US National 1st Class

Breadcrumbs

This Curriculum is intended to assist candidates studying for the NIULPE Facility Operator Certification Series

Recommended Study Program:
It is recommended that, before undertaking this examination, the candidate completes Power Engineering Course of study, offered through a recognized and approved technical institute or training provider which addresses the Syllabus ‐ Curriculum Outline.

Topic 1 Rankine and Brayton Cycles

Learning Outcome

Discuss the application of the Rankine and Brayton cycles to a power plant.

Learning Objectives

  1. Explain heat engines and their application to a steam power plant.
  2. Explain the Rankine Cycle using a steam temperature‐entropy diagram.
  3. Evaluate a Rankine Cycle power plant in terms of efficiency, work ratio, specific steam consumption, isentropic efficiency and efficiency ratio.
  4. Explain the Rankine Cycle improvements that can be incorporated into a power plant.
  5. Explain the Brayton Cycle and its application to a gas turbine.
  6. Explain the Brayton Cycle using pressure‐volume and temperature‐entropy diagrams.
  7. Evaluate a Brayton Cycle power plant in terms of temperatures, work output, and efficiency.
  8. Explain the Brayton Cycle improvements that can be incorporated into a power plant.
  9. Describe the design, layout, and advantages of a gas turbine / steam turbine combined cycle plant.
  10. Explain the total energy concept as it applies to a power plant.

 

Topic 2 Thermodynamics of Steam

Learning Outcome

Perform calculations for thermodynamic cycles of steam.

Learning Objectives

  1. Describe the basis for non‐flow processes of vapors.
  2. Explain the constant volume process for steam and calculate heat supplied, work done and internal energy.
  3. Explain the constant pressure process for steam and calculate heat supplied, work done and internal energy.
  4. Explain the constant temperature process for steam and calculate heat supplied and work done.
  5. Calculate steam entropy given the steam conditions.
  6. Explain the significance of a Temperature‐Entropy diagram for steam.
  7. Explain the reversible adiabatic process for steam and calculate work done and internal energy.
  8. Explain the significance of a Mollier chart for steam.

 

Topic 3 Steady Flow Process Calculations

Learning Outcome

Perform steady flow process calculations for vapors and gases.

Learning Objectives

  1. Describe the steady‐flow energy equation and calculate the work done in a steady‐flow process.
  2. Calculate the power consumed in a steady‐flow process.
  3. Explain the principle of conservation of energy and supersaturation as they apply to a nozzle and calculate nozzle inlet and outlet velocities.
  4. Calculate the initial dryness fraction of steam in a throttling process.
  5. Determine, using a Mollier Chart, the quality, enthalpy, and entropy of steam entering a calorimeter.
  6. Calculate energy transfer, work done, and power produced in a steam turbine.
  7. Calculate the heat lost, surface area, required cooling water flow, and heat transfer coefficient in a steam condenser.
  8. Define and calculate availability and effectiveness in the context of the steady‐flow processes.

 

Topic 4 Thermodynamics of Perfect Gases

Learning Outcome

Perform calculations for thermodynamic cycles of perfect gases.

Learning Objectives

  1. Review the behavior of perfect gases.
  2. Explain Joule’s law and its significance.
  3. Calculate the heat added or rejected by a mass of perfect gas under changing temperature and pressure conditions.
  4. Explain the isothermal cycle using a pressure‐volume diagram and calculate heat rejected and work done using a perfect gas as the working fluid.
  5. Explain the reversible adiabatic cycle using a pressure‐volume diagram and calculate work done, final volume, and final temperature using a perfect gas as the working fluid.
  6. Calculate work done in a polytropic cycle using a perfect gas as the working fluid.
  7. Using the heat energy equation, calculate the efficiency of a polytropic compression process for a perfect gas.
  8. Explain the Gibbs‐Dalton law and calculate the work done and heat flow per kilogram when a gas mixture is expanded.

 

Topic 5 Expansion and Heat Transfer

Learning Outcome

Perform calculations for expansion and heat transfer.

Learning Objectives

  1. Explain how thermal expansion and contraction is allowed for in boiler and piping design.
  2. Calculate the linear and volumetric expansion of a header or pipe, given internal temperature conditions.
  3. Calculate heat transfer by conduction.
  4. Calculate the heat flow through a compound insulated wall.
  5. Calculate the thickness of insulation required to maintain a given temperature gradient.

 

Topic 6 Refrigeration Calculations

Learning Outcome

Perform thermodynamic calculations for a refrigeration system.

Learning Objectives

  1. Explain the Carnot Cycle as it applies to refrigeration using temperature‐entropy and pressure‐enthalpy diagrams.
  2. Calculate the Carnot coefficient of performance of a refrigeration system and a heat pump system.
  3. Calculate the refrigerating effect of a refrigeration system.
  4. Calculate the coefficient of performance of a refrigeration system and a heat pump system.
  5. Demonstrate graphically, using temperature‐enthalpy diagrams, the effect on refrigeration capacity of using a throttle valve in place of an expansion machine, of superheating at the compressor inlet, of undercooling the condensed refrigerant, and of using a flash chamber.
  6. Calculate the mass flow of refrigerant in a system.
  7. Calculate the swept volume of a compressor cylinder, given its volumetric efficiency.
  8. Calculate the power requirement of a refrigerant compressor.

Topic 1 Lifting Machines

Learning Outcome

Perform calculations for lifting machines.

Learning Objectives

  1. Calculate velocity ratio, mechanical advantage, efficiency, effort and maximum load for lifting machines.
  2. Calculate velocity ratio, mechanical advantage, efficiency, effort and maximum load of a differential pulley block.
  3. Calculate velocity ratio, mechanical advantage, efficiency, effort and maximum load of a worm gear and worm wheel.
  4. Calculate velocity ratio, mechanical advantage, efficiency, effort and maximum load of a worm‐driven screw jack.
  5. Calculate velocity ratio, mechanical advantage, efficiency, effort and maximum load of a turnbuckle.
  6. Calculate velocity ratio, mechanical advantage, efficiency, effort and maximum load of a hydraulic jack.

 

Topic 2 Energy and Momentum

Learning Outcome

Perform calculations involving potential energy, kinetic energy, and momentum of bodies in linear and rotating motion.

Learning Objectives

  1. Define potential and kinetic energy.
  2. Calculate the potential energy of a compressed spring.
  3. Describe the behavior of a spring‐mass system and calculate the maximum compression of a spring caused by contact with a moving mass.
  4. Describe the effect of friction losses on potential and kinetic energy.
  5. Define linear momentum and calculate the coefficient of restitution.
  6. Calculate the kinetic energy and velocity of an elastic head‐on collision.
  7. Define angular momentum and calculate the changes in momentum of rotating shafts.
  8. Calculate the kinetic energy and velocity of a rotating shaft.
  9. Calculate the time required to change the rotational velocity of a shaft.

 

Topic 3 Centripetal Force and Acceleration

Learning Outcome

Perform calculations involving centripetal and centrifugal forces.

Learning Objectives

  1. Calculate the centripetal acceleration of a rotating body in uniform circular motion.
  2. Calculate the centrifugal force on a rotating body in uniform circular motion.
  3. Calculate the tension in an attachment cord for vertically revolving masses.
  4. Calculate the speed and period of a conical pendulum.
  5. Calculate the positions of balancing masses to equalize centrifugal forces.
  6. Calculate the stress in a rotating flywheel rim.
  7. Calculate the velocity, acceleration, and accelerating force of a reciprocating component such as a piston driving, or driven from, a crankshaft.

 

Topic 4 Torque and Torsion

Learning Outcome

Perform calculations involving torque and torsion.

Learning Objectives

  1. Calculate angular velocity given the angular momentum of a rotating shaft.
  2. Calculate strain in a solid bar under torsion load.
  3. Calculate the stress at a given radius in a solid shaft.
  4. Calculate torsional stress and strain in a hollow shaft.
  5. Calculate modulus of rigidity and torsional resilience for a solid shaft.
  6. Calculate the power consumed by torque acting on a rigid body rotating about a fixed axis.
  7. Calculate maximum and mean torque for solid and hollow shafts of circular cross section.
  8. Calculate the deflection of a closely coiled helical spring.

 

Topic 5 Stress and Strain

Learning Outcome

Perform calculations involving stress, strain, shear forces, and bending moments.

Learning Objectives

  1. Explain the behavior of stress and strain in solids.
  2. Calculate single and double shear stress in a solid bar subject to oblique loading.
  3. Define the modulus of elasticity.
  4. Calculate stress, strain, and the equivalent modulus of elasticity for a compound bar.
  5. Calculate stress due to restricted thermal expansion.
  6. Calculate the elastic strain energy of a solid bar.
  7. Calculate the instantaneous compression and stress of a solid bar subjected to suddenly applied and shock loads.
  8. Calculate stresses in pressure vessels due to internal pressure.
  9. Using the fundamental bending equation, calculate bending moment, moment of inertia, modulus of elasticity, radius of curvature, maximum stress, and location of neutral axis.
  10. Compare the strengths of beams using the modulus of section.
  11. Calculate the deflection of a beam under load.

 

Topic 6 Static Fluids

Learning Outcome

Perform calculations involving fluids at rest.

Learning Objectives

  1. Calculate the relative density of a liquid mixture.
  2. Calculate the pressure indicated by a manometer.
  3. Calculate the energy transmitted by a pressurized liquid.
  4. Calculate the pressure and force on the surfaces of a tank containing non‐mixing liquids.
  5. Calculate the position of the centre of pressure of a tank containing non‐mixing liquids.
  6. Explain Archimedes’ principle.
  7. Calculate the relative density from the buoyant force on a submerged body and its true and apparent weights.
  8. Calculate the tension and stress in the cable or wire supporting a submerged solid body.
  9. Calculate the density of a floating body, given the volume of liquid that it displaces.

 

Topic 7 Fluids in Motion

Learning Outcome

Perform calculations involving fluids in motion.

Learning Objectives

  1. Explain the equation of continuity.
  2. Calculate the fluid flow through a valve, given the valve diameter and lift.
  3. Calculate flow through rectangular and triangular notches.
  4. Calculate the total energy of a liquid in motion.
  5. Calculate the pressure in a pipe given the cross‐sectional area and liquid flow rate.
  6. Calculate the diameter, velocity, and flow through an orifice given the coefficient of discharge.
  7. Calculate flow through horizontal and vertical venturi given the discharge coefficient.
  8. Compare the resistance to flow of various liquids due to their viscosity using the velocity gradient and coefficient of viscosity.
  9. Explain the significance of steady and unsteady liquid flows with regard to Reynold’s number.
  10. Using Poiseuille’s equation, calculate liquid flow in a pipe and the pressure required for the liquid flow to overcome viscosity.
  11. Calculate the theoretical head imparted to water by a centrifugal pump.
  12. Calculate the manometric head and efficiency, and power consumed by a centrifugal pump.
  13. Calculate the power available from a hydraulic turbine.
  14. Explain the design and significance of convergent and convergent‐divergent nozzles and calculate the critical pressure of a steam nozzle.

Topic 1 Metallurgy

Learning Outcome

Discuss the selection, properties, and stress effects of steel.

Learning Objectives

  1. Describe the structure of metals.
  2. Explain the nature and significance of phase changes in iron and steel due to temperature change.
  3. Explain how alloying elements affect phase changes in steel and state the major alloying elements used in steel.
  4. Explain the effect of temperature on the tensile strength of steel.
  5. Explain the criteria for the assessment of materials.
  6. Explain what creep is, and why it is important to monitor its effects on equipment.
  7. Explain the methods of stress analysis.
  8. Explain failure analysis.

 

Topic 2 Corrosion, Chemistry and Processes

Learning Outcome

Explain the chemistry and processes of corrosion mechanisms.

Learning Objectives

  1. Explain how atomic and molecular structures affect corrosion.
  2. Explain the anodic and cathodic processes of corrosion.
  3. Explain the electromotive force series and galvanic series.
  4. Explain the effect of polarization
  5. Explain corrosion of single metals.
  6. Explain the processes of crevice corrosion and pitting corrosion.
  7. Explain the process of microbiologically influenced corrosion.
  8. Explain the process of stress induced corrosion.
  9. Explain the processes of erosion‐corrosion.

 

Topic 3 Boiler Corrosion

Learning Outcome

Discuss the mechanisms of corrosion in boilers.

Learning Objectives

  1. Explain the impact of corrosion
  2. Explain the agents of corrosion found in water
  3. Explain the mechanisms and significance of magnetite formation and magnetite depletion on boiler tube surfaces.
  4. Explain the mechanisms and significance of economizer and superheater corrosion.
  5. Explain the mechanism, identification, and significance of flue‐gas side corrosion of boiler components.
  6. Explain the mechanism, identification, and significance of low temperature corrosion of boiler components.
  7. Explain the relationship between boiler water chemistry and corrosion of copper alloys in feedwater systems.
  8. Explain the mechanisms and significance of deaerator cracking and corrosion.

 

Topic 4 Corrosion Monitoring and Prevention Techniques

Learning Outcome

Explain techniques used to monitor and prevent corrosion.

Learning Objectives

  1. Describe the methods of monitoring and analyzing corrosion.
  2. Explain the design, applications, and operation of cathodic protection systems.
  3. Explain the use of protective coatings for corrosion control.
  4. Describe the regulatory and safety requirements relating to corrosion monitoring.
  5. Describe chemical control of corrosion.

 

Topic 5 Corrosion Prevention Programs

Learning Outcome

Explain corrosion prevention programs.

Learning Objectives

  1. Explain the corrosion characteristics and susceptibility of engineering materials and their selection for various purposes.
  2. Describe the chemical, mechanical, and operational factors that are considered in controlling corrosion in steels.
  3. Describe the chemical, mechanical, and operational factors that are considered in controlling corrosion in copper alloys.
  4. Explain the risks and required precautions involved with chemical cleaning of boiler surfaces.
  5. Explain the steps taken to reduce waterside and fireside corrosion during dry and wet storage of a boiler.
  6. Explain the development, components, and management of a corrosion prevention program for cooling water systems, including the selection, application and characteristics of biocides.
  7. Explain the development, components and management of a corrosion prevention program for piping and pressure vessels.
  8. Explain the development, components and management of a corrosion prevention program for rotating equipment.

 

Topic 6 Fuel Types

Learning Outcome

Discuss the characteristics and applications of coal, oil, and non‐conventional gaseous and liquid fuels.

Learning Objectives

  1. Explain the factors involved in the selection of primary and secondary fuel for a new installation.
  2. Describe the fuel handling considerations and fuel burning characteristics for non‐conventional solid fuels including municipal waste, petroleum coke and biomass.
  3. Compare the fuel burning characteristics of non‐conventional gaseous fuels, including refinery gas, landfill gas, digester gas, carbon monoxide, liquid petroleum gases (LPGs) and acid gases.
  4. Compare the fuel burning characteristics of black liquor.
  5. Compare the physical properties and fuel burning characteristics of different grades of oil.
  6. Describe the considerations for coal cleaning and blending.
  7. Describe the purpose and process of coal gasification.
  8. Differentiate between low heating value and high heating value fuels.
  9. Describe the design and operational considerations for the use of low heating value fuels.
  10. Explain the economic considerations for fuel selection for multifuel burners.

 

Topic 7 Burner Design

Learning Outcome

Explain the criteria for burner design and selection.

Learning Objectives

  1. Describe the general criteria for effective burner design.
  2. Describe the classes of burner designs, based on the fuel in use.
  3. Compare the design strategies for mixing fuel and air including: co‐flow, cross‐flow, flow stream disruption and entrainment.
  4. Describe the design considerations for a duct burner.
  5. Sketch a typical multi‐nozzle duct burner layout.
  6. Describe the relationship of burner selection to furnace design.
  7. Describe the relationship between coal pulverizer selection and burner design.
  8. Describe burner design methods to reduce noise.
  9. Explain the principle, significance, application, and design of staged combustion burners, including staged fuel flow and staged air flow burners.

 

Topic 8 Combustion Optimization

Learning Outcome

Explain the considerations for obtaining optimum efficiency and operation of burners.

Learning Objectives

  1. Explain the inherent assumptions and factors considered when determining combustion efficiency.
  2. Explain the methods and limitations for obtaining maximum efficiency from the combustion of gaseous fuels.
  3. Explain the methods and limitations for obtaining maximum efficiency from the combustion of liquid fuels.
  4. Explain the methods and limitations for obtaining maximum efficiency from the combustion of solid fuels.
  5. Explain the economic and efficiency factors for fuel and burner management in real time operating conditions for a multifuel system.
  6. Describe the use of electronic instruments to continuously monitor combustion efficiency.
  7. Explain the significance of flame shape, color and temperature.
  8. Explain the effect of excess air on combustion stability and boiler efficiency.
  9. Explain the symptoms, significance and corrective action for common combustion problems.

 

Topic 9 Combustion Safety and Emissions

Learning Outcome

Discuss safety and environmental considerations in burner operation, including strategies for NOX control.

Learning Objectives

  1. Describe the requirements for safe operation of a combustion system.
  2. Compare the significance of burner safety devices for different fuel types.
  3. Explain the cause and prevention of furnace explosions in boilers and fired heaters.
  4. Describe the processes for dust reduction in coal handling systems.
  5. Describe the procedures for dealing with coalbunker and pulverizer fires.
  6. Explain the effect of excess air and combustion efficiency on emissions parameters.
  7. Explain pre‐treatment as a strategy for NOX reduction (fuel switching, additives and fuel pre‐treatment).

  8. Explain combustion and operational modification as a strategy for NOX reduction (low NOX burners, staged combustion, water/steam injection, burners out of service, low excess air and air preheat and furnace temperature reduction.

  9. Explain process modification as a strategy for NOX reduction (reduced production, electrical heating, improved thermal efficiency and product switching).

  10. Explain post treatment as a strategy for NOX reduction (SCR and SNCR).

  11. Explain the effect on NOX emissions of boiler design, boiler condition and boiler loading characteristics.

  12. Explain the reasons for and significance of flue gas recirculation.

 

Topic 10 Water Pre-Treatment

Learning Outcome

Describe the processes used to treat raw water for power plants, including detailed chemistry where applicable.

Learning Objectives

  1. Describe the mechanisms of coagulation and flocculation.
  2. Describe the chemical processes and reactions of oxidation of organic contaminants.
  3. Describe the chemical processes and reactions of iron and manganese removal from raw water.
  4. Describe the chemical processes and reactions in a lime‐soda softener.
  5. Describe the chemical processes and reactions in a sodium zeolite softener.
  6. Describe the chemical processes and reactions in a hydrogen zeolite softener.
  7. Describe the chemical processes and reactions in a demineralizer.
  8. Describe the chemical processes and reactions in a dealkalizer.
  9. Describe the mechanisms of membrane technology, including chemical and mechanical cleaning methods and clean‐in‐place design.
  10. Describe the chemical processes and mechanisms of electrodialysis (ED) and electrodeionization (EDI.)
  11. Describe the chemical processes and reactions of oxygen scavenging and metal passivation.
  12. Describe the methods by which silica is removed from feedwater and condensate.

 

Topic 11 Internal Water Treatment

Learning Outcome

Describe the processes used to treat boiler water and condensate, including detailed chemistry where applicable.

Learning Objectives

  1. Explain the principles, reactions and control of chelation.

  2. Explain the principles, reactions and control of a coordinated phosphate program.
  3. Explain the phenomenon of phosphate hideout.
  4. Explain the principles, reactions and control of a congruent phosphate program.
  5. Explain the principles, reactions and control of an equilibrium phosphate program.
  6. Explain the principles, reactions and control of an all‐volatile treatment program.
  7. Explain the principles, reactions and control of a polymer treatment program.
  8. Explain the principles, reactions and control of an oxygenated water treatment program.
  9. Describe the mechanism of sludge conditioning.
  10. Describe the mechanism of antifoam conditioning.
  11. Describe the chemical processes and reactions of condensate treatment, including corrosion prevention, deaeration and polishing.

 

Topic 12 Water Treatment Management

Learning Outcome

Explain the monitoring, management, and maintenance of water treatment systems.

Learning Objectives

  1. Explain the financial management of the costs and benefits of water treatment.
  2. Apply raw water analysis to the selection of a water treatment system.
  3. Explain monitoring and control of cycle chemistry.
  4. Describe the troubleshooting process when a cycle chemistry parameter deviates from the acceptable range.
  5. Describe the selection and maintenance of resins for zeolite, demineralizer, dealkalizer and condensate polisher service.
  6. Describe the procedures and interpretation for tube deposit analyses.
  7. Explain the inspection procedure for internal boiler components in relation to water treatment.
  8. Describe a typical maintenance program for components of water treatment systems, including: water filters, clarifiers and lime‐soda softeners, sodium zeolite softeners, demineralizers, mixed bed and condensate polishers, reverse osmosis units, microfiltration, electrodialysis and electrodeionization units and deaerators.
  9. Describe the selection, responsibilities, and management of water treatment consultants.

 

Topic 13 Non-Boiler Water Treatment

Learning Outcome

Explain the monitoring and management of potable water and cooling water treatment systems.

Learning Objectives

  1. Describe the regulatory requirements for potable water quality and monitoring.
  2. Describe the parameters and interpretation of potable water analyses.
  3. Describe the selection and mechanism of oxidation agents.
  4. Describe the mechanism of ultraviolet sterilization.
  5. Explain the components and management of a cooling water treatment program.
  6. Describe the use and chemistry of biocides in cooling water.
  7. Describe the use and chemistry of corrosion inhibitors in cooling water.
  8. Explain the use of chelants in cooling water.
  9. Explain the use of threshold scale inhibitors in cooling water.
  10. Explain the use of surfactants, dispersants and biodispersants in cooling water.

Topic 1 Electrical Energy Management

Learning Outcome

Discuss the concepts and techniques of electrical energy management.

Learning Objectives

  1. Explain the concept of energy management and identify the operational factors that are included in an energy management program.
  2. Describe the significance, components, responsibilities and procedure of an energy audit.
  3. Explain the significance and application of power factor management, including the effects of: capacitor banks, synchronous motors, inductive and resistive loads, transformers, voltage regulation for synchronous generators and synchronous compensators.
  4. Calculate capacitor ratings required for power factor correction.
  5. Explain, using a sketch, the purpose, applications, design and operation of a static uninterruptible power supply (UPS).
  6. Explain the concept and significance of distributed generation, including the design implications for electrical distribution systems.
  7. Describe the benefits of UPS in a distributed generation system, including the use of UPS as a bridge between utility and internal power.
  8. Explain the benefits of motor‐generator sets, internal combustion engines and micro‐turbines in a distributed generation system.
  9. Explain the design, operating principle, and benefits of a fuel cell in a distributed generation system.
  10. Explain the purpose, components, and operation of emergency power systems, including the physical interconnection between emergency power and main power.
  11. Explain the concept, significance, and management of peak load reduction, including utility contract obligations and use of internal generation.
  12. Explain the concept and principles of generation load dispatch including contract obligations.

 

Topic 2 Plant and Equipment Efficiencies

Learning Outcome

Explain and calculate power plant and equipment efficiencies.

Learning Objectives

  1. Describe methods used to maximize efficiency of steam power plants and minimize energy losses.
  2. Calculate boiler gross efficiency using input‐output method and heat loss method.
  3. Calculate turbine performance and efficiency.
  4. Calculate the condensate savings and heat gained through improvements in condenser efficiency.
  5. Describe the components and significant parameters of a typical computerized plant performance management system, including a program to reduce controllable losses.
  6. Describe the efficiencies of a simple cycle gas turbine and various cycle improvements that can be made.
  7. Describe different methods for waste heat recovery and the resultant improvement of efficiency.
  8. Compare the inherent efficiencies of Once‐Through Steam Generators (OTSG) with Heat Recovery Steam Generators (HRSG).
  9. Calculate the steam generated and efficiency of a combined cycle plant, given system data.

 

Topic 3 Power Plant Construction

Learning Outcome

Explain the regulations, processes, and procedures pertaining to the design, construction, and modification of plant facilities.

Learning Objectives

  1. Describe the general criteria, including economics, which must be considered in determining the need for additional facilities and in deciding between new plant construction and existing plant expansion.
  2. Describe the general criteria to be considered in the design of a new plant.
  3. Describe the regulatory permitting processes for a construction project, including environmental feasibility study.
  4. Describe a quality assurance /quality control (QA/QC) program for pressure equipment, including the process for accepting, receiving, and approving new and used vessels.
  5. Describe the major considerations and steps involved in the construction of a new plant, from design to completion.
  6. Explain the role of the Chief Power Engineer and regulatory inspectors in a plant construction project.
  7. Explain the components and management of a construction health and safety program.
  8. Explain the process of coordinating plant expansion activities with the operation of the existing plant, including tie‐in of the old and new facilities.
  9. Interpret, in detail, the information provided in construction drawings.

 

Topic 4 Commissioning and De-Commissioning

Learning Outcome

Explain the regulations, processes, and procedures pertaining to the commissioning and de‐commissioning of plant facilities.

Learning Objectives

  1. Explain the sequence for commissioning a new plant.
  2. Explain the detailed procedures for commissioning a boiler.
  3. Explain the detailed procedures for commissioning a steam turbine.
  4. Explain the detailed procedures for commissioning a gas turbine.
  5. Explain the detailed procedures for commissioning a piping system.
  6. Explain the detailed procedures for commissioning a large fan.
  7. Describe the content and significance of a performance contract/guarantee for new equipment or a new plant.
  8. Explain the specific procedures for re‐commissioning a plant after a major outage.
  9. Explain the obligations and liabilities of de‐commissioning a plant, including regulatory requirements.
  10. Explain the specific procedures for de‐commissioning a plant.

 

Topic 5 Retrofitting

Learning Outcome

Explain the benefits, applications, and processes of retrofitting power plant equipment.

Learning Objectives

  1. Explain the considerations that are used to determine whether replacement, re‐powering, retrofitting or upgrading should be undertaken.
  2. Explain the regulatory requirements for modifications to equipment and systems, including pressure equipment, electrical systems and environmental impact.
  3. Explain the overall process and responsibilities when modifying or retrofitting plant systems.
  4. Describe the benefits of control system retrofitting with smart instrumentation.
  5. Describe the retrofitting methods used to improve boiler efficiency and capacity including superheater upgrades, economizer upgrades, combustion system upgrades, improved air heater seals, improved waterwall design, environmental enhancements and control upgrades.
  6. Describe the retrofitting methods used to improve steam turbine efficiency including improved turbine blades and diaphragms, turbine stage additions and improved blade tip sealing.
  7. Describe the retrofitting methods used to improve gas turbine efficiency including upgrading inlet guide vanes, improved seals, tighter clearances, improved combustion liners, improved turbine blades and vanes, thermal barrier coatings, compressor blade coatings, compressor stage additions and compressor supercharging.

Topic 1 Codes, Acts and Regulations

Learning Outcome

Explain the significance and application, at the Chief Engineer level, of boiler and pressure vessel legislation and regulations.

Learning Objectives

  1. Describe the typical duties of the chief engineer as set out in boiler and pressure vessel legislation.

  2. Describe the legal foundation for the boiler and pressure vessel legislation.
  3. Define statutory delegation of powers as they apply to the Boiler and Pressure Vessels Act.
  4. Describe the authority that safety officers (inspectors) have within their jurisdiction.
  5. Determine what the offences and penalties are under the act and the appeal process.
  6. Describe the typical regulations under the Boiler and Pressure Vessels Act.
  7. Describe the typical codes and standards referenced by the Boiler and Pressure Vessels Act.

 

Topic 2 ASME Section I

Learning Outcome

Demonstrate familiarity with the content of A.S.M.E. Section I, and perform calculations involving cylindrical components, openings, compensations, safety and safety relief valves, and stays in boilers.

Learning Objectives

  1. Describe the organization of ASME Section I and its application.
  2. Calculate the required thickness or maximum allowable working pressure of a cylindrical shell.
  3. Calculate the required thickness or maximum allowable working pressure of a seamless, unstayed dished head, flat head, and formed head.
  4. Calculate the maximum dimensions of openings, and the strength of compensation required for reinforcement of openings in cylindrical shells, headers, or heads.
  5. Calculate the requirements for braced surfaces and support stays.
  6. Calculate the required tubesheet thickness and maximum allowable working pressure for firetube and watertube boilers.
  7. Calculate required wall thicknesses of plain circular furnaces, circular flues, Adamson ring reinforced and corrugated furnaces.
  8. Calculate the required size and capacity of pressure relief valves.

 

NOTE: The content of this chapter, including formulae and calculations, is based on the 2007 edition of the ASME codes. While studying, students should refer to the 2007 ASME “Academic Extract” or the complete 2007 codes

 

Topic 3 ASME Section VIII and IX

Learning Outcome

Demonstrate familiarity with the content of A.S.M.E. Sections VIII and IX, and perform calculations involving cylindrical components, openings, compensations, safety and safety relief valves, and stays in pressure vessels.

Learning Objectives

  1. Describe the organization of ASME Section VIII Division 1 and its application
  2. Calculate the required thickness or maximum allowable working pressure of a cylindrical shell in a pressure vessel.
  3. Calculate the required thickness or maximum allowable working pressure of a seamless dished head, flat head and formed head in a pressure vessel.
  4. Calculate the reinforcement requirements of openings in a pressure vessel.
  5. Calculate the minimum required thickness of a cylinder using ligament efficiency.
  6. Calculate the required dimensions and locations of staybolts and braced surfaces in a pressure vessel.
  7. Calculate the required size and capacity of pressure relief valves for a pressure vessel.
  8. Explain the significance of A.S.M.E. Section IX.

 

NOTE: The content of this chapter, including formulae and calculations, is based on the 2007 edition of the ASME codes. While studying, students should refer to the 2007 ASME “Academic Extract” or the complete 2007 codes

 

Topic 4 CSA B-51 and B-52

Learning Outcome

Describe the content and requirements, and interactions with C.S.A. B‐51 and C.S.A. B‐52.

Learning Objectives

  1. Describe the content and requirements of C.S.A. B‐51
  2. Describe the content and requirements of C.S.A. B‐52
  3. Explain the role and interactions of regulatory authorities and the Chief Engineer with regard to C.S.A. B‐51 and B‐52.

 

Topic 5 Piping and API Codes

Learning Outcome

Explain the significance and application, at the A.S.M.E. B31.1, A.S.M.E. B31.3, A.P.I. 510 and A.P.I. 570.

Learning Objectives

  1. Explain the significance and applications of ASME B31.1 Power Piping.
  2. Describe the general content of ASME B31.1 Power Piping.
  3. Explain the significance and applications of ASME B31.3 Process Piping.
  4. Describe the general content of ASME B31.3 Process Piping.
  5. Explain the significance and applications of API 510 Pressure Vessel Inspection Code: In‐service Inspection, Rating, Repair and Alteration.
  6. Describe the general content of API 510 Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair and Alteration.
  7. Explain the significance and applications of API 570 Piping Code: In‐service Inspection, Rating, and Alteration of Piping Systems.
  8. Describe the general content of API 570 Piping Code: In‐service Inspection, Rating, and Alteration of Piping Systems.
  9. Explain the role and responsibilities of the chief engineer with regard to the ASME and API Codes.