Electricity and Electrical Engineering in Process & Industrial Plants

Electrical systems are the backbone of process and industrial plants, ensuring reliable power supply, efficient operations, and safety. This course provides a comprehensive understanding of electrical technology applications, system design principles, configurations, and maintenance practices tailored for industrial environments. Participants will learn how to design, inspect, maintain, repair, and troubleshoot electrical systems to ensure optimal performance, minimize downtime, and comply with industry standards. Through lectures, hands-on tutorials, case studies, and practical exercises, this course equips participants with the skills to manage electrical systems effectively in industrial settings.

Audience

This course is designed for:

Electrical engineers and technicians working in process and industrial plants.
Maintenance personnel responsible for electrical systems in manufacturing facilities.
Plant engineers and operators involved in power distribution and control systems.
Energy consultants and project managers overseeing industrial electrical projects.
Graduates and postgraduates in electrical engineering seeking practical expertise.

Course objectives

By the end of this course, participants will be able to:

Understand the principles and applications of electrical technology in process and industrial plants.
Design and configure electrical systems for specific industrial applications.
Conduct routine inspections, preventive maintenance, and repairs on electrical equipment.
Troubleshoot common issues in electrical systems and implement corrective actions.
Apply industry best practices for safe and reliable operation of electrical systems.
Use diagnostic tools and techniques to assess system health and performance.

Course contents

Day–1: Fundamentals of Electrical Technology in Industrial Plants

Introduction to electricity and key electrical components in industrial settings.
Understanding industrial electrical loads: Lighting, HVAC, and process equipment.
Electrical safety principles: Grounding, bonding, and arc flash prevention.
Overview of electrical standards: NEC, IEC, IEEE, and OSHA.
Hands-on panel demonstration, case study on safety incidents, quiz, and pretest.

Day–2: Electrical System Design and Configuration

Industrial electrical system design: Load calculations, voltage levels, and redundancy.
Understanding single-line diagrams, feeder circuits, and distribution networks.
Motor control systems: Starters, VFDs, soft starters, and efficiency improvement.
Power factor correction and harmonic mitigation techniques.
Group design exercise, case study on power factor impact, and quiz.

Day–3: Inspection, Maintenance, and Repair

Routine electrical inspections: Visual checks, thermal imaging, and insulation testing.
Preventive maintenance: Cleaning, lubrication, calibration, and component replacement.
Identifying common electrical failures: Overheating, insulation degradation, mechanical issues.
Repair techniques: Component replacement, motor rewinding, and transformer reconditioning.
Hands-on inspection, maintenance planning case study, and quiz.

Day–4: Troubleshooting and Fault Analysis

Common electrical faults: Overloads, short circuits, ground faults, insulation breakdown.
Root cause analysis using data logging, diagnostics, and predictive analytics.
Step-by-step troubleshooting methods for industrial electrical systems.
Safety protocols during fault diagnosis and repairs.
Hands-on fault diagnosis, case study on panel tripping, and quiz.

Day–5: Advanced Topics and Final Assessment

Emerging technologies: Smart grids, IoT monitoring, and predictive maintenance.
Energy efficiency strategies: Demand-side management, load shedding, renewables.
Industry standards and best practices for electrical system longevity.
Future trends: Digitalization, automation, and sustainability in industrial electrical systems.
Final written test, post-test evaluation, and group discussion on lessons learned.

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