Course Description

DURATION

21 hours (Three (3) days)

TARGET GROUP

The course is prepared for those who are interested to become competent person (engineers) in Internal Combustion Engine (ICE) and they are; new engineers, team leaders/coordinators, operations engineer, maintenance team leaders, engineers, operations team leaders, inspection, senior operations and maintenance personnel.

TARGETED INDUSTRY/INDUSTRIES

Oil & Gas, Petrochemicals, Power Plant, Renewal Energy Plant, Co-Generation Plant, Palm Oil Mills and Refineries, Plywood Industries, Hotels and all industries that are using Internal Combustion Engines.

CERTIFICATION

This course is suitable for ICE engineers that are willing to sit for the Internal Combustion Engine Engineer’s Certificate of Competency examination with the Department of Occupational Safety and Health, Malaysia (DOSH).

COURSE OBJECTIVE

This course will guide the participant to have better understanding on how to pass the Department of Occupational Safety and Health (DOSH) Internal Combustion Engine Engineer’s Certificate of Competency Examination.

The program also covers the design, installation, operation and maintenance of these machines by highlighting characteristic features of various reciprocating piston engine types, gas turbine types, their efficiencies, vulnerabilities, reliability, operation and maintenance peculiarities.

COURSE OUTCOMES

At the end of the course, the delegates will be able to: –

• Sit for ICE Engineers’ examination conducted by DOSH.
• Describe the ICE fundamental, ICE classification and engine performance.
• Understand on various Piston Engine, 2 –Stroke & 4 -Stroke engine structure, operation and timing diagram, Diesel Combustion Ignition engine, Petrol Spark Ignition engine, Turbocharger, starting system, Lubrication system, Fuel system and Cooling system, Engine operation and maintenance.
• Understand on various Gas Turbine Engine, theory, major components and function, auxiliaries’ equipment, Control system, fire protection and instrumentation system, Gas Turbine operation, performance, maintenance
• Understand about material behaviors for any rotation machines
• Understand the DOSH examination question and interview format

TRAINING METHODOLOGY

• Lecture
• Pre- and Post-Test
• Classroom discussions
• Short video presentation
• Case study

COURSE CONTENTS

Factories and Machinery Act 1967 (Act 139)

• Certificates of Competency – Examinations, Regulations 1970
• Person-In-Charge, Regulations 1970
• Notification, Certificate of Fitness and Inspection, Regulations 1970
• Safety, Health and Welfare, Regulations 1970

An Introduction to Internal Combustion Engines

• Overview of Internal Combustion Engine
• ICE Classifications
• Intermittent Combustion Engine
• Continuous Combustion Engine
• Rotary Engine

Gas Turbines

• Basic theory of gas turbine systems
• Gas turbine process
• Types of Gas Turbine applications
• Advantages and Disadvantages of Gas Turbine
• Operating Principles
• Gas Turbine Main Components;
  • Compressor Section
  • Combustion Section
  • Turbine Section
• Gas Turbines Typical Loads
• Classification of Gas Turbines;
  • Basic type of gas turbine;
    • Aero
    • Industrial
  • Gas turbine classifications;
    • Single shaft
    • Spilt shaft
  • Compressor classifications
• Major Components and Its Function
• Start-up and Shutdown Guidelines
• Maintenance Procedures

Reciprocating Engines

• Classification of Internal Combustion Engines
  • Method of Ignition
  • Cycle of Operation
  • Numbers of Cylinders
  • Arrangement of Cylinders
  • Speed
  • Method of Cooling the Cylinder
• Engine Performance
• Diesel Engine Plant Auxiliaries
• Lubrication
• Engine Starting Methods
• Starting and Stopping Procedures
• Valves Positions
• Compression Ratio
• Firing Order
• Engine Main Components

Combustion of Fuels

• Introduction of Combustion
• Combustion Theory;
  • Perfect combustion
  • Complete combustion
  • Incomplete combustion
• Gaseous Fuels
• Characterization of Gaseous Fuels
• Typical Heating Value of Some Gaseous Fuels
• Liquid Fuels;
  • Characterization of Liquid Fuels
  • Flash Point
• Heat Rate
• Gas Turbine Combustion
• Diesel Engine Combustion;
  • Indirect-Injection Engine
  • Direct-Injection Engine

Non-Destructive Testing Fundamentals

• Dye penetrant test
• Ultrasonic testing
• Radiographic testing
• Magnetic-particle inspection
• Visual Inspection

Material Science and Engineering

• Classification of materials
• Metallic Crystal Structures
• Imperfection in Solids
• Mechanical Properties of Metals
• Material deformations
• Engineering Stress-strain
• Materials testing
• Correlation between Hardness and Tensile Strength
• Failure Mechanism
• Mechanical working of steel
• Heat Treatments of Steels

Review of DOSH Examinations

• Part C (Interview) and Part B (Written Examination)