Level 5 – Industrial Services

HND Unit 63 Unit code: K/615/1525

Introduction

Behind the scenes in many modern-day manufacturing facilities there lies a complex system of services that powers production, both day and night. The underlying aim of this unit is to enhance the students’ understanding of the electrical supply systems, industrial air compressors, steam services, refrigeration systems and heat pumps that are used in an array of industrial engineering environments.

This broad-based methodology reflects the fact that operations engineering encompasses many disciplines and, as such, engineers must be conversant in the wide scope of service provision. The intention is to encourage students to develop a holistic approach to the design, operation, installation and maintenance of both industrial services and operating equipment.

The student will be introduced to the fundamental principles of electrical power and lighting systems, the rudiments of industrial compressed air systems, the provision of steam for both power generation and process plant, and the applications and precepts of refrigeration plant and heat pumps.

On successful completion of this unit students will be able to manage and maintain a wide range of commonly encountered industrial systems.

Learning Outcomes

By the end of this unit students will be able to:

  1. Apply the operating principles of electrical power and lighting
  2. Investigate the applications and efficiency of industrial
  3. Discuss provision of steam services for process and power
  4. Review industrial refrigeration and heat pump

Content

Electrical power:

Construction, starting and speed control of polyphase induction motors

Three-phase transformers: construction, clock number and group, parallel operation

Electrical distribution: power system topologies, efficiency, power factor causes and correction, effect on cost of supplies, circuit protection

Lighting systems:

Lighting fundamentals: SI units, energy efficient circuit design and layout LO2 Investigate the applications and efficiency of industrial compressors

Industrial compressors:

Types and applications of industrial compressors Role of intercoolers, dryers and air receivers Efficiency and performance of air compressors

Hazards and faults: safety consideration and associated legislation LO3 Discuss the provision of steam services for process and power use

Steam power plant:

Use of tables and charts to analyse wet and dry saturated steam Circuit diagrams showing steam raising plant

Process steam: enthalpy of evaporation, available energy Overall plant efficiencies for process

Power steam: superheated steam, turbine efficiency, Rankine cycle, cooling towers

Overall plant efficiency for power Efficiencies and improvements

Heat pumps and refrigeration:

Typical industrial heat pump and refrigeration systems Application of the second law of thermodynamics Reversed heat engines: reversed Carnot cycle

Vapour compression cycle

Refrigerant fluids: environmental impact Refrigeration tables and charts (p-h diagrams)

Coefficient of performance for heat pumps and refrigerators