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Heavy Manufacturing of Typical Static Equipment

L&T EduTech via Coursera

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Overview

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Welcome to the comprehensive course on Process Plant Equipment and Materials for Construction. This course is designed to provide aspiring Engineers and professionals in the field with a deep understanding of the intricacies involved in designing, fabricating, and maintaining essential equipment for industrial processes. In the first part of this course, we will delve into the diverse world of process plant equipment and materials. From classification and layout considerations to mechanical and thermal properties affecting design, learners will explore the fundamentals of equipment selection and construction. Through case studies and real-world examples, participants will gain insights into the specialized requirements of various industrial sectors, including refineries, petrochemicals, power plants, and fertilizers. The course will cover essential topics such as metal forming processes, surface development, plate bending, and refractory applications, providing a solid foundation for further exploration into the intricacies of process plant construction. In the second part of the course, we will focus on the critical techniques of shell forming and tube bending, essential for the fabrication of process plant equipment components. Learners will delve into the principles and practices of metal forming processes, including sheet metal forming, plate bending, and dished end forming. They will also explore the intricacies of tube bending and pipe bending, mastering techniques to create efficient piping systems required in industrial facilities. Through hands-on exercises and demonstrations, participants will develop practical skills in shaping raw materials into intricate components, ensuring structural integrity and functionality in process plant equipment. The final part of the course will provide a comprehensive overview of the manufacturing lifecycle of pressure vessels, integral components of process plant equipment. Learners will gain insights into the types of pressure vessels, components, and manufacturing processes involved in their fabrication. From planning and sequencing to plate cutting, welding, refractory application, and post-weld heat treatment, learners will explore each stage of the manufacturing cycle in detail. Through case studies and practical examples, they will understand the importance of precision, quality control, and adherence to safety standards in ensuring the reliability and integrity of pressure vessels for Industrial applications. By the end of this course, participants will emerge with a holistic understanding of process plant equipment and materials, equipped with the knowledge and skills to excel in the material selection, fabrication, and maintenance of Industrial facilities. Join us on this journey as we unravel the complexities of process plant construction and empower you to make meaningful contributions to the field of Industrial Heavy Engineering. Target Learners:  Working Professional of Mechanical, Manufacturing and Chemical Engineers  Undergraduate students of Mechanical, Manufacturing & Chemical Engineering  Students from Manufacturing and Automation  Post-Graduate Students of Computer Integrated Manufacturing  Practicing Engineers in Process Plant equipment  Diploma students of Mechanical / Manufacturing

Syllabus

  • Overview of Process Plant Equipment and Materials for Construction
    • Process plant equipment is the foundation of several industrial sectors, each having its own classification and layout requirements. In this course, we will look into the complex world of process plant equipment and building materials, providing a thorough introduction for aspiring Engineers and professionals in the Industry. First, we explore the classification of process plant equipment in several industrial sectors, such as refineries, fertilizers, petrochemicals, and power plants. Learners will get an understanding of the specialized equipment and machinery utilized in each area, as well as the process flows and layout considerations, through extensive discussions and examples. Next, we look at the intricate layouts of refinery units, fertilizer units, petrochemical units, and power plants. Understanding the layout of equipment within these facilities is critical for optimizing operations, providing safety, and increasing efficiency. Learners will learn about common plant layouts and equipment combinations using visual aids and virtual tours. Mechanical and thermal attributes are critical factors in the design and performance of process plant equipment. Learners will investigate how differences in microstructure, alloying components, and heat treatment methods affect material properties, durability, and performance under a variety of operational circumstances. Furthermore, selecting materials for specific applications is an important part of process plant design. Material property, financial factors, and design needs must all be carefully considered to achieve the best possible performance and lifespan of the equipment. By the end of this course, learners will have a thorough understanding of process plant equipment and materials, as well as the knowledge and abilities necessary to design, build, and operate industrial facilities in a variety of industries. Join us on this adventure as we explore the complexities of process plant development and provide you with the tools you need to excel in this dynamic profession.
  • Shell Forming and Tube Bending
    • "Shell forming and tube bending for process plant equipment" encompass critical techniques in the fabrication of various components, ensuring the structural integrity and functionality of equipment used in industrial processes. Metal forming processes play a pivotal role in shaping raw materials into intricate components required for process plant equipment. Sheet metal forming techniques involve the manipulation of flat metal sheets through processes such as bending, stretching, and rolling. Surface development techniques aid in transforming flat sheets into complex shapes required for components like cylindrical and conical shells. Plate bending is a key aspect of shell forming, where flat plates are bent to form cylindrical or conical shells, essential for vessels and tanks used in process plants. Dished end forming techniques are employed to shape the ends of cylindrical shells, ensuring a secure and leak-tight closure. Tube bending and pipe bending are crucial processes for creating complex piping systems required in process plant equipment. By bending tubes and pipes to specific angles and radii, Engineers can design efficient and space-saving layouts for conveying fluids or gases within the plant. The plate bending process involves the precise manipulation of metal plates to achieve desired shapes and dimensions. Through a short video demonstration, learners will gain insights into the various steps involved in plate bending, from initial setup to the final forming of the plate into the desired shape. By mastering shell forming and tube bending techniques, Engineers and fabricators can effectively produce components essential for process plant equipment, ensuring durability, efficiency, and safety in Industrial operations. Through hands-on practice and theoretical understanding, learners will develop the skills necessary to excel in the fabrication of process plant equipment components.
  • Typical Manufacturing Cycle for Process Plant Equipment - Pressure Vessel
    • The manufacturing cycle for pressure vessels, crucial components in process plant equipment, involves a series of meticulous steps to ensure safety, quality, and reliability in various industrial applications. Pressure vessels come in diverse types based on construction and service requirements, including cylindrical, spherical, and non-cylindrical vessels designed for specific functions and operating conditions. Components of a pressure vessel typically include the shell, heads or dished ends, nozzles, manways, supports, and internals, each serving a vital role in containing and regulating fluid or gas pressure. The typical manufacturing lifecycle of a pressure vessel begins with meticulous planning, sequencing, and scheduling to optimize production efficiency and meet project deadlines. Plate cutting and rolling processes are employed to fabricate the cylindrical shell, while forming techniques such as petal forming are used for head fabrication. Welding plays a crucial role in assembling pressure vessel components, with long seam and circular seam setups ensuring leak-tight joints and structural integrity. Refractory application techniques are employed to line vessels operating at high temperatures, protecting them from heat-induced damage. Machining operations are used to obtain precise dimensions and surface finishes on pressure vessel components, while coating and surface preparation techniques improve corrosion resistance and life expectancy. Post-weld heat treatment, including stress relief, is used to reduce residual stresses and improve material characteristics, hence maintaining the integrity of welded seams. Through a comprehensive case study, learners will explore the importance of fixtures, supporting structures, and furnace settings in post-weld heat treatment processes, ensuring uniform heating and cooling for optimal results. By mastering the manufacturing cycle for Pressure vessels, Engineers and technicians can ensure the safe and efficient operation of process plant equipment, meeting stringent quality standards and regulatory requirements in various industrial sectors.

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