design, components, application, and limitations of Distributed Control Systems (DCS).
- Describe the principle, design, application, and limitations of Programmable Logic Controllers (PLC).
Topic 5 Fuels and Combustion Calculations
Learning Outcome
Perform combustion and furnace draft calculations and explain flue gas analysis.
Learning Objectives
- Describe the nature of combustion and the different types of fuels.
- Calculate the mass and volumetric analysis of a fuel.
- Describe proximate and ultimate analysis and calculate the heating value of fuel.
- Given the results of a bomb calorimeter test, calculate the heating value of a fuel.
- Calculate the amount of air and excess air required for combustion of fuel.
- Explain flue gas analysis parameters and their significance.
- Calculate theoretical draft, flue gas velocity, and stack diameter.
- Calculate draft fan power and efficiency.
Topic 6 Firing and Draf t Equipment
Learning Outcome
Explain the design, components, and auxiliary equipment of steam generator furnaces.
Learning Objectives
- Describe steam generator furnace designs including cyclone furnaces and divided furnaces. Explain the purpose and placement of furnace arches.
- Explain the purpose and design of separately fired superheat and reheat furnaces.
- Explain the purpose, types, characteristics, and placement of refractory in a furnace.
- Describe the principle, design, and application of oil, gas, and coal burners.
- Describe the principle, design, and application of pulverizers.
- Describe the principle, design, and application of ash and slag disposal systems.
- Explain the significance, monitoring, and control of ash fusion temperature.
- Describe the designs and applications of forced and induced draft fans.
- Explain the methods which control furnace draft.
Topic 7 Combustion Control and Safeguards
Learning Outcome
Explain combustion control methods and safeguard components.
Learning Objectives
- Describe, using a sketch, the combustion control arrangements in a steam generator.
- Explain series, parallel, and series/parallel combustion control.
- Explain turbine‐following, boiler‐following, and integrated combustion control systems.
- Describe the operation of purge, fan failure, and flame failure interlock systems.
- Describe the operation of flame detectors.
- Describe, using a sketch, a typical programming sequence for a packaged boiler control system.
- Describe the typical limiting devices and alarms for a packaged boiler combustion system.
Topic 8 Environmental Monitoring
Learning Outcome
Explain the significance of environmental parameters and methods of monitoring.
Learning Objectives
-
Explain the significance of the following air quality parameters: particulates, stack opacity, SO2 concentration, SO2 mass flow, NOX concentration, NOX mass flow, mercury, O2, CO2, and hydrocarbons.
-
Explain the basic principles of operation for Continuous Emissions Monitoring System (CEMS) measurement instruments.
- Explain the general requirements for Continuous Emissions Monitoring Systems (CEMS).
- Explain the significance of the following water quality parameters: iron, phosphorous, biochemical oxygen demand (BOD), chemical oxygen demand (COD), hydrocarbons, temperature, flow, pH, and nitrogen.
- Explain the general requirements for wastewater monitoring.
- Explain how data received from environmental monitoring equipment is interpreted.
- Explain the significance of environmental monitoring equipment failure.
- Describe the procedures used for troubleshooting environmental monitoring equipment.
Topic 9 Environmental Control Methods
Learning Outcome
Explain the methods used to remove SO2, NOX, CO2 and particulates from boiler flue gases.
Learning Objectives
- Describe the purpose, design, operation, and application of Flue Gas Desulfurization (FGD) systems.
- Describe the purpose, design, operation, and application of Selective Catalytic Reduction (SCR) systems.
- Explain the significance of NOX reduction in a power plant, and the procedures and equipment used to reduce NOX emission from a boiler and from a gas turbine.
- Explain the purpose, effects, and application of flue gas chemical conditioning in a power plant.
- Explain the significance, procedures, and equipment for reduction of CO emission from a boiler.
- Describe the purpose, design, operation, and application of a baghouse.
- Describe the purpose, design, operation, and application of an electrostatic precipitator.
Topic 1 Alternating Current Theory
Learning Outcome
Explain characteristics and perform calculations involving AC circuits.
Learning Objectives
- Explain the vector relationships between AC voltage and current.
- Explain the significance of root mean square values for AC sine waves. Calculate root mean square and peak‐to‐peak values for AC sine waves.
- Explain voltage/current relationships and calculate power in purely resistive circuits.
- Explain voltage/current relationships in purely inductive circuits.
- Explain voltage/current relationships in purely capacitive circuits.
- Explain voltage and current relationships in circuits having resistance/inductance and resistance/ capacitance combinations.
- Calculate impedance, reactance, true and apparent power, and power factor in AC circuits.
- Explain the significance of power factor and how it can be improved in AC circuits.
- Explain the principle and significance of three‐phase AC circuits, star, and delta connections in alternators, transformers and AC motors.
- Calculate phase voltage, phase current and apparent and true power in a three‐phase AC circuit.
Topic 2 Direct Current Machines
Learning Outcome
Explain the construction and operating principles of DC generators and motors.
Learning Objectives
- Describe the construction and operating principles of a DC generator.
- Explain the principle and application of compensating windings, interpoles, and lap and wave armature windings.
- Explain the principles, applications, and load/voltage characteristics of generators.
- Describe the parallel operation and voltage regulation of DC generators.
- Review the principle of DC motor operation, including torque development and back EMF.
- Calculate torque and speed of a DC motor.
- Explain the principle and application of shunt, series, and compound‐wound DC motors including speed control.
- Explain the principle and application of counter‐E, current limit and time limit DC motor automatic starters.
- Explain the principle and application of dynamic and regenerative braking.
- Calculate efficiency and discuss the reasons for power losses in a DC motor and generator.
Topic 3 Alternating Current Generators
Learning Outcome
Explain the construction and operating principles of AC generators.
Learning Objectives
- Explain the operating principles, design and construction of alternators with salient‐pole and cylindrical rotors.
- Explain the relationship between alternator speed, frequency, and number of pole pairs.
- Describe the purpose and construction of an exciter.
- Describe the purpose and design of alternator voltage regulators.
- Describe alternator cooling systems, including circulating air cooling, hydrogen cooling, and stator winding cooling water systems.
- Describe shaft sealing arrangements for an alternator.
- Explain the theory and significance of alternator synchronization and parallel operation including the impact on power factor.
- Explain efficiency and power losses in an AC generator.
Topic 4 Alternating Current Motors
Learning Outcome
Explain the construction and operating principles of AC motors.
Learning Objectives
- Describe the principle of a pulsating magnetic field for single‐phase AC motors and rotating magnetic field for three‐phase AC motors. Describe general rotor and stator construction.
- Describe the torque/speed characteristics of induction motors and the relationship between torque, slip and rotor speed.
- Define full‐load amps, locked rotor amps and service factor amps.
- Describe the principles, applications, and operation of wound rotor motors.
- Describe the principles, applications, and operation of single‐phase AC motors. Include universal, shaded‐pole, split‐phase, capacitance‐start, repulsion‐start, and reluctance‐start.
- Describe the principles, applications, starting methods and operation of a synchronous motor.
Learning Outcome
Explain the construction and operating principles of transformers.
Learning Objectives
- Describe the construction of core type and shell type transformers.
- Explain the factors that affect transformer rating.
- Calculate load, power, iron and copper losses, and efficiency in a transformer.
- Explain the purpose and procedures for transformer short and open circuit tests.
- Describe the methods of cooling a transformer.
- Describe the methods of connecting a transformer, including delta‐delta, star‐star, delta‐star, and star‐delta.
- Explain the theory and significance of transformer paralleling.
- Describe the applications of instrument transformers.
- Describe the protective measures and devices used on transformers.
Topic 6 Electrical System Protection
Learning Outcome
Describe the protective devices used on alternators, motors, and electrical circuits.
Learning Objectives
- Describe the significance of fuses and circuit breakers for circuit protection including continuous rating, interrupting capacity, and inverse time principle.
- Describe the purpose and designs of different types of fuses.
- Describe the operation of circuit breakers used for different voltages, including moulded‐case, oil‐immersed, airblast, air‐break, vacuum, and SF6 switchgear.
- Describe the operation of switches and contactors used for different voltages.
- Explain the purpose, and significance of protection relaying as it applies to a large alternator.
- Explain the purpose and significance of the protection devices for a large electric motor.
Topic 7 Air and Gas Compression
Learning Outcome
Explain the construction and operation of large air compressors and compressed air systems.
Learning Objectives
- Describe the design and application of compressors, including prime mover selection.
- Describe reciprocating compressor designs.
- Describe rotary compressor designs.
- Describe centrifugal and axial compressor designs.
- Describe the types and operation of coolers and air dryers, including desiccant types.
- Describe the installation of a compressed air system, including all ancillary equipment and typical instrumentation.
- Describe the regulation and control of compressors.
- Describe the monitoring and protection devices for a compressed air system.
- Explain the effects of altitude, air temperature, and humidity on air compressor performance.
- Describe the monitoring, troubleshooting, and typical preventive maintenance for a compressed air system.
Topic 8 Refrigeration Systems and Equipment
Learning Outcome
Explain the construction and operation of refrigeration systems.
Learning Objectives
- Describe the types of refrigerants.
- Describe the principles and operation of vapor compression refrigeration systems.
- Describe the principles and operation of absorption refrigeration systems.
- Describe the principles and operation of multi‐stage and cascade refrigeration systems.
- Describe the principles, applications, and operation of heat pump and thermoelectric systems.
- Describe the design of hermetic refrigeration systems.
- Describe the design and operation of refrigeration compressors.
- Describe the design and operation of evaporators, condensers, receivers, scale traps and dehydrators.
- Describe the design and operation of absorbers.
- Describe the design and operation of valves and fittings.
Topic 9 Refrigeration Safety, Control, and Operation
Learning Outcome
Explain the procedures, standards, instrumentation, and controls for a refrigeration system.
Learning Objectives
- Describe the codes and standards which apply to the design, installation, and operation of arefrigeration plant.
- Describe the purpose and operation of the various operating, actuating, limiting and safety controlsused in refrigeration systems.
- Explain refrigeration metering devices.
- Explain evaporator and compressor capacity controls.
- Describe the detailed startup and shutdown procedures for a refrigeration system.
- Explain absorption system startup and shutdown.
- Explain leak testing, charging, purging, and compressor lubrication.
- Describe the common operating problems and troubleshooting procedures for a refrigeration system.
Topic 10 Refrigeration Calculations
Learning Outcome
Perform refrigeration system calculations.
Learning Objectives
- Describe the general refrigeration cycle and the application of the Carnot cycle.
- Describe the relationship between enthalpy and pressure for a refrigeration cycle.
- Define and calculate the refrigerating effect and the mass of refrigerant circulated.
- Calculate the coefficient of performance for a refrigeration system.
- Calculate the capacity of a refrigeration machine.
- Calculate the theoretical power of a refrigeration compressor.
- Calculate the theoretical bore and stroke of a refrigeration compressor.
- Details
Learning Outcome
Explain concepts and solve problems involving vectors, force systems and friction.
Learning Objectives
- Define concurrent, coplanar vectors and draw space diagrams for forces and displacements.
- Draw a vector diagram and use it to graphically determine the resultant and equilibrant of a force system.
- Use trigonometry to resolve forces into components and to calculate the resultant and equilibrant of a force system.
- Given a coplanar, concurrent force system, calculate any unknown forces.
- Define static and sliding friction, coefficient of friction, and use the coefficient formula to calculate the coefficient, force, or mass in a simple friction problem.
- Explain friction angle and perform friction calculations for forces applied parallel to the horizontal plane.
- Calculate the coefficient of friction, object mass, and applied forces for objects moved on a horizontal surface by forces that are NOT parallel to the plane.
Topic 2 Work, Power, Energy: Linear and Angular Motion
Learning Outcome
Explain concepts and solve problems involving velocity and acceleration, the Laws of Motion and work, power and energy.
Learning Objectives
- Define force, force due to gravity, and work. Calculate the work done in moving objects horizontally and vertically.
- Define power and mechanical efficiency. Calculate the power expended when work is done, plus the power developed and mechanical efficiency of a reciprocating engine.
- Define potential and kinetic energy. Calculate the energies of stationary and moving objects.
- Define, and show the relationships between, distance, displacement, speed, linear velocity, and linear acceleration.
- Using linear motion relationships, calculate the displacements, velocities and accelerations of bodies moving in a straight line.
- Define and calculate angular displacement, angular velocity and angular acceleration.
Topic 3 Heat, State Change, Calorimetry
Learning Outcome
Explain terminology regarding heat and perform calculations regarding heat during changes of state and calorimeter tests.
Learning Objectives
- Define and explain internal energy, heat, specific heat, heat units, temperature and explain the relationship between the different temperature scales.
- Define sensible heat and use the sensible heat equation to calculate the amount of heat required to change the temperature of a substance, the mass of the substance, and the temperature change, if no change of state occurs.
- Explain the changes of state and define latent heat, latent heat of fusion, andlatent heat of evaporation.
- Given start and end conditions, calculate the heat required to change the states of water and other substances.
- Determine the final temperatures and the original masses for mixtures of ice, water, steam, and other substances.
- Explain the working principle of a simple calorimeter and use the calorimeter equation to determine specific heat and final temperature.
- Explain water equivalent and perform calculations involving calorimetry and water equivalents.
Topic 4 Thermal Expansion and Heat Transfer
Learning Outcome
Explain concepts and perform calculations involving the thermal expansions of solids and liquids and heat transfer by conduction.
Learning Objectives
- Explain the thermal conditions that cause expansion of solids and liquids and describe the relationship between linear, superficial (area) and volumetric expansion.
- Given known conditions, calculate linear expansion or contraction, temperatures, and/or expansion coefficients for solids.
- Given known conditions, calculate superficial expansion or contraction, temperatures, and/or expansion coefficients for solids.
- Given known conditions, calculate volumetric expansion or contraction, temperatures, and/or expansion coefficients for solids or liquids.
- Calculate the stress produced in a pipe or its supports when thermal expansion is restricted.
- Explain the methods of heat transfer: conduction, convection, and radiation.
- Define thermal conductivity and calculate the quantity of heat conducted, the temperature difference, or the material thickness when heat is transferred through flat walls and plates.
Topic 5 Steam Properties and Calculations
Learning Outcome
Define properties of saturated and superheated steam and, using information from the steam tables, calculate the heat required to produce steam at various conditions; determine the equivalent and factor of evaporation for steam boilers.
Learning Objectives
- Define and explain the following terms: saturation temperature, saturated steam, dry saturated steam, wet saturated steam, dryness fraction, superheated steam, enthalpy.
- Identify, from the pressure‐based and temperature‐based steam tables, the properties of saturated steam at specified conditions.
- Identify, from the superheated steam tables, the properties of superheated steam at specified conditions.
- Calculate the heat required to produce dry saturated or superheated steam at given conditions, from feedwater at given conditions.
- Calculate the dryness fraction of wet steam and/or the heat required to produce wet steam at a given dryness fraction.
- Explain the properties of steam on a temperature‐enthalpy diagram.
- Define and calculate heat rate, equivalent evaporation and factor of evaporation for a boiler.
Topic 6 Gas Laws and Calculations
Learning Outcome
Explain the laws of perfect gases and perform calculations involving the expansion and compression of gases.
Learning Objectives
- Explain Boyle’s Law, Charles’ Law, Gay‐Lussac’s Law, and the General Gas Law and use these to calculate pressure, temperature and/or volume changes for perfect gases.
- Explain the Characteristic Gas Constant and use the Characteristic Gas Equation to determine the mass, the conditions, and the constant for a gas.
- Explain isothermal, adiabatic, and polytropic processes (expansion and compression) for a gas, state the formula for each process, and compare the processes on a pressure/volume diagram.
- Calculate unknown pressures, volumes and temperatures for gases during isothermal adiabatic, and polytropic processes.
- Explain and calculate the work done in a cylinder under constant pressure.
- Explain and calculate the work done in a cylinder during an isothermal expansion or compression.
- Explain and calculate the work done in a cylinder during an adiabatic expansion or compression.
- Explain and calculate the work done in a cylinder during a polytropic expansion or compression.
Topic 7 Chemistry Fundamentals
Learning Outcome
Explain the fundamental principles in the structure, formation and interaction of chemical compounds and the importance of chemistry in industrial operations.
Learning Objectives
- Define each term and explain the relationship between atoms, ions, elements, molecules, compounds, and mixtures.
- Using the Periodic Table of the Elements, determine the atomic numbers and the atomic masses of elements.
- Explain electronegativity and the bonding of ions.
- Explain the formation of chemical compounds, explain typical reactions and apply fundamental principles to the balancing of simple chemical reactions.
- Calculate the amount of reactants required or products produced in a chemical reaction.
- Define acids, bases, and salts and explain their properties.
- Define organic chemistry and explain, in general terms, the structure and applications of hydrocarbons and hydrocarbon derivatives.
- Explain typical applications of chemistry in industry, including water treatment and testing, corrosion, combustion, hydrocarbon processing, petrochemical and pulp and paper processes.
Topic 8 Metallurgy and Materials
Learning Outcome
Explain the production, properties and applications of metallic and non‐metallic materials.
Learning Objectives
- Define and explain the importance and application of mechanical properties of materials, including brittleness, hardness, ductility, malleability, plasticity, elasticity, and toughness.
- Describe material testing, including tension test, Brinell and Rockwell hardness tests, Charpy and Izod impact tests.
- Describe the blast furnace and cupola furnace methods for iron production and compare the characteristics of gray, white, malleable, and ductile cast iron.
- Define steel and explain the compositions and characteristics of low carbon, medium carbon and high carbon steels.
- Define alloy steels, and explain the benefits of alloying elements, including nickel, chromium, molybdenum, vanadium, copper, lead, manganese and tungsten.
- Explain the purposes of hot working, cold working and heat treating of metals.
- Describe the production of carbon and alloy steel, using the open hearth, basic oxygen and electric‐arc furnace processes.
- Describe the properties and applications of non‐ferrous metals and alloys.
- Explain the basic structure, properties and applications of polymers, ceramics and composites.
Learning Outcome
Explain the mechanisms that cause corrosion and the methods used to monitor and control corrosion.
Learning Objectives
- Define corrosion terms and explain the causes and characteristics of corrosion types, including galvanic, atmospheric, stray current, biological, stress cracking, hydrogen induced, sulphide stress cracking and chloride stress cracking.
- Explain specifically the nature and sources of corrosion on the water side of boilers, including caustic corrosion, hydrogen damage, and pitting.
- Explain the environmental factors that affect corrosion.
- Explain the principles of corrosion inhibitor mechanisms, including adsorbed films, passivation, cathodic precipitates, and neutralization.
- Describe the principles and applications of cathodic protection devices or systems, including sacrificial anodes, galvanic anodes, impressed current, and groundbeds.
- Describe the principles and applications of corrosion monitoring devices, including coupons, electrical resistance probes, galvanic probes, and hydrogen probes.
- Describe corrosion inspection procedures, including ultrasonics and radiography.
Topic 1 Legislation and Codes for Power Engineers
Learning Outcome
Explain the purpose of, general content of, and interaction with the legislation and codes that pertain to the design and operation of boilers and related equipment.
Learning Objectives
- Explain Codes and Standards.
- Explain the purpose and scope of the National Board of Boiler Inspectors (NBBI).
- Explain the scope of the ASME and state the purpose and general content of the following sections of the the ASME Codes: Section I, II, IV, V, VI, VII, VIII, IX.
Topic 2 Code Calculations - ASME Section I
Learning Outcome
Using the ASME Code ‐ Section I, and ASME Section II D. Table 1A, calculate the design thickness and pressure of boiler tubes, drums, and piping, and calculate the capacities of pressure relief valves.
Learning Objectives
- Given the tube material specification numbers, and other necessary parameters, use the formulae in PG‐27.2.1 to calculate either the minimum required wall thickness or the maximum allowable working pressure for a boiler tube.
- Given the material specification, construction method, and other necessary parameters, use the formulae in PG‐27.2.2 to determine the minimum required thickness and or maximum allowable working pressure for boiler drums, headers, or piping.
- Given the required specifications and operating conditions, use formula PG‐29.1 to calculate the minimum required thickness of a seamless, unstayed dished head.
- Given the required specifications and operating conditions, use formulae in paragraphs PG‐29.11 and PG‐29.12 to calculate the minimum required thickness of an unstayed, full‐hemispherical head.
- Using ASME Section I, Paragraphs PG‐67 to PG‐73, identify code information with respect to pressure relief valves and, using Table A‐44, calculate the required pressure relief valve capacity for a given boiler.
Topic 3 Fuels, Combustion, and Flue Gas Analysis
Learning Outcome
Explain the properties and combustion of common fuels and the analysis of combustion flue gas.
Learning Objectives
- Explain/define complete combustion, incomplete combustion, combustion products, and write balanced combustion equations.
- Explain the purpose and benefits of excess air and calculate the theoretical and excess air required for the complete combustion of a given fuel.
- Explain proximate analysis, ultimate analysis, and heating value of a fuel and describe the use of calorimetry to determine heating value. Explain higher and lower heating values.
- Given the ultimate analysis of a fuel, use Dulong’s Formula to calculate the heating value of the fuel.
- Describe the properties, classifications and combustion characteristics of coal.
- Describe the properties, classifications and combustion characteristics of fuel oil.
- Describe the properties and combustion characteristics of natural gas.
- Explain the use and combustion characteristics of alternatives to traditional fossil fuels, including biomass, coke and oil emulsions.
- Explain the analysis of flue gas for the measurement of O2, CO, and CO2 in relation to combustion efficiency. Describe typical, automatic flue gas analyzers.
- Explain the formation, monitoring and control of nitrogen oxides (NOX), sulfur dioxide, and particulates.
Topic 4 Piping Design, Connections, Support
Learning Outcome
Discuss the codes, designs, specifications, and connections for ferrous, non‐ferrous and non‐metallic piping and explain expansion and support devices common to piping systems.
Learning Objectives
- Identify and explain the general scope of the ASME, ANSI, ASTM codes and standards with respect to piping and pipe fittings. Differentiate between power piping (Code B31.1) and pressure piping (Code B31.3).
- Explain methods of pipe manufacture; size specifications and service ratings, and the material specifications and applications for ferrous pipe.
- Using pipe specifications and the ASME code Sections I and II you will be able to identify the size of pipe required for a particular installation, process or operating condition.
- Explain the materials, code specifications and applications of common, non‐ferrous metal piping and cast iron.
- Describe screwed, welded, and flanged methods of pipe connection and identify the fittings used for each method.
- Describe the construction, designs, and materials of flange gaskets and explain the confined, semi‐confined, and unconfined flange styles.
- Explain the materials, construction and approved applications of common, non‐metallic pipe.
- Explain the effects of temperature on piping; explain the mechanisms and the dangers of expansion in piping systems, including attached equipment.
- State the purpose and explain the designs, locations and applications of simple and offset U‐bend expansion bends.
- Describe designs, locations, care and maintenance of slip, corrugated, bellows, hinged, universal, pressure‐balanced, and externally pressurized expansion joints.
- Describe design, location, operation of pipe support components, including hangers, roller stands, variable spring hangers, constant load hangers, anchors, and guides.
Topic 5 Steam Traps, Water Hammer, Insulation
Learning Outcome
Explain the designs and operation of steam trap systems, the causes and prevention of water hammer, and the designs and applications of pipe insulation.
Learning Objectives
- Explain the dynamics, design, and components of steam/condensate return systems for steam lines and condensing vessels. Explain roles and locations of separators and traps.
- Describe the design, operation and application of ball float, inverted bucket, thermostatic, bi‐metallic, impulse, controlled disc, and liquid expansion steam traps.
- Explain the selection, sizing and capacity of steam traps and explain the factors that determine efficient trap operation.
- Explain the procedures for commissioning, testing, and maintenance of steam traps.
- Explain and compare condensate‐induced and flow‐induced water hammer in steam and condensate lines. Explain the typical velocities, pressures and damage that can be created in steam/condensate lines due to water hammer.
- Describe specific trap and condensate return arrangements that are designed to prevent water hammer in steam and condensate lines.
- State precautions that must be observed to prevent water hammer and describe a typical steam system start‐up procedure that will prevent water hammer.
- State the purposes of insulation and explain the properties required for a good insulating material. Explain thermal conductivity, K‐Factor and R‐Value.
- Identify the most common industrial insulating materials, describe the composition and characteristics of each, and explain in what service each would be used.
- Describe common methods for applying insulation to piping and equipment, including wrap and clad, blanket, insulated covers and boxes. Explain the care of insulation and cladding and the importance of maintaining good condition.
Learning Outcome
Describe the designs, configurations and operation of the common valve designs that are used in power and process piping.
Learning Objectives
- Explain the factors that determine the suitability and applications of the major valve styles; gate, globe, ball, plug, butterfly and needle.
- Explain the factors that determine the selection of valve materials, and describe examples of typical valve body and trim materials. How are common control valves identified?
- Describe the configurations and applications for gate valves, including gate designs (solid, split, flexible, sliding), stem configurations (rising, non‐rising, outside screw‐and‐yoke, inside screw), and bonnet designs (flanged, screwed, welded).
- Describe the designs and applications of globe valves, including conventional disc, composition disc, plug‐type disc, and angle valves. Describe high‐pressure plug‐type control valves.
- Describe the designs, application and operation of single‐seated and double‐seated balance valves. Explain caged trim for balanced control valves.
- Describe the designs and applications of typical plug valves, including tapered and cylindrical plug, four‐ way, eccentric, and jacketed.
- Describe the designs and configurations for mixing and diverter valves.
- Describe the designs and operation of diaphragm valves.
- Describe designs and operation of butterfly valves, including vertical, horizontal, swing‐through, lined, and high‐performance.
- Describe the design, application, and operation of gear, motor, air‐diaphragm, and air‐piston actuators for valves.
Topic 7 AC Theory and Machines
Learning Outcome
Explain formation and characteristics of AC power, and describe the design, construction and operating principles of AC generators, motors and transformers.
Learning Objectives
- Explain the creation of single phase and three‐phase alternating power; define cycle, frequency and phase relationships (voltage/current) for AC sine waves.
- Define the following terms and explain their relationships in an ac circuit: capacitance, inductance, reactance, impedance, power factor, alternator ratings (kVA and kW).
- Describe the stator and rotor designs, operation, and applications for salient pole and cylindrical rotor
alternators
- Describe water, air and hydrogen cooling systems for large generators.
- Explain parallel operation of alternators and state the requirements for synchronization. Describe manual and automatic synchronization.
- Describe the design, applications and operating principles for large three‐phase squirrel cage and wound rotor induction motors.
- Describe the design and operating principle of synchronous motors.
- Explain variable speed control, variable speed starting, and step starting for large induction motors.
- Explain the principles and applications of power transformation. Perform transformer calculations.
- Describe the designs and components of typical core and shell type transformers, including cooling components.
Topic 8 AC Systems, Switchgear, Safety
Learning Outcome
Identify the components of typical AC systems and switchgear and discuss safety around electrical systems and equipment.
Learning Objectives
- Using a one‐line electrical drawing, identify the layout of a typical industrial AC power system with multiple generators, and explain the interaction of the major components.
- Explain the function of the typical gages, meters, and switches on an AC generator panel.
- Explain the purpose and function of the circuit protective and switching equipment associated with an AC generator: fuses, safety switches, circuit breakers, circuit protection relays, automatic bus switchover, grounding and lightning arrestors.
- Explain the components and operation of a typical Uninterruptible Power Supply (UPS) system.
- Explain safety procedures and precautions that must be exercised when working around and operating electrical system components. Explain grounding.
Topic 9 Electrical Calculations
Learning Outcome
Define terms and perform simple calculations involving DC and AC power circuits.
Learning Objectives
- Use Ohm’s Law and Kirchhoff’s Laws to calculate current, resistance or voltage drop in series or parallel multi‐resistor circuits.
- Calculate unknown resistances using a Wheatstone Bridge circuit.
- Explain and perform calculations involving electrical power, work and energy.
- Calculate the frequency, period and phase angle for an AC sine wave.
- Define terms and calculate the peak‐to‐peak, root mean square, and maximum values for AC voltage and current.
- Given required parameters, calculate the inductive reactance, capacitive reactance, total reactance, and impedance for an AC circuit, plus circuit frequency and current flow.
- Calculate real power, imaginary power and power factor for an AC circuit.
- Given the load, voltage and power factor of a 3‐phase generator, calculate the kVA and kW ratings of the generator.
Topic 10 Control Loops and Strategies
Explain the operation and components of pneumatic, electronic and digital control loops, and discuss control modes and strategies.
Learning Objectives
- Describe the operation, components and terminologies for a typical control loop.
- Describe the operation and components of a purely pneumatic control loop. Explain the function of each component.
- Describe the operation and components of an analog/electronic control loop. Explain the function of each component.
- Describe the operation and components of a digital control loop. Explain the function of each component.
- Explain the purpose, operation, and give examples of on‐off, proportional, proportional‐plus‐reset, and proportional‐plus‐reset‐plus‐derivative control. Define proportional band and gain.
- Describe and give typical examples of feed forward, feed back, cascade, ratio, split‐range, and select control.
- Explain, with examples, the purpose and incorporation of alarms and shutdowns into a control loop/ system.
- Explain the interactions that occur and the interfaces that exist between an operator and the various components of a control loop/system, including the components of a controller interface.
Topic 1 Watertube Boiler Designs Learning Outcome
Describe common designs, configurations and circulation patterns for modern bent‐tube watertube boilers and steam generators and explain how boilers are rated.
Learning Objectives
- Explain the difference between packaged, shop assembled, and field‐erected watertube boilers. Explain how boilers are rated.
- Explain the process of water circulation in a watertube boiler and the factors that influence circulation.
- Identify examples of and describe the A, O, and D design configurations and explain the water and gas circulation patterns for each. Define integral furnace.
- Define a steam‐generating unit, identify oil and gas‐fired units, and explain the components, heating surfaces, and flow patterns through a typical unit. State typical temperatures throughout the unit.
- Differentiate between critical and super‐critical boilers.
- Explain the purpose and advantage of forced circulation and describe the flow through a typical controlled circulation boiler.
- Explain the purpose and design of a once‐through boiler.
Topic 2 Special Boiler Designs
Learning Outcome
Describe the designs, components, firing methods, and operating considerations for some special boilers used in industry.
Learning Objectives
- Describe typical designs, components and operating strategies for once‐through, steam flood boilers.
- Describe typical designs, components and operating strategies for Fluidized Bed boilers.
- Describe typical designs, components and operating strategies for Heat Recovery Steam Generators.
- Describe typical designs, components and operating strategies for Black Liquor Recovery boilers used in pulp mills.
- Describe typical designs, components and operating strategies for Refuse boilers used in waste disposal.
- Describe typical designs, components and operating strategies for waste heat, biomass boilers.
Learning Outcome
Explain Code requirements, in general terms, and describe construction and assembly methods for the major components of a large boiler.
Learning Objectives
- Explain top and bottom support and describe the support techniques for various components of a large boiler, including lateral supports for furnace walls. Explain allowances for expansion.
- Explain the purpose, design, locations and installation methods for boiler casing insulation, refractory, and cladding.
- Describe the methods used to fabricate boiler tubes.
- Describe the preparation, fabrication, and testing of boiler drums.
- Describe methods of attaching tubes to drums and headers, including expanding and welding, and explain where each method would be used.
- Explain code requirements/sizes for, and describe the designs and installation of, manholes and handholes, including welded handholes. Explain procedures for removing and installing covers.
- Describe the field assembly of a large boiler or steam generating unit.
Topic 4 Boiler Heat Transfer Components
Learning Outcome
Explain the purpose, location, design and operating conditions for the major heat transfer components of a large watertube boiler or steam generator.
Learning Objectives
- Describe baffle designs and locations and explain their significance to boiler heat transfer.
- Describe the designs of integral furnace sidewall and header arrangements, including tube‐and‐tile, tangent tube, and membrane.
- Define primary, secondary, convection, radiation, platen, and pendant as they apply to superheaters. Describe the locations of superheaters within a steam generator and state the operating characteristics of convection and radiant superheaters.
- Explain the purpose and design of a separately‐fired superheater.
- Explain the purpose and describe the locations of reheaters. Explain the position of and flow through the reheater in relation to the superheaters.
- Describe designs and locations for integral and separate economizers.
- Describe the designs, operation, and location of plate, tubular, and rotary regenerative air heaters.
- Explain operating care and considerations that must be given to the various heat transfer sections of the boiler.
- Explain a typical water and gas temperature profile through a large steam generating unit.
Topic 5 High Pressure Boiler Fittings
Learning Outcome
Describe the design and operation of common external and internal fittings attached to the pressure side of a high‐ pressure boiler.
Learning Objectives
- Describe the design, installation, operation, and setting of a high‐pressure pressure relief valve. Explain the Code requirements for size, capacity and locations of the pressure relief valves on a boiler.
- Describe the code requirements for boiler pressure gages, including attachment and locations.
- Describe common designs, connections and components of high‐pressure water columns and flat gage glasses, including illumination and quick shut‐off devices and bulls‐eye glasses. Explain testing and maintenance of a high‐pressure gage glass.
- Describe the float and probe designs for low‐water fuel cutoffs and explain how these are tested.
- Describe boiler steam outlet arrangements and fittings including gate, angle, and globe stop valves and globe, Y, angle, and spring‐cushioned non‐return valves.
- Describe manual blowoff piping arrangements. Describe the design and operation of sliding disc, seatless sliding plunger, seat and disc, and combination valves. Explain manual blowoff procedures. Describe the requirements for a blowoff tank.
- Explain the components of the steam drum internals of a watertube boiler. Describe the design and operation of various steam separation devices, including baffles, primary and secondary separators, and scrubbers.
Topic 6 Burner Designs and Supply Systems
Learning Outcome
Describe the typical components of fuel supply systems and describe common burner/furnace designs for gas, oil, and coal‐fired boilers.
Learning Objectives
- Describe a complete fuel gas supply system from fuel gas header to burner and explain the function of each component, including control and shut‐off valves, auto‐vents, and instruments. State the typical operating pressures.
- Describe the design and operation of spud and ring burners, and explain high‐efficiency, low NOX designs.
- Describe a complete fuel oil supply system from storage tanks to burners and explain the function of each system component.
- Describe the design and operation of air, steam, and mechanical atomizing burners.
- Describe a coal supply system from stockpiles to burners for a typical pulverized coal furnace.
- Describe the design and operation of a pulverized coal burner and explain turbulent vertical, tangential, and cyclone furnaces.
- Describe the design and operation of ball, impact, ball‐race, and bowl mill pulverizers.
- Describe the designs and operation of underfeed, overfeed, and crossfeed stokers for furnaces burning solid fuels.
Topic 7 Boiler Draf t and Flue Gas Equipment
Learning Outcome
Explain boiler draft systems and fans and describe the equipment used to remove ash from flue gas.
Learning Objectives
- Define and explain the applications and designs of natural, forced, induced and balanced draft.
- Explain how draft is measured, monitored, and controlled in a large, balanced draft boiler. Explain the position of control dampers.
- Describe typical draft fan designs, single and double inlet arrangements, and explain methods used to control fan output.
- Explain the start‐up and running checks that must be made on draft fans.
- Describe typical windbox and air louver arrangements and distinguish between primary and secondary air.
- Describe the design and operation of flue gas particulate clean‐up equipment, including mechanical and electrostatic precipitators and baghouse filters.
- Describe the design and operation of ash handling systems, including hydro and air systems, bottom ash systems, and scraper conveyor systems.
- Describe the designs and operation of SO2 recovery systems, including lime and wet gas scrubbing.
Topic 8 Boiler Control Systems
Learning Outcome
Explain the components and operation of automatic control systems for boiler water level, combustion, steam temperature, and start‐up.
Learning Objectives
- Describe on‐off and single element control of boiler feedwater.
- Explain swell and shrinkage in a boiler. Describe the components and operation of a two‐element feedwater control system, explaining the interaction of the controllers.
- Describe the components and operation of a three‐element feedwater control system.
- Describe the components and operation of a direct combustion control system.
- Describe the components and operation of a ‘steam flow – airflow’ combustion control system.
- Describe the components and operation of a ‘fuel flow – airflow’ combustion control system.
- Describe the components and operation of an ‘airflow – fuel flow’ combustion control system.
- Describe the components and operation of a multi‐element combustion control system.
- Describe steam temperature control methods and equipment, including attemperation (desuperheating), gas recirculation, gas bypass, and tilting burners.
- Describe the automatic, programmed start‐up sequence for a gas‐fired boiler.
Learning Outcome
Describe common procedures in the operation and maintenance of high pressure boilers.
Learning Objectives
- Explain the steps involved in the commissioning of a new boiler or before starting a boiler after major repairs, including:
- hydrostatic test
- external and internal inspections
- drying out refractory
- boiling out
- testing shutdowns and safety devices
- Describe the wet and dry methods when laying up a boiler for an extended time, including nitrogen blanketing.
- Describe the proper shut down and preparation of a boiler for internal inspection.
- Describe a thorough inspection of the water and furnace sides of a boiler.
- Describe typical equipment and procedures for cleaning the water side of a boiler:
- mechanically
- chemically
- Explain routine tasks and visual monitoring that the operator must perform on a large operating boiler.
- Explain the procedures and precautions that an operator must exercise to avoid furnace and pressure‐side explosions.
- Describe sootblowing systems and describe the procedures for operating sootblowers.
Topic 10 Internal Water Treatment for Boilers
Learning Outcome
Discuss internal water treatment methods and systems for the control of scale, corrosion, and carryover and explain testing and monitoring strategies.
Learning Objectives
- Explain the causes and effects of boiler scale; explain the most common internal methods of scale control, including phosphate treatment, chelate treatment, sludge conditioning and dispersion.
- Explain the causes and effects of boiler and condensate return line corrosion; explain treatment methods for acidic, caustic, oxygen, and carbon dioxide corrosion, including sulphite, hydrazine, and amine treatment.
- Explain the mechanical and chemical causes, effects and types of carryover; explain methods of carryover control, including the use of antifoam and blowdown.
- Describe the design and explain the operation of simple blowdown, heat recovery, and automatic blowdown systems.
- Explain, in general terms, the sampling and testing strategies for boiler internal conditions; describe typical sampling and automatic monitoring equipment.
- Describe typical chemical feed systems, including pot feeders, continuous feed with day tanks, and continuous feed with pump tanks.
Topic 11 Boiler Water Pretreatment
Learning Outcome
Explain the purpose, principles, equipment, and monitoring of boiler water pretreatment processes.
Learning Objectives
- Describe the design and explain the terms, purpose and operation of a clarifier, using coagulation, flocculation, and subsidence.
- Describe the design and explain the terms, purpose and operation of gravity and pressure filters.
- Describe the design and explain the terms, purpose and operation, including chemical reactions for a cold lime softener.
- Describe the design and explain the terms, purpose and operation of a hot lime softener.
- Explain the principles of ion exchange softening in general, identifying the common anions and cations in untreated water.
- Describe the design, components, and operation of a sodium zeolite softening system including chemical reactions.
- Describe the design, components, and operation of a hydrogen zeolite softening system including chemical reactions.
- Describe the design, components, and operation of a dealkalization system including chemical reactions.
- Describe the design, components, and operation of a demineralizer system, including mixed bed and degasification.
- Explain the principle and operation of a reverse osmosis system.
- Describe the design, principle, and operation controls of a typical deaerator.
Learning Outcome
Explain pressure vessel design, stresses, and operating considerations.
Learning Objectives
- Define “pressure vessel” and explain, in general terms, how pressure vessels are regulated in design, construction and repair (including purpose of Section VIII, ASME).
- Explain the stamping/nameplate requirements for pressure vessels and identify terms and specifications on a typical nameplate.
- Describe the weld locations on a typical pressure vessel and identify head designs, including ellipsoidal, torispherical, hemispherical, conical, and toriconical.
- Describe acceptable nozzle attachment methods, including reinforcements; describe inspection openings.
- Explain the loads that contribute to stresses in pressure vessels, including pressure, thermal, attachments, static, wind, seismic, and cyclic loads.
- Explain the components and fittings of a typical pressure vessel.
- Explain operating and maintenance considerations for the safe operation of pressure vessels, including the appropriate use of hydrostatic and pneumatic testing.
Describe auxiliary support and control systems for steam turbines and explain start‐up and shutdown procedures.
Learning Objectives
- Describe typical lube oil systems for small and large steam turbines.
- Explain the purpose and describe the design and operation of barring gear and jacking oil systems on a large turbine.
- Describe a condensing turbine circuit and explain typical operating parameters.
- Explain and state the applications, where applicable, of the following governor types: speed‐sensitive, pressure‐sensitive, nozzle, throttle, and bypass. Explain governor droop and isochronous control.
- Explain the operation and the major components of the three main speed‐sensitive governor systems: mechanical, mechanical‐hydraulic, and electronic‐hydraulic.
- Explain the operation and describe the components of typical mechanical and electronic overspeed trip systems.
- Explain the sequence followed for the cold start‐up and the shutdown of a non‐condensing steam turbine.
- Explain the sequence followed for the cold start‐up and the shutdown of a condensing and extracting steam turbine.
Topic 2 Turbine Condenser Systems
Learning Outcome
Explain typical designs, components and operating principles of steam turbine condensers.
Learning Objectives
- Explain the purposes of a turbine condenser in a steam plant cycle and describe a typical condensing circuit, with operating temperatures and pressures.
- Explain the design, operation and applications of the jet condenser, including the ejector type.
- Explain the design, operation and applications of the surface condenser, including air cooled and water‐ cooled, down flow and central flow.
- Describe construction details for surface condensers, including shells, tube attachment, supports, and allowances for expansion.
- Explain the effects of air in a condenser and describe the design and operation of single and two‐stage air ejectors. Explain the detection of condenser air leaks. Explain vacuum pumps.
- Explain the devices and operating considerations used to protect a condenser against high backpressure, high condensate level, and cooling water contamination. Describe a cooling water leak test.
- Describe the operating conditions and corresponding design considerations for condensate extraction pumps and cooling water pumps.
- Describe a feed water heater system in conjunction with a steam condenser and explain the designs of low‐pressure and high‐pressure feed water heaters.
Topic 3 Gas Turbine Principles and Designs
Learning Outcome
Explain common designs, major components, operating principles, and arrangements for industrial gas turbines.
Learning Objectives
- Explain gas turbine advantages and disadvantages, background and industrial applications. Identify the types of gas turbines, their major components and describe the operating principles of a simple gas turbine.
- Explain single and dual shaft arrangements for gas turbines. Describe open cycle and closed cycle operation.
- Describe a typical open cycle gas turbine installation, including buildings or enclosures, intake and exhaust systems, auxiliary systems, and reducing gear.
- Explain the efficiency and rating of gas turbines and describe the purpose and applications of gas turbine cycle improvements, including intercooling, regenerating, reheating and combined cycle.
- Describe various aspects of compressor design and centrifugal and axial types of compressors.
- Describe the types, operation, components and arrangements of combustors.
- Describe turbine section design and operation especially with respect to blading and materials.
- Explain the types and functions of the control systems and instrumentation needed for gas turbine operation.
- Explain the typical operating parameters of a gas turbine; describe the effects of compressor inlet temperature, compressor discharge pressure, and turbine inlet temperature on gas turbine performance.
Topic 4 Gas Turbine Auxiliaries and Operation
Learning Outcome
Describe the support auxiliaries for a gas turbine and explain common operational, control and maintenance procedures.
Learning Objectives
- Describe the types of bearings used in a gas turbine and explain the components, operation, protective devices and routine maintenance of a typical lube oil system.
- Describe and explain the operation and routine maintenance of a typical fuel gas supply system for a gas turbine.
- Describe and explain the operation and routine maintenance of a typical fuel oil supply system for a gas turbine.
- Explain the control of NOX from a gas turbine and describe the purpose and operation of water/steam injection and dry low NOX systems.
- Explain the purpose, location and operation of the gas turbine starting motor and turning gear.
- Describe the compressor intake and the turbine exhaust components.
- Describe the preparation and complete start‐up sequence for a gas turbine.
- Describe the shutdown sequence and procedure for a gas turbine.
- Explain the purpose and describe typical on‐line and off‐line waterwash procedures for gas turbine blades.
Topic 5 Cogeneration Systems and Operation
Learning Outcome
Explain cogeneration and describe common configurations, components and applications.
Learning Objectives
- Define cogeneration and explain its purpose, advantages, and applications.
- Explain the components and operation of simple‐cycle cogeneration systems.
- Explain the components and operation of combined‐cycle, gas/steam turbine cogeneration systems.
- Explain the components and operation of a fully fired, combined‐cycle cogeneration system.
- Explain single‐shaft and dual‐shaft combined‐cycle power plants.
- Explain the general control strategies and components, for both power and steam production, including diverter and duct burner operation.
- Describe the various designs of heat recovery steam generators (HRSGs) and explain their industrial applications.
- Explain the environmental considerations and techniques in the operation of a cogeneration system.
- Describe typical cogeneration systems that use internal combustion engines (gas or diesel) and heat recovery water heaters (HRWHs).
- Explain a typical start‐up procedure for a combined cycle cogeneration system.
Topic 6 Compressor Theory and Designs
Learning Outcome
Explain the classification, designs, and operating principles of industrial air and gas compressors.
Learning Objectives
- Explain compressor terminologies, including compression ratio, capacity, staging, intercooling and aftercooling. Explain the effects of moisture in compressed gases. Explain the effects of altitude on the compression process.
- Describe the operation and common arrangements of reciprocating compressors, including single‐ acting, double‐acting, and tandem arrangements.
- Identify the components of a reciprocating compressor and describe the operation of plate and channel valves.
- Describe internal and external lubrication systems for reciprocating compressors.
- Describe the design and explain the operating principles of rotary compressors, including sliding vane, rotary lobe, and rotary screw.
- Identify the components and controls for a packaged industrial screw compressor.
- Describe designs and principles of centrifugal compressors/blowers, including single and multi‐stage designs.
- Describe designs and principles of axial compressors/blowers.
Topic 7 Compressor Auxiliaries and Operation
Learning Outcome
Explain the controls and system auxiliaries for a typical instrument air system and explain startup procedures for air compressors.
Learning Objectives
- Describe the control devices and strategies for air compressors, including start‐and‐stop, variable speed, constant speed; describe pilot and unloader devices.
- Explain the design and operation of an anti‐surge system for a dynamic compressor.
- Describe the designs of water and air‐cooled aftercoolers and intercoolers, with separators.
- Describe the components, arrangement, and parameters of a typical, complete instrument air system, including wet and dry receivers, dryers.
- Describe the components and operating principles and sequences of instrument air dryers. Explain dewpoint monitoring of air systems.
- Describe the design, fittings, and operating consideration for air receivers.
- Explain the start‐up procedure for a positive displacement compressor.
- Explain the start‐up procedure for a dynamic compressor/blower.
Topic 8 Refrigeration Principles and Systems
Learning Outcome
Explain the classification and properties of refrigerants and describe the operating principles and components of compression and absorption systems.
Learning Objectives
- Explain the required properties of a refrigerant and describe the six group classifications for refrigerants. Identify the properties of common refrigerants.
- Explain the ammonia compression refrigeration cycle, explaining the purpose of each major component and stating typical pressures and temperatures in the system.
- Explain direct and indirect refrigeration. Describe a centrifugal compression system, using chilled water.
- Describe and explain the operation of a two‐stage, duplex compressor system with a brine cooler.
- Describe and explain the operation of a two‐stage refrigeration system with a rotary booster compressor.
- Describe and explain the operation of a low‐temperature multi‐stage refrigeration system.
- Explain the components and operating principle of an ammonia absorption system.
Topic 9 Refrigeration Auxiliaries and Operation
Learning Outcome
Explain control and safety devices on a compression refrigeration system and explain procedures and equipment to control oil, non‐condensables, moisture, refrigerant, and brine.
Learning Objectives
- Explain the purpose, design and operation of the following controls on a compression refrigeration system: expansion valve, low‐side float, high‐side float, compressor controls (temperature and pressure‐ actuated), and condenser cooling water control.
- Explain the purpose of the following refrigeration system safety devices: high‐pressure cutout, oil pressure cutout and pressure relief devices.
- Explain the effects of oil in ammonia and Freon systems and describe the location and operation of an oil separator and oil still. Explain how oil is manually drained from these systems.
- Explain the effects and location of non‐condensable gases. Describe the operation of manual and automatic purge devices.
- Explain the effects of moisture in a refrigeration system and describe its removal.
- Explain leak testing of a system and describe the procedure for adding refrigerant.
- Explain the principles of brine control in an indirect system and explain the procedures for charging and controlling brine strength.
- Explain refrigeration safety and environmental issues.
Topic 10 Heat Exchangers and Cooling Towers
Learning Outcome
Describe the design, operation, and applications of various types of industrial heat exchangers.
Learning Objectives
- Describe double pipe heat exchangers, including jacketed pipe, U‐tube, and concentric pipe designs.
- Describe shell‐and‐tube heat exchangers including fixed straight tube and U‐tube designs. Describe common front and rear head designs, shell flow configurations, and explain the purpose of baffles.
- Explain the operation and the typical fittings/equipment on the steam/condensate side of a reboiler and a feed water heater.
- Describe the design and operation of a plate‐and‐frame exchanger.
- Describe the design and components of overhead, aerial coolers, including fan and cooler arrangements. Explain cooler control
- Describe the design and components, including controls, of an overhead, aerial condenser. Explain condenser operation, control and precautions when used to condense excess steam.
- Describe the design and explain the operation of natural draft cooling towers, including atmospheric and hyperbolic styles
Learning Outcome
Describe the design, components, operation, and applications of direct‐fired and indirect‐fired natural draft process heaters.
Learning Objectives
- Describe the common process applications for direct‐fired heaters. Explain direct‐fired heater designs and classifications.
- Describe the design, identify the tube banks and explain the fluid and combustion gas flows through a multi‐burner, vertical fired heater.
- Describe typical burner designs and configurations, identifying burner components, including air registers, pilots, and flame scanners. Describe burner operation.
- Describe the fuel gas supply system to the burners and explain the purpose of the major fittings.
- Describe the monitoring, control, and shutdown devices on a typical heater.
- Explain heater start‐up procedure, including the lighting of additional burners once flame is established. Explain heater shutdown procedure.
- Describe the design, components and operation of a typical horizontal, indirect‐fired heater such as a salt bath heater.
- Explain start‐up and shutdown procedures for an indirect‐fired heater.
Learning Outcome
Explain the purpose, designs, processes and control of industrial wastewater treatment.
Learning Objectives
- State the purpose of wastewater treatment, list typical waste liquids, and explain the legislation and permitting, including parameters, for the disposal of wastewater.
- Sketch an industrial wastewater treatment system and describe the processes that occur at each stage of treatment.
- Describe the equipment and process involved in the removal of suspended solids from wastewater, including screening, flotation, and sedimentation.
- Describe the equipment and process involved in the removal of colloidal solids from wastewater, including chemical coagulation, flocculation, and clarification.
- Describe the equipment and process involved in the biological removal of solids from wastewater, including activated sludge, rotating biological contactors, and trickling filters.
- Describe the control strategy for a wastewater treatment system. Define and explain the control of and sampling points for the main control parameters, including nutrients, BOD, COD, pH, and settle ability.
Topic 13 Plant Maintenance and Administration
Learning Outcome
Explain typical components of maintenance and administration programs for utilities and process facilities.
Learning Objectives
- Explain typical communication and accountability structures within a large facility, including theresponsibilities for external communication.
- Describe the typical components and responsibilities of scheduled and preventive maintenancemanagement programs.
- Explain the importance and extent of record keeping and describe the quality and content requirements for operating logbooks and records.
- Using a complete boiler turnaround and inspection as an example, describe project management usingtwo methods, Gantt Chart and critical path.
- Explain the importance of procedures in the operation of a facility and describe the application ofwell‐written procedures to personnel training and daily operation.
- Explain typical environmental monitoring and management programs for operating facilities.
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