2KG TRAINING

2KG Training COURSES

Courses

Pump Operation and Maintenance 4-days

• Basic Pump Principles • Pump- Motor Alignment
• NPSH • Bearings
• Cavitation • Pump Packing
• Work & Efficiency • Mechanical Seals
• Pump Classification • Practical Maintenance
• Pump Curves • Avoiding Wear

Pumping System Assessment Workshop 3-days

• Basic Principles
• Pumping Systems and Pump Control
• Mechanical Components and Driver
• Pump system power consumption and energy
efficiency
• Identify common operating issues in pump
systems and how to resolve them
• Benefits of assessing pumping systems
• Explain the function of different pump system
components, such as drivers, bearings, seals,
piping, valves, and instrumentation
• Life Cycle Costing and Pump Reliability
• Pumping System Assessments
• Maintaining Pumping Systems
• Interaction between pump behavior and system
behavior
• Implement optimization solutions
• Importance of preparing a financial proposal using
LCC analysis, NPV and ROI
• Identify optimization opportunities in existing
systems and new design

ASME B31.3 Process Piping 4-days

• Enhance participants’ understanding and • History of Codes and Definitions
application of the B31.3 Code. • Consideration of Design
• In-class problem solving • Pressure Design of Piping and Piping Components
• Directly applying the rules and equations of the • Piping Flexibility Analysis
B31.3 Code
• Limitations of Piping and Piping Components Pump
• Illustrate correct applications for specific design testing
and operating conditions
• Pipe Supports
• Understand the principle intentions of the Code • Leak Testing
and why the Code is not a handbook
• Piping Failures and Their Causes

ASME Section VIII Div 1 3-days

Design and Fabrication of Pressure Vessels
• Code rules, scope and jurisdiction
• General requirements related to materials and
testing
• Material toughness, impact testing requirements
• Joint categories and joint efficiencies
• Welding requirements
• Committees, operation and voting procedures
• Editions, addenda and interpretations
• Design Requirements
• Procedures for external pressure (vacuum) and
compressive loads
• Design loadings and allowable stresses
• Design criteria and strength theory for Division 1
• Formulas for internal pressure and tensile loading
• Openings and reinforcement
• Hydrostatic and pneumatic testing
• Background of the design rules
• Open discussion of design problems
• General requirements related to stamping, reports,
testing, PWHT, tolerance and NDEs

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 2KG Traininh
2KG Training Courses Cont.

Inspection, Repairs and Alterations of Pressure Vessels 2-days

• Introduction to post construction codes
• Standards and the interrelation of various
documents
• Explanation of the responsibilities of the users,
manufacturers, repair organizations, regulatory
agencies and authorized inspectors
• Detailed requirements of NBIC
• Differences between the NBIC and API-510
• Examples of repairs and alterations and the
documentation requirements for each
• Open discussion of specific situations and
problems brought up by attendees
• An introduction to API-579
• How to obtain National Board stamp
• Evaluation of corroded areas
• Evaluation of corroded areas
• Evaluation of misalignments and other geometric
flaws
• Simple Level 1 evaluation procedures for other flaws
• An introduction to the ASME post Construction
Committee
• Overview of work being performed by API, ASME and
PVRC related to post construction issues
• Examples demonstrating the application of the rules

ASME Section VIII Div 2 4-days

Design and Fabrication of Pressure Vessels
• Introduction to the ASME Boiler & Pressure • Acceptance criteria for design
Vessels • Stress classification and stress linearization
• Comparison of Divisions 1 and 2 of Section VIII • Fatigue analysis exemption rules
• Theories of failure and design margins of various • Fatigue analysis
codes • Simplified elastics-plastic analysis
• General requirements of the new Division 2 • Fabrication requirements
• Responsibilities of various parties
• PWHT requirements
• Materials requirements
• Tolerances
• Material toughness and impact testing • NDE requirements
• General requirements of the new Division 2 • Pressure testing
• Responsibilities of various parties requirements
• Documentation and stamping
• Design rules for internal pressure
• Pressure relief requirements
• Design for buckling
• Example problems
• Deign of formed and flat head • Discussion
• New method for design of openings
• Design for external loadings
• Stress analysis methods

Compressors: Design, Operation and Maintenance 4-days

• Introduction to Compressors
• Mechanical Design of Centrifugal Compressors
• Review
• Design and Materials of Reciprocating Compressor
Components
• Compressor Characteristics and Selection Criteria
• Skill test and assessment
• Maintenance Strategies, Tactics and Procedures
• Applying and determining the frequency of condition
based
• Turbo compressors, Reciprocating compressors,
Displacement compressors
• Implementing Root Cause Failures Analysis to prevent
• recurrence of Compressors Problems
• Repairs and Spares Assessment
• Skill test & assessment

Vibration Analysis 1 4-days

• Implementing Condition Based Maintenance
• Introduction to Vibration Monitoring
• Vibration Severity Measurement
• Practical Vibration Measurement
• Vibration Data Acquisition
• Principles of Vibration Analysis
• Vibration Spectral Analysis
• Practical Vibration Measurement
• Vibration Qualification & Assessment
• Introduction to Structural Resonance
• Vibration Analysis & Fault Finding
• Practical Data Collection
• Recognition of Poor Data
• Vibration Monitoring Survey
• Introduction to Balancing
• Training Examination & Course Review
• Optional BINDT PCN VA Cat 1 Exam

2KG Training Phindi Mbedzi t +27 (0) 11 325 0686 c +27 (0) 71 125 6188 e phindi@2kg.co.za
 2KG Traininh
2KG Training Courses Cont.
Vibration Analysis Intermediate 2
• Select the appropriate machinery vibration
measurement technique
• Set up instruments for basic resolution of
amplitude, frequency and time
• Perform basic vibration analysis of machinery and
components such as shafts, bearings, gears, fans,
pumps and motors using spectrum analysis
• Maintain a data base of results and trends
• Perform basic (single channel) impact tests to
determine natural frequencies;
Mechanical Seals
• Introduction to Sealing Technology
• Mechanical Seal Systems
• Mechanical Seal Reliability
Turbo & Reciprocating compressors
• Compressors and Their Application
• Turbocompressor Operation and Maintenance
• Turbocompressor Troubleshooting
API 650 & 653 Advanced Storage Tanks
• Review of codes requirements, structural design,
materials, fabrication and erection for new
storage tanks
• Tank shell design (1 foot method, variable design
point method)
• Tank roof, bottom layout design
• Tank material selection
• Tank internal structural members design
• Shell opening and Nozzle design
• Wind and seismic loading analysis
• Tank foundation design
• Elevated temperature tanks design
• Internal external floating roof
• Tanks with internal pressure
• Tank construction, welding qualification procedure
• Inspection of Storage Tanks, NDE tests
• Corrosion evaluation and tank life calculation
API 579-1 ASME FFS-1 Fitness for Service
• Introduction to the ASME FFS-1 / API 579-1
standard
• Roles and Responsibilities
• The FFS Engineering Assessment Procedure
• Brittle Fracture
• General Metal Loss
• Local Metal Loss
• Pitting Corrosion
• Fire Damage
2KG Training Phindi Mbedzi t +27 (0) 11 325 0686 c +27 (0) 71 125 6188 e phindi@2kg.co.za
4-days
• Classify, interpret and evaluate the test results
(including acceptance tests) in accordance with
applicable specifications and standards
• Recommend minor corrective actions
• Understand basic single-plane field balancing
concepts
• Be aware of some of the causes and effects of bad
measurement data
2-days
• Seal Selection
• Dry Gas Seals
2-days
• Mechanical Design of Reciprocating Comprssors and
Operational Problems
• Reciprocating Compressor Troubleshooting
• Maintenance, Overhaul and Repair of Reciprocating
Compressors
5-days
• Tank shell, roof, bottom and foundation evaluation
• Introduction to Brittle Fracture Mechanics
• Tank repair and alteration
• Pre and post weld heat treatment
• Dismantling and reconstruction
• Tank settlement criteria, measurement and evaluation
• Tank lifting methods and stress induced on tank shell,
roof and corner welds
• Tank ventilation requirements API 2000
• Tank maintenance and repair management (Tank
program- data sheet)
• Riveted tank design to API 12 A, maintenance-repair
• Tank operations level set up API 2350
• API 580-581 Risk based Inspection Planning
• API 571 damage mechanism
• Fit-For-Service API 579
• Finite Element Modeling of Storage Tanks
5-days
• Design by Analysis
• Hydrogen Blisters, HIC and SOHIC
• Weld Misalignment and Shell Distortions
• Crack-like flaws
• Creep
• Dents and Gouges
• Laminations
• Fatigue
 2KG Traininh
2KG Training Courses Cont.
API Tank Terminal Management
• Extend the life of aging tanks and teach state of
the art maintenance practice to help tank terminal
and farm operators cope with current challenges.
• Learn the world’s best instruction on tank and
tank farm lifetime integrity management
• Explore various options such as tank repair,
alteration and reconstruction
• Apply the latest technology, tools and procedures
on the instrumentation, inspection and
maintenance of tanks and tank farms in order to
achieve the maximum performance and efficiency
• Develop tank and tank farm inspection plans and
intervals and set up inspection and maintenance
programs/schedules
• State-of-the-Art finite element analysis to develop
best fit maintenance program for storage tanks
and perform Fitness-For-Service assessments
using the rules of API and international codes.
• Master the most effective tank evaluation
techniques and perform tank life prediction
calculations with dominant failure modes
• Assess the configuration, operation and
management practices of tank farms in terms of
facility capacity, operational effectiveness, and
the cost/benefit of feed, intermediate and product
storage
Steam Turbines: Design , Operation & Maintenance
• Operating Principles, Impulse Turbines, Reactions
Turbines, Application Ranges, Configurations,
Application Constraints
• Turbine Components
• Turbine Rotors, Blading, Diaphragms, Nozzles,
Steam Chests, Glands and Gland Systems,
Bearings, Balancing, Rotor Dynamic, Governing
Systems, Lube Oil Management
• Thermodynamics, Steam (Water) Rates,
Condensing and Backpressure Turbines, Single
and multistage Types, Process Considerations.
• Operation and Maintenance of Steam Turbines
• Possible Modifications
• Life extension, rerating and uprating, and revamp
efforts of mechanical drive steam turbines (20 to
100,000 HP)
Variable Speed Drives
• Introduction
• Electrical Basics
• Hydraulics Basics
• Chemistry Basics
• Instrumentation Basics
• Prime Utility Costs
• Plant Utilities
• Application of Control Valves
2KG Training Phindi Mbedzi t +27 (0) 11 325 0686 c +27 (0) 71 125 6188 e phindi@2kg.co.za
5-days
• Appreciate the importance of codes, standards,
regulations & recommended practices in terms of
hazard and safety management
• Recognize considerations of materials of construction
& various corrosion protection strategies and tactics
including cleaning, coating, & cathodic protection
• Perform fire protection of tanks & tank farms:
venting, frangible roofs, flame & detonation arrestors,
protection from ignition by static electricity, principles
& practices of bonding and grounding, principles of
inerting, electrical classification, selection criteria for
fire suppression systems
• Apply tank emission control measures & procedures
to satisfy regulatory requirements
• Execute a system approach on tank and tank farm
operations including tank entry, tank bottoms,
sludge/desludging, source reduction, mitigation,
vapour freeing, degassing and tank cleaning
• Distinguish the function of structural parts and fittings
for conventional storage tanks
• Explain the design and operational aspects of storage
tanks, tank farm and tank terminals
3-days
• Commissioning, Start-Up, Run-In and Shut-Down,
Surveillance and Health Monitoring, Performance
Measurement, Monitoring and Tracking, Steam
Turbine Washing, Steam Turbine Inspection,
Maintenance, Overhaul and Repair (IMO&R)
• Examples from Recent Failure Incidents Attributed to
Design Defects, Processing and Manufacturing
Deficiencies, Assembly Errors, Off-Design or
Unintended Service Conditions, Maintenance
Deficiencies, etc.
• Predictive vs. Preventive Maintenance Techniques
• Determination of Which Method to Use
• Machinery Reliability Audits and Reviews
• Overview, Reliability Impact on Plants
2-day
• Alternate Final Control Elements
• Variable Frequency Drive Technology
• Control Valves vs Variable Speed Drives
• Typical Variable Speed Drives Application
• Selling a Project: The Economic Approach
• Applications
• HVAC Applications
 2KG Traininh
2KG Training Courses Cont.

Valves: Selection, Installation and Operation 4-days

• Hydraulic concepts • Valve sizing
• Valve requirements and applications • Valve selection and build variations
• Valve categories: Principles of operation • Valve Actuators: an overview
• Factors governing valve selection

Piping Systems 4-days

• Pipe manufacturing methods & materials
• Pipe fittings and application , valve placement
• The concepts force, work, energy and power
• Pipeline profiling and hydraulic gradient
• System head curves
• The behavior of liquids other than water
• Compound pipelines
• Trouble shooting and remedial action
• Designing suction and delivery pipe work systems
• Water hammer: calculation and prevention
• Installation, testing and commissioning of pipe lines
• Coatings and other protection procedures
• Life cycle costing for pipe work systems

Reliability Improvement 3-days

• Reliability program basics • Asset improvement
• Asset care • Reliability program benefits
• Asset monitoring

Advanced Pumps 2-days

• Simple End Suction Pump • Centrifugal Pump Affinity Laws
• Pump Cross Section • Calculating the power input required by the Pump
• Parts List • What is NPSH required and NPSH available
• ANSI Pump Curve Sensitivity for Pump Reliability • How to deal with unsatisfactory NPSH problems
• API Pump Curve Practices • Cavitation
• How Centrifugal Pumps work • What is Specific Speed – Ns or Nq
• Radial Thrust • Typical Characteristic Curve Shapes for Centrifugal
• Axial Thrust Pumps
• Calculating Pump Total Head • Flow Control in Centrifugal Pumps
• Typical Centrifugal Pump Performance Curves

Pressure Safety Valve 3-days

• Introduction and history of PSV design • Disassembly of PSV/POSV
• Organizations associated with PSV Standards • Inspection prior to repair
Development and Enforcement • Lapping and grinding
• Statutory requirements • Assembly
• “VR” Accreditation Program • Testing, pressure testing and sealing
• National Board Inspection Code • Nameplate stamping
• ASME Code Sections I and VIII • Calibration
• PSV & POSV principles of operation • Quality systems
• Installation requirements for PSV/POSV • Non-destructive examination
• Operational problems with PRV/POSV • Sizing and selection of PSV’s
• Pressure relief device certifications • Steps for obtaining National Board “VR” Stamp
• Nameplate data interpretation
• PSV/POSV repair
• Troubleshooting

2KG Training Phindi Mbedzi t +27 (0) 11 325 0686 c +27 (0) 71 125 6188 e phindi@2kg.co.za
 2KG Traininh
2KG Training Courses Cont.

Safe & Efficient Boiler Operation 3-days

• Examine the origins and development of boilers,
and code requirements, such as ASME Sections I
and VIII, API and ISO Standards, and legal
requirements of boiler construction.
• Fundamentals of power boiler construction and
design
• The requirements for boiler water treatment and
effects of poor treatment
• Operational malfunctions of boilers
• Identify the application, installation requirements and
troubleshooting of PSV’s
• Understand the inspection, maintenance, operation,
troubleshooting and repair of Boilers
• The correct start-up and shut-down procedures.
• Boiler efficiency, combustion analysis & tuning
• Boiler damage and degradation mechanisms, and
boiler inspection
• Maintenance and repair of boilers

Industrial Flow Measurement 3-days

• Introduction: Review of Fluid Properties |
Flowmeter Performance | Linearization and
Compensation | Totalization
• Differential Pressure Flowmeters: Orifice Plate|
Venturi | Other DP Producing Elements
• Magnetic Flowmeters: Construction | Operating
Constraints
• Mass Flowmeters: Coriolis Mass Flowmeters
• Oscillatory Flowmeters: Fluidic | Vortex Shedding
• Open Channel Flow Measurement: Weirs | Flumes
• Flowmeter Selection: Criteria
• Positive Displacement Flowmeters: Helical Gear |
Nutating Disc |Oval Gear | Piston and Other
Technologies
• Thermal Flowmeters: Construction | Operating
Constraints
• Turbine Flowmeters: Axial | Other Technologies
• Ultrasonic Flowmeters: Principles of Operation |
Installation Considerations
• Correlation Flowmeters: Technologies | Installation
Requirements | Performance
• Insertion Flowmeters: Available Technologies |
Operating Constraints

Bearings 2-days
• Introduction to bearings Technology • Mounting and Dismounting
• Lubricant Types, users and selection criteria • Causes of Failures and Failure Analysis
• Fits and Tolerance’s

Root Cause & Failure Analysis 2-days

• RCFA Introduction • Asset Hierarchy
• Video – Swiss Cheese Model • Asset Criticality
• RCFA Terminology • Maintenance Content Optimization (PMO & RCM)
• Physical/Human/Latent Failure Elements • Workflow Management
• People & Process influences • Condition Monitoring
• Risk mitigation • Proactive Maintenance
• Video – Bowtie Risk Evaluation • Spares Management
• RCFA Methodologies • FRACAS
• Video – Fishbone & Five-Why • RCA/RCFA
• RCA/RCFA Cause Map Fundamentals • Defect Elimination
• RCA/RCFA Process • Video – Optimum Defect Elimination &
• RCA/RCFA Triggers & Scale Downtime/Delay Recording
• RCA/RCFA Business Impact • Workshop – Recording Failure Data & $-Pareto
Application
• RCA/RCFA Program Failures
• Workshop – RCA Triggers & RCA Scale
• RCA/RCFA vs. FMEA/RCM
• Workshop – Fishbone & 5-Why Application • Workshop – Cause Mapping Application

2KG Training Phindi Mbedzi t +27 (0) 11 325 0686 c +27 (0) 71 125 6188 e phindi@2kg.co.za