EBK Professional Engineers Training Manual
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ENGINEERS BOARD OF KENYA
GUIDELINES FOR THE PROFESSIO PROFESSIONAL NAL TRAINING OF ENGINEERS
SEPTEMBER 2014
Page 1 of 33
Introduction
A professional engineer has been defined by the Engineering Societies of Western Europe and the USA (EUSEC) as follows: “A professional engineer is competent by virtue of his fundamental education and training
to apply the scientific method and outlook to the analysis and solution of engineering problems. He is able to assume personal responsibility for the development and application of engineering science and knowledge, notably in research, designing, construction, manufacturing superintending managing and in the education of the engineer. His work is predominantly intellectual and varied and not of a routine mental or physical character. It requires the exercise of original thought and judgment and the ability to supervise supe rvise the technical and administrative of others. His education will have have been such as to make him capable of closely and continuously following progress in his branch of engineering science by consulting newly published work on a worldwide basis. Assimilating such information and applying it independently. He is thus placed in a position to make contributions to the development of engineering science or its applications. His education and training will have been such that he will have acquired a broad and general appreciation of the engineering sciences as well as a thorough insight into the special features of his own Branch. In due time he will be able to give authoritative technical advice and to assume responsibility for the direction of important tasks in his branch."
Page 2 of 33
Contents 1.0
Background To Professional Training Tr aining For Engineers ........................................................ ...................................................................................... .............................. 5
2
Training in General Management .................................................................................................................... ...................................................................................... .............................. 6
2.1
General management ....................................................................................................................................... 6
2.2
Financial management: ................................................... ................................................................................................................. ................................................................................. ................... 6
2.3
Marketing management: .................................................................................................................................. 7
2.4
Planning for human resources .......................................................................................................................... .............................................................. ............................................................ 7
2.5
Environment and Workplace Safety and Health ...................................................... .............................................................................................. ........................................ 7
2.6
Professional Ethics .......................................................... ........................................................................................................................ ................................................................................. ................... 8
3.1
Introduction to Agricultural Engineering ........................................................ ......................................................................................................... ................................................. 9
3.2
Training Content for Agricultural Engineers ................................................................................ ................................................................................................... ................... 9
3.2.1
Design, Research and Product Development ................................................................................................... ................................................................................ ................... 9
3.2.2
Farm and Field Operations and Maintenance .......................................................... ................................................................................................ ...................................... 11
3.2.3
Workshop Practice and Maintenance ............................................................................................................. .............................................................. ............................................... 11
3.3
Areas of engagement for Agricultural Engineers ..................................................... ........................................................................................... ...................................... 13
4
Discipline Specific Training for Civil Engineers ..................................................... ........................................................................................... ...................................... 14
4.1
Introduction to civil engineering .......................................................... .................................................................................................................... .......................................................... 14
4.2
Training Content for Civil Engineers E ngineers .............................................................. ............................................................................................................. ............................................... 14
4.2.1 4.2.2
Design Office Practice .................................................... .................................................................................................................. ............................................................................... ................. 14 Construction Site Practice ....................................................................................................................... .......................................................... .................................................................... ....... 15
4.3
Areas of engagement for Civil Engineers ...................................................................................................... ..................................................................................... ................. 16
5
Discipline Specific Training for Electrical Engineers .................................................................................... ........................................................ ............................ 17
5.1
Introduction to Electrical Engineering .......................................................................................... ........................................................................................................... ................. 17
5.2.1
Common Proficiency Requirements for ALL Electrical Engineers ............................................................... ........................................................ ....... 17
3
Discipline Specific Training for Agricultural Engineers ................................................................................. ..................... ............................................................ 9
5.2.1.1 Design Office and Consultancy Practice ......................................................... ........................................................................................................ ............................................... 17 5.2.1.2 Operations and Maintenance ............................................................... ......................................................................................................................... .......................................................... 18 5.2.1.2 Workshop Practice .......................................................................................................................................... 19 5.2.2
Proficiency Requirements Specific to sub specialties. ....................................................... ................................................................................... ............................ 20
5.3
Areas of Engagement for Electrical Engineers .............................................................................................. .................................................................. ............................ 24
6 6. 1
Discipline Specific Training for Mechanical Engineers ................................................................................ .................................................... ............................ 26 Introduction to Mechanical Engineering E ngineering ........................................................................................................ ......................................................... ............................................... 26
6.2
Training Content ............................................................................................................................................ 26
6.2.1
Design Office Practice .................................................... .................................................................................................................. ............................................................................... ................. 26
6.2.2
Workshop Practice, Plant Engineering and Maintenance .............................................................................. 27
6.3
Areas of Engagement for Mechanical Engineers ..................................................... ........................................................................................... ...................................... 29
7
Discipline Specific Training for Chemical and Process Engineering ............................................................ ..................................................... ....... 30
7.1
Introduction to Chemical Engineering ........................................................................................................... .................................................................................................. ......... 30
7.2
Training Content for Chemical Engineers ..................................................................................................... 30
7.2.1
Process and Equipment Design ........................................................... ..................................................................................................................... .......................................................... 30
7.2.2
Chemical Plant Operations and Control ......................................................... ........................................................................................................ ............................................... 31
Page 3 of 33
List of Tables
Table 3. 1 Summary Summary of Training Training for Agricultur Agricultural al Engineers Engineers
12
Table 4. 1 Summary Summary of Training Training for Civil Civil Engineers Engineers
16
Table 5. 1 Summary Summary of Training Training for Electrica Electricall Engineers Engineers
24
Table 6. 1 Summary Summary of Training Training for Mechan Mechanical ical Engineers Engineers
28
Table 7. 1 Summary Summary of Training Training for Chemical & Process Engineers Engineers
33
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1.0
Background To Professional Training For Engineers
Practical training is to be directed towards providing opportunities for the graduate engineer to achieve responsible experience. Usually there are two phases to the training programme. The first of these is where the graduate engineer learns to bridge the gap between theory and practice and the second phase where he acquires the ability and demonstrates a willingness to accept and exercise responsibility. There is in fact hardly any dividing line between training and experience, they are complimentary and continue throughout the life of the professional engineer. engineer. A graduate engineer given a systematic and disciplined introduction to his professional life will learn more quickly to recognize his responsibilities as a professional engineer and to use his knowledge in a realistic way, than one who is set to work without a proper introduction and briefing. Correct training will be achieved effectively and efficiently if the graduate is soon made to appreciate his personal responsibility to his employer and his profession; understands that success in modern engineering depends upon teamwork and good human relations; that practical engineering problems rarely have a unique solution and that cost and time are important factors in all engineering activities. Having established established a proper approach to training, each graduate will require a specific course related to his own needs and those of the organization organization for which he is working. The end product product of a good training training scheme scheme is a fully proficient and and competent professional engineer. The Th e tra train inin ing g pro progra gramm mme e iis s divide divided d into into two two main main compo componen nents ts:: i.
Traini Tra ining ng on gener general al mana manage gemen ment: t: This This is appli applica cabl ble e to to all all inter interns ns and and cuts cuts ac acros ross s all all disciplines.
ii.
Discipline specific topics: The specific disciplines are: 1) Agricultural Engineering 2) Chemical and Process Engineering 3) Civil Engineering 4) Electrical Engineering 5) Mechanical Engineering
Within each discipline major topics have been identified. Against each major topic and indicative minimum number of months has been specified. The mentor is expected to develop a programme such that the total number of months sums to a minimum of 36 months, the duration of the internship period.
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2
Training in General Management
Training on general managemen managementt is generic across all disciplines disciplines and forms part of the structural training for specific disciplines. Acquisition of management skills is a life- long learning process that continues throughout the internship programme and beyond. Management cuts across all businesses and therefore any person working at supervisory level and above in a business needs an understanding of basic management principles. The main purpose of general management module therefore is to ensure trainees acquire relevant knowledge, skills, attitudes and other characteristics to conduct relevant management activities in their areas of work. Proposed Approach: EBK will organize a one week non-residential seminar for the providers of the training in General Management Skills to ensure the providers appreciate the expected outputs of the training. The ideal ideal size size for for each each session session is deeme deemed d to to be 25-30 trainees trainees.. The The select selected ed venue venues s ffor or the seminars should be within the region of attachment. Training Train ing Cost: Cost: The The trainin training g will will be subsidize subsidized d by EBK under GEIP GEIP pr progra ogramme. mme. The candidate may however be required to pay some nominal fee. At the end of the training, the trainees will have competencies in the following areas: 2.1
General management
This will include:
Organizational structure, business planning, and administration
Procurement, inventory management and stores management
Production planning, scheduling, quality management and control
Contract management and administration Supervision, directing, control, coordination and delegation
2.2
Financial management: management:
Budgeting and budget controls
Costing and estimation
Basic book keeping and financial record keeping and interpretation of financial
records
Controlling of receipts
Inventory management and controls
Controlling expenditure;
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2.3
Marketing management: management:
Market research, planning, and segmentation
Pricing and pricing strategies
Advertising, Promotion, promotion strategies and publicity
Distribution and distribution strategies
Product (quality, branding, image, packaging and design, service warranties)
Human resources management 2.4
Planning for human resources analysis s and and job design design for purpose purpose of having having a job job desc descript ription ion and a Job analysi
specification
Recruitment and selection processes including interviewing skills
Tra Trainin ining g and and developm development ent includi including ng provid providing ing on the job tra trainin ining, g, guidanc guidance, e,
coaching and mentoring
Performance management and appraisal and linking appraisal to compensation
and training
Compensation management including determining salaries, wages, benefits other incentive and motivation
Industrial/labour relations management including all the Kenyan labour laws,
discipline and disciplinary procedures, handling disputes and conflict at work
Occupational health and safety management to meet the Occupation Health and
Safety Act (OSHA) 2007 Communication skills
Effective listening
Providing feedback
Report writing and presentation skills
Effective public speaking
Cross cultural and gender sensitive communication
Negotiation and conflict management skills
2.5
Environment and Workplace Safety and Health
Environmental laws and regulations
Environme Environmental ntal and social impact assessment assessment and audit (ESIA and EA)
Environmental management systems (EMS) Safety and health
Health and safety committee rules
Occupational accidents
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Personal protective equipment (PPE)
Safe work procedures
Workplace inspection techniques
Machinery safety
Construction safety
Plant safety
Fire safety Electrical safety
Chemical safety
Workplace health hazards
Occupational diseases
First aid management management
HIV/AIDs awareness
Alcohol and drug abuse
Legislative framework and standards
2.6
Safety and health management Professional Ethics
The e appl applic icat atio ion n of Code Code of Et Ethi hics cs for for Engi Engine neer ers s in th the e Work Work plac place. e. Th
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3
Discipline Specific Training for Agricultural Agricultural Engineers
3.1
Introduction to Agricultural Agricultural Engineering
Agricultural engineering is that branch of professional engineering which requires such education and experience as is necessary to understand and apply engineering principles to the design, construction and use of specialized equipment, machines, structures and materials relating to the agricultural industry and economy. Agricultural engineering is applied in irrigation and water resources engineering, power and machinery engineering and mechanization, process and food engineering and built environment engineering. Key competencies associated with a trainee agricultural engineer include:
Solid and structural mechanics,
Materials science, production,
Manufacturing,
Machines and control,
Th Therm ermod odyna ynami mics, cs,
Heat transfer, fluid mechanics, hydraulics,
Soil dynamics and plant-soil-water relationship.
The Th e tra traine inee e will will hav have e integ integra rated ted engine engineer ering ing scien science ce and and design design wi with th applie applied d biolog biologica ical, l, environmental and agricultural sciences. 3.2
Training Content for Agricultural Agricultural Engineers
The intern, under the supervision of a registered registered Professional Professional Engineer Engineer and within the period indicated should gain sufficient skill-based insights in the following: i.
Design ,Research and Product Development
ii.
Farm and Field Operations and Maintenance
iii.
Workshop Practice and Maintenance
iv.
General Management
3.2.1 Design, Research and Product Development 3.2.1.1
Irrigation and Water resources
Design and development of irrigation (drip, sprinkler, flood and mechanized )
and water supply systems in farms
Design of drainage systems;
Product development and Prototype testing. Mechanization
Design modifications, evaluation, development and prototyping of machinery
with ergonomic considerations; considerations;
Selection and design for controlled traffic farming.
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3.2.1.2
Post Harvest and Bio-processing Bio-processing
Design, specification and standards for crop and animal product storage
structures,
Selection, design modifications and development of bio-processin bio -processing g machinery
and equipment for post-harvest post-harvest operations.
Product development and Prototype testing. Built Environment
Farm building and structures: design and modifications Familiarization with energy supplies to the farm: electricity, biogas, wind power,
solar power, water power and engine e ngine power;
Design of farm waste disposal systems;
Design, construction and maintenance of farm infrastructure;
Design modifications, construction and operation of controlled environments environments..
3.2.1.3
Environmental Issues
Environmenta Environmentall laws and regulations
Environmental and Social Impact Assessment and Audit (ESIA and EA)
Environmental Management Systems (EMS) Consulting Services: Consultancy and conditions of engagement:-
3.2.1.4
Consultancy
Pre-feasibility ility and viability studies Pre-feasib
Preliminary designs and final designs,
Systems designs and derivation of bills of quantities,
Derivation of specifications and applicable standards,
Preparation of tender documents and tendering processes (local and
international),
Procurement laws and procurement process, Contract management,
Final inspection and commissioning,
Preparation of as-built drawings and final project report.
Conditions of engagement: International Federation of Consulting Engineers
(FIDIC),
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3.2.2 Farm and Field Operations Operations and Maintenance Maintenance 3.2.2.1
Irrigations and Water resources
Evaluation of land and water resources
Remote sensing and GIS
Integration, Operation, maintenance and management of irrigation, drainage
and soil conservation systems in agricultural activities
Development and operation of smallholder irrigation and water use schemes
Rain water harvesting technologies
3.2.2.2
Mechanization
Time e sched schedules ules and machin machinery ery manage managemen mentt in in all all field field operati operations ons;; Tim
Optimal use of power within the three levels (manual, animal and engine
power) of mechanization. mechanization. Post Harvest and Bio-Processing
Bio-processing at farm and industrial levels e.g. milling, oil extraction, sugar
production, milking machines and dairy processing equipment
Post harvest preservation techniques – dehydration, refrigeration, refrigeration, sealed-bin
storage and chemical treatment
Tech Technica nicall suppor supportt in small small and and medium medium scale scale agro agro proce processin ssing g and and agro agro food food
industry cleaning, sorting, grading, palletizing and Quality assessment and assurance – cleaning,
packaging.
Food safety and storage
3.2.2.3
Built Environment
Electrification at farm level, bio-sensors and instrumentation
Harnessing of bio-energy
Construction and maintenance of agricultural structures including
farmhouses, greenhouses, greenhouses, abattoirs, market centers, etc.
Agricultural waste management
access road construction
3.2.3 Workshop Practice Practice and Maintenance Maintenance
Material forming; including forging. Plate and pipe bending, sheet metal work and
press work.
Material removal; includes the use of common hand tools and machine tools for
turning, shaping, milling, drilling, and grinding.
Join Jointing ting and welding; welding; includes includes rivetin riveting, g, boltin bolting, g, weldi welding, ng, brazing brazing and and solde soldering ring
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Casting processes; includes some experience of pattern making.
Heat and surface treatment of materials; includes tempering, annealing, cleaning
and plating.
Metrology and testing; including the use of gauges and measuring instruments in
marking out, inspection and other workshops processes.
Familiarization with use of maintenance manuals, parts catalogues and
preventive plant and breakdown maintenance schedules
Routine monitoring of plant performance, fault diagnosis and servicing
techniques
Maintenance of log books, machinery repair and maintenance records
Specification, selection, installation, testing and commissioning of machinery and
plant Procurement and stores & inventory management
Computer application in manufacturing systems
Parts inspection and site acceptance tests
Process automation design
Production planning, manufacture and control (ergonomics) of industrial products, tools, jigs and fixtures, dies and patterns
Familiarization with industrial engineering and interrelationships of technical,
production and service departments
Assessment of plant infrastructure condition
Material handling procedures
Table 3. 1 Summary Summary of Training Training for Agricultur Agricultural al Engineers Engineers
General Requirements
Min Duration
Sub- topics
(months) Irrigation and water resources Mechanization Design and Research and Product Development
Post harvest and bio-processing 9 Built environment Environmental issues Consulting services
Farm and Field operations and
Irrigation and water resources 12
Maintenance
Mechanization
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General Requirements
Min Duration
Sub- topics
(months) Post-harvest and bio-processing Built Environment
Material forming and removal Maintenance
Workshop practice and maintenance
9
Specifications and commissioning of plant Industrial engineering and plant infrastructure Material handling Financial management Marketing management
General management
6
Human resource management Communication skills Environment Safety and health
3.3
Areas of engagement for Agricultural Engineers
The most common common areas of engagement engagement for agricultural agricultural engineers engineers include: - research research and education, agro-industries, renewable energy industries, manufacture of agricultural machinery, post-harvest food and by-products processing industry, irrigation and water resources management industries, environmental and social impact assessment and audit (ESIA and EA) agencies.
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4
Discipline Specific Training for Civil Engineers
4.1
Introduction to civil engineering
Civil engineering deals with planning, designing and construction of infrastructure, utilities, buildings and their maintenance. The broad areas of civil engineering are:
Structural and Geotechnical Engineering,
Waste Water and Environmental Engineering, Hydrology and Water Resources Engineering,
Highway and Transportation Engineering and
Civil Engineering Construction.
The train trainee ee must must have have academ academic ic compet competenc ence e iin n theo theory ry of struct structure ures s and and struct structura urall desi design, gn, geotechnical engineering engineering and foundations, hydraulics, environmental and sanitation engineering, highways highways and traffic, civil engineering materials, surveying and site investigations, construction and contract management, costs, drawings and CAD, experimenting. 4.2
Training Content for Civil Engineers
The training training program programme me for civil engineer engineers s will cover cover the following following major areas: areas: 1) Design Office Practice 2) Site Experience 3) General Management The intern, under the supervision of a licensed registered registered Professional Professional Engineer(s) Engineer(s) and within the period indicated should gain sufficient skill-based insights in the following: 4.2.1 Design Office Practice Practice 4.2.1.1 Induction to the Organization The trainee will undergo undergo an induction induction programme programme in the organization organization in the following areas: i. ii. iii.
History and size of organization Management structure and functions Communication systems systems in the organization
4.2.1.2 Design Practice The graduate graduate engineer engineer will have sufficient sufficient exposure exposure to the following:
Organization of the design office and associated offices.
Project planning and programme of design work.
Familiarization with standards, codes of practice, design manuals and other
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relevant reference materials. Preliminary Site Information Review
Review of existing site investigation records (design data assumptions, possible
alternative designs and associated costs).
Site inspection and survey for design.
Site investigation including knowledge of equipment and techniques.
Tes Testin ting g of of s samp amples les to obtain obtain design design data and proper proper use of test testing ing equipm equipment. ent.
Feasibility Studies including economic and environmental considerations Tec Techni hnical cal and economi economic c eval evaluat uation, ion,
Social and environmental impact considerations. Engineering / Technical Design
Design and specifications and preparation of drawings for temporary, permanent
and maintenance works using conventional methods and computer aided design (CAD) methods, where available.
Documentation for Contracts
Preparation of bills of quantities according to standard methods of measurements
and estimating costs.
Familiarization with the law of contract, statutory requirements, conditions of
contract and other contract documents.
Familiarization with dispute resolution methods.
Ten Tender der prepara preparation tion and evaluat evaluation. ion.
Familiarization with local and International Tendering Procedures
4.2.2 Construction Site Practice Practice
Planning and programming of construction
Resource planning, allocation and control
Familiarization with methods of construction and their pertinent details.
Familiarization with Setting out of works and surveying instruments. Mechanical plant and their application output, capacity Familiarization with Mechanical
and associated costs.
Knowledge of characteristics of materials, their cost, storage and handling.
p rocedures. Quality control procedures.
Measurement ent of works, assessment of variations and issuance of interim Measurem
payment certificates. certificates.
Management of health, safety and risk on site.
Environmental Monitoring and Audit
Staff and labour relations; working conditions and welfare.
Corporate and public communications.
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Site administration including control and management of subcontracts.
Maintenance of Site records and preparation of progress and other reports.
Table 4. 1 Summary Summary of Training Training for Civil Civil Engineers Engineers General Requirements
Durat Duration ion
Sub-topics Induction Preliminary site Information review
Design Office Practice
18
Feasibility studies Engineering/technical design Documentation for contracts Construction planning and programming Methods of construction Quality control procedures
Construction Site Practice
12 Measurement and certification of works Environment, health and safety on site General site administration Financial management Marketing management Human resource management
General management
6 Communication skills Environment Safety and health
4.3
Areas of engagement for Civil Engineers
The Th e ar areas eas wh wher ere e civi civill engi engine neer erin ing g grad gradua uate tes s wi will ll fi find nd empl employ oyme ment nt inclu include de but but not not limit limited ed to Public Utilities and Infrastructure departments for Roads, Water, Irrigation, etc; Building Industry Consulting Firms and Contractors.
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5
Discipline Specific Training for Electrical Electrical Engineers
5.1
Introduction to Electrical Electrical Engineering
Electrical engineering deals with the study and application of the theories of electricity, electronics, and electromagnetism, electrical engineers apply scientific knowledge to solve technical problems and develop products and services that benefit society. Electrical engineering encompasses electrical power generation & distribution, electronics, wired & wireless communications, robotics, computers, radar, ultrasonics, lasers, fiber optics, digital signal processing, analog and digital control systems among others. Expected academic competence areas include: i.
Electrical circuit theory
ii.
Electrical power systems,
iii.
Instrumentation Instrumentat ion and control
iv.
Microwaves and antennas antennas
v.
Elements of mechanical engineering
vi.
Electrical measurements, measurements,
4.2 Training Content for Electrical Engineers The intern intern,, unde underr the the superv supervisi ision on of a regi registe stere red d Prof Profess ession ional al Engin Engineer eer and within within th the e period indicated should gain sufficient skill-based insights in the following: 5.2.1 Common Proficiency Requirements Requirements for ALL Electrical Electrical Engineers i. ii.
Design Office and Consultancy Practice Operations and Maintenance
iii.
Workshop Practice
iv.
General Management
5.2.1.1
Design Office and Consultancy Practice
Organization of a drawing office
Understanding of electrical drawings and schematics
Modification of drawings and its procedures.
Preparation of shop drawings and accompanying documents
Familiarization with laws and regulations covering electrical design
Familiarization with the applicable design standards and codes of practice
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Computer aided drawing office practice
Generation of cost estimates
Familiarization with project stages
Design analysis and review
Familiarization with different types of project implementation strategies
Preparation of specifications and design documentation
Preparation of bills of quantities, tender documents and evaluation of
tenders
Familiarization with local and international tendering procedures
site supervision of project works
Product performance, reliability and maintenance
Product interaction with the environment and impact on society
Component selection and integration of components and sub-systems into
larger systems 5.2.1.1.2
Consultancy and conditions of engagement:engagement:Pre-feasibility and viability studies,
preliminary designs and final designs,
Systems designs and derivation of bills of quantities,
Derivation of specifications and applicable standards,
Preparation of tender documents and tendering processes (local and
international), procurement laws and procurement process,
Contract management,
Final inspection and commissioning,
Preparation of as-built drawings and final project report, among others.
Conditions of engagement: engagement: FIDIC.
5.2.1.2
Operations and Maintenance
Basic Electrical Circuits
Principles of Electrical Grounding/ Earthing
Understanding of maintenance purposes and types.
Develop ability to read Electrical Drawings and Schematics
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Electrical Power Distribution Systems
Electrical Protective Devices
Understanding of Static Electricity and its control methods
Awareness of electrical safety requirements and Electrical Safety in
Troub Tr oubles leshoo hootin ting g
Electrical Safety And Risk Assessment
Understanding Understandin g of methods of maintaining electrical machines and
equipment
Diagnosis of faults in machines, equipment and installations using non-destructive non-destru ctive procedures
UPS, Rectifiers, Inverters And Batteries: Fundamentals of Maintenance Maintena nce ,Testing And Troubleshooting Troubleshooting
Understanding of Electrical Troubleshooting Techniques
understanding understan ding of Condition Monitoring for Electrical Equipment
Understanding of inspection and testing methods
Maintenance Scheduling for Electrical Equipment
Testin ting g and and Commis Commissio sionin ning g Proc Procedu edures res Tes
i mprovements through modifications and Systems and/or product improvements
upgrading
Planned and breakdown maintenance of electrical systems and equipment
Plan, design and specify materials required for corrective and preventive
maintenance of plant/equipment/system, including preparation of schedules for costs of materials and labour requirement
Improvementt of production methods, procedures and standards Improvemen
through critical evaluation of production materials, systems and problems
providing technical assistance during commissioning of structures,
equipment, processes or systems 5.2.1.2 Workshop Practice This will involve attachment to various workshops dealing with electrical repairs,
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fabrications and testing. The experience experience should cover but not be be limited to the following:following:-
General Workshop Safety
Electrical safety and regulations
Earthing concepts
Electric Shocks and Treatment
Electrical Engineering measurement equipment and tools
Maintenance, repair and charging of Batteries
Dismantling and rewinding of electrical machines (Motors, Generators,
Tran Tr ansfo sform rmers ers))
Inspection of rewound electrical machines and equipment and
testing for continuity, insulation, and correct rotating voltage.
Wiring regulations
Types pes of cable cables s and and electri electric c acce accesso ssories ries includ including ing switche switches, s, plug, plug, c circu ircuit it Ty
breakers, fuses
symbols for electrical wiring schematics e.g. switches, lamps, sockets
voltage, current and power measurement
Soldering methods and skills
5.2.2 Proficiency Requirements Requirements Specific to sub specialties. specialties. In addition to the common proficiency requirements, requirements, specific skills will be required by the sub-specialties as follows. 5.2.2.1
Power Engineering
(1) Planning
Load Planning
Network Planning
Inventory Management
(2) Design / Construction
Generating Station
External Plant
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Generator Specification
Substation Design
Protection
Transm nsmiss ission ion Syst System em Desig Design n Tra
Distribution System Design
Customer Equipment and Service Requirements
(3) Operation / Maintenance
Power Station
External Plant
Station Operation & Maintenance
Regulations/Standards
Efficiency Study of Power Systems
5.2.2.2
Electronic and Telecommunications Telecommunications Engineering
Understanding and Troubleshooting of Ethernet and Automation Networks
Troubleshooting, g, Design Designing ing and Installing Installing Digital and Analog Closed Closed Troubleshootin
Circuit TV Systems
Hands-on Data Communications, Networking and TCP/IP Troubleshooting
Understandin Understanding g and application of Fibre Optic Systems
Data Communications, Networking and Protocols for Industry
Practical Troubleshooting & Problem Solving of Industrial Data Communications
Practical Troubleshooting and Problem Solving of Modbus Protocols
Practical Radio Telemetry Systems
Practical Routers & Switches
Fundamentals of Telecommunications and Wireless Communications Communications
Practical Fundamentals of Voice over IP (VoIP)
Traf affic fic Studi Studies es Tr
Switching philosophy, matrices, statistical multiplexes, digital switching,
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digital signal standard bit rates and interface signal levels
Network Planning
International Regulations
Application of ITU-T and the ITU-R Recommendations
Project Coordination
Construction Practice
Project Administration
Evaluation of system availability and reliability on the basis of MTBF and
MTTR Establishmentt of maintenance maintenance programmes taking into account the Establishmen
Mean Time between Failures (MTBF) and the Mean Time To Restore (MTTR) criteria.
Customer Relations Compilation and analysis of maintenance reports and fault statistics
Efficiency Study
Asset Management
5.2.2.3
Manufacturing / Production Engineering
Production Analysis
Project Proposal
Management Accounting
Material Properties
Asset Management
Quality Control
Maintenance Schedules
5.2.2.4
Instrumentation Instrumentation and Control Engineering
Programmable Logic Controllers (PLCs) for Automation and Process Control
Analytical Instrumentation in On-Line Applications
Management Alarm Systems Management
Process Control
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Boiler Control and Instrumentation
Practical Building Automation Systems
Installation, Calibration and Maintenance of Electronic Instruments
Distributed Control Systems (DCS)
Data Acquisition using Personal Computers and Standalone Systems
Process, Electrical & Instrumentation Drawings and Documentation
Troubleshootin Troubleshooting g of Data Acquisition & Supervisory Control And Data Data
Acquisition (SCADA) Systems
Selection, Installation, Commissioning and Maintenance of Fiscal Flow
and Metering Equipment
Industrial Automation Functional Specifications for PLCs, DCSs and SCADA
systems
Industrial Flow Measurements
Understand the purpose of a Hazard and Operability( HAZOP) in the
development of a plant
Define and use Process Flow diagrams, P&ID's, Instrument lists,
Specification forms, Logic diagrams, Location plans, Installation details and Loop diagrams
Understand process control devices and the symbols used to define them
Be familiar with the use u se of specifications to control the design scope of a
project
Instrument Schedules, Drawings & Diagrams
Instrument specifications
Ladder logic and Fail safe design
Hazardous Area considerations
Change Control
Switches, Relays and Contacts
Panel Layout and Schematics
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Table 5. 1 Summary Summary of Training Training for Electrica Electricall Engineers Engineers General Requirem Requirements ents
Duration
Section
(months)
Design Office
Design Office Practice Pr actice and Consulting Services
12
Consultancy Practice Consultancy Conditions of engagement
Electrical Circuits;drawings,distribution systems and devices Electrical safety and risks assessments Operations and Maintenance
6
Fundamentals of commissioning, maintenance ,Testing and Troubleshooting Product improvements through modifications and upgrading
General Workshop Safety, Electrical safety and regulations Electrical Engineering measurement Workshop Practice
12
Handling electrical electrical machines Electrical wiring schematics
Financial management Marketing management Human resource management General Management
6
Communication skills Environment Safety and health
5.3
Areas of Engagement for Electrical Engineers
The most most comm common on areas areas of of engag engageme ement nt of electri electrical cal engine engineers ers include include:: - buildin building g Electrical services, instrumentation and control engineering, academics/research, Page 24 of 33
manufacturing/production engineering, electronic and telecommunications engineering, and power engineering.
Page 25 of 33
6
Discipline Specific Training for Mechanical Mechanical Engineers
6. 1
Introduction to Mechanical Engineering
Mechanical Engineering is that branch of professional engineering that deals with engineering problems related to generation, transmission and utilization of energy in the thermal or mechanical form and also with engineering problems relating to production of tools, machinery and their products and to heating, ventilation, refrigeration and plumbing. It is concerned with research, design, production, operational, organizational and economic aspects of the above. The expected expected academic competence competence areas include: include: i. ii.
Solid and structural mechanics, mechanics, Materials science,
iii.
Production/manufacturing,
iv.
Machines and control,
v. vi. 6.2
Thermodynamics/hea Thermodyna mics/heatt transfer and Fluid mechanics/hydraulics. Training Content
The intern, under the supervision supervision of a registered Professional Professional Engineer Engineer and within the period indicated should gain sufficient skill-based insights in the following: i. ii. iii.
Design Office Practice Workshop Practice, Plant Engineering and Maintenance General Management
6.2.1 Design Office Office Practice Practice
Materials in engineering practice
Design and production processes
Computer Aided Design and Computer Aided Manufacture
Word processing, spreadsheet, presentation, project management software
Specifications, standards, codes and practice in engineering design and
manufacture
Jigs and fixtures fixtures drawin drawings gs (detail (detail and assembly), assembly), layout and engineerin engineering g
drawings
Estimation of production costs
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Modification and adaptation design in maintenance
Scheduling maintenance design and repairs
Failure assessment and troubleshooting
Product and process design and equipment
Consultancy and conditions of engagement Consultancy: Pre-feasibility and
viability studies, preliminary designs and final designs,
systems designs and derivation of bills of quantities,
derivation of specifications and applicable standards,
preparation of tender documents and tendering processes (local and
international),
procurement laws and procurement process,
contract management,
final inspection and commissioning,
preparation of as-built drawings and final project report,
Conditions of engagement: FIDIC.
6.2.2 Workshop Practice, Practice, Plant Engineering and Maintenance Maintenance
Material forming; including forging plate and pipe bending, sheet metal
work and press work.
Material removal; includes the use of common hand tools and machine
tools for turning, shaping, milling, drilling, and grinding. and welding; includes riveting, riveting, bolting, bolting, welding, brazing and Jointing and
soldering
Casting processes; includes some experience of pattern making.
Heat and surface treatment of materials; includes tempering, annealing,
cleaning and plating.
Metrology and testing; including the use of gauges and measuring
instruments in marking out, inspection and other workshops processes. maintenance ce manuals, parts catalogues and Familiarization with use of maintenan
preventive plant and breakdown maintenance schedules
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performance, fault diagnosis and servicing Routine monitoring of plant performance,
techniques
Maintenan Maintenance ce of log books, machinery repair and maintenance records
selection, iinstallation, nstallation, testing and commissioning of Specification, selection,
machinery and plant
Procurement and stores & inventory management
Computer application in manufacturing manufacturing systems
acceptance tests Parts inspection and site acceptance
Process automation design
Production planning, manufacture and control (ergonomics) of industrial
products, tools, jigs and fixtures, dies and patterns
Familiarization with industrial engineering and interrelationships interrelationships of
technical, production and service departments
Assessment of plant infrastructure infrastructure condition
Material handling procedures
Fami Familiar liariza ization tion with Environment Environmental al Management Management Systems Systems (EMS)
Table 6. 1 Summary Summary of Training Training for Mechan Mechanical ical Engineer Engineers s
Duration
General Requirements
Sub-topics
(months)
Essential of the Design Office Computer aided design (CAD) Consultancy Practice
Specifications, standards and codes of practice Design Office Practice
12
Preparation and documentation of tenders Conditions of engagement Contract Management
Page 28 of 33
Duration
General Requirements
Workshop Practice, Plant
Sub-topics
(months) 18
Engineering and
Material forming and removal Maintenance
Maintenance Specifications and commissioning of plant Industrial engineering and plant infrastructure Material handling General management
6
Financial management Marketing management Human resource management Communication skills Environment, Safety and health
6.3
Areas of Engagement for Mechanical Engineers
The employment employment opportunities opportunities available for for mechanical mechanical engineers engineers are in manufacturing manufacturin g iindustries, ndustries, power generation, plant operation and maintenance, equipment design, transport, building services, medical engineering, etc.
Page 29 of 33
7
Discipline Specific Training for Chemical and Process Engineering Engineering
7.1
Introduction to Chemical Engineering
“Chemical Engineering is that branch of professional engineering that embraces studies
or activities relating to the development and application of processes in which chemical or physical changes of materials are involved. These processes are usually resolved into a coordinated series of unit physical operations and unit chemical processes. Chemical engineers devise ways to make products from raw materials using chemical processes in a cost effective, efficient and environmentally sustainable way.”9 Key competencies associated with a trainee chemical engineer include: principles of heat and mass transfer, chemical process and equipment design, chemical reaction engineering, chemical thermodynamics, continuous and stage-wise separation processes, process control and measurements, measurements, environmental control and quality control. The industries industries that are mostly mostly associated associated with chemical engineerin engineeringinclude: ginclude: - oil and gas, gas, petroc 7.2
Training Content for Chemical Engineers
The intern, under the supervision of a registered registered Professional Professional Engineer Engineer and within within the period indicated should gain sufficient skill-based insights in the following: 7.2.1 Process and Equipment Design 7.2.1.1
Process Drawings.
This shall entail ability to prepare, read and and interpret interpret engineering engineering drawings drawings which is important in design and operations of chemical processes. The trainee shall be expected to gain experience in the following areas of engineering draw drawings ings and flowcharts.
Ability to competently read and interpret process flow sheets, and Piping and Instrumentation drawings.
Experience in preparing and modifying engineering drawings and process flow
charts
Ability to use computer aided techniques in simulation, drafting and design
of chemical equipment and process units. 7.2.1.1
Design of Equipment and Process Plants
It is expected ex pected that the trainee shall gain exposure in project development and design to the stage of going to tender and shall cover the following areas:Page 30 of 33
Developing project concept and scope
Undertaking a project technical and economic feasibility study
Determining applicable design standards, codes of practice and relevant governing
legal/regulatory framework for the proposed project.
Preparing preliminary process plant design
Undertaking development of detailed equipment and process design
Developing process equipment specifications and equipment selection
Fundamentals of project execution planning Tender Preparations and Project
Contracting. The trainee shall be exposed to the procurement process that involves the following activities:-
Detailing of project cost estimates for budgetary purposes
Ten ende derr do docu cume ment nt prep prepar ara ation tion T
T Ten ende derr eval evalua uati tion on and and awar award d
Preparation of project contracts
7.2.2 Chemical Plant Operations and Control 7.2.2.1
Process Planning & Scheduling
Trainees shall shall familiarize themselves with the day day to day planning planning of production and optimization of processes to meet plant production targets. It will include the following activities:
Using various tools and methods, to prepare optimum (monthly, weekly, and daily) production schedules.
Scheduling of process plant activities to achieve production targets.
Programmin Programming g of raw materials inputs
Collection and interpretation of measured plant process data
Preparation of daily process reports
7.2.2.2
Process Optimization;
The trainee will be involved involved in activities activities that establish establish process process and equipment equipment efficiency, especially especially in areas of o f energy utilization and production optimization.
Optimizing process operating conditions to achieve production targets.
Preparation of plant mass and energy balances.
Energy efficiency analysis and investigations to establish optimal energy
utilization.
Seeking solutions for process operation and production upsets through trouble shooting Page 31 of 33
7.2.2.3
Process Control;
The trainee shall get exposure in areas areas of production production regulation regulation and monitoring monitoring through use of process instrumentation, and will include the following activities:activities:-
Acquiring knowledge of underlying process instrumentation principles.
Experience in the functions of various control devices and their maintenance.
Achieve knowledge in monitoring and interpretation of controlled process parameters;
7.2.2.4
Quality Management;
The trainee will gain experience in both raw materials and and products quality controls, and will engage in the following activities:-
Understand Understanding ing the principles that set final product specifications and standards.
Th The e proce process ss of formul formulati ating, ng, implem implement enting ing and monito monitorin ring g of qualit quality y cont control rol
procedures.
Knowledge of the relevant test standards and procedures ;
Actual experience in laboratory practices in conducting tests on raw materials,
intermediate streams, and finished products.
Experience in statistical analysis and design of experiments.
7.2.2.5
Plant Maintenance Maintenance Planning
The Th e tra traine inee e will will be be involv involved ed in plann plannin ing g for for sche schedul duled ed preve prevent ntive ive main mainten tenan ance ce and and coordination of breakdown maintenance with the relevant maintenance departments, involving the following activities:
performance records of Inspection and evaluation of performance using performance various plant equipment to identify need for maintenance maintenance
maintenance. e. Participation in programming for scheduled preventive maintenanc
Trouble-shooti Trouble-shooting ng to identify identify and resolve resolve operational operational problems of technical nature. Environmental Management
7.2.2.6
Monitoring and control
A chemical process plant has identifiable features with potential for environmental pollution. The trainee will familiarize with the sources of plant pollution and methods in place for monitoring and control:
Understanding ing of relevant national laws and regulations related to Understand environmental environmen tal management, knowledge of other relevant industry or
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internationall environmental best practices in use in the plant. internationa
Gaining experience experience in specific pollution control measures in place in the plant
Working knowledge knowledge of plant wastes and management of such waste (solid, liquid, gaseous) including hazardous waste management
Participation in the environmental impact assessment and risk auditing
Table 7. 1 Summary Summary of Training Training for Chemical Chemical & Process Process Engineers Engineers General Requirements
Duration
Sub-topics
(months)
Process and equipment Design
12
Process Drawing
Design of Equipment and Process
Plants
Project Tender Preparations and Project Contracting.
Chemical plant operations
18
and contro controll
Process and planning and scheduling
Process Optimization
Process control
Quality management
Plant maintenance planning
Environmental management
Financial management
Marketing management
Human resource management
Communication skills
Environment
Safety and health
General management
6
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