Turbomachinery Reliability, Inspection, Maintenance, Repair and Audits

“TAKE ADVANTAGE OF THIS EXCELLENT OPPORTUNITY TO LEARN COMPRESSOR & TURBINE THEORY AND EASY PRACTICAL METHODS TO TROUBLESHOOT TURBOMACHINERY”

Instructor: Anibal R Arias – SEMTEC (view profiles)
Upcoming Session : Yogyakarta, 28 October – 1 November 2013

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  • Bearings & Seals, Vibration, Lube & Seal Oil Systems, Condition Based Maintenance & Modernization Strategies
  • Optimize Your Condition Based Equipment Reliability Program
  • Maximize Plant Production & Reliability
  • Confirm OEM Performance Guarantee
  • Optimize Equipment Utilization

Course Objective:
Basic turbomachinery operation and maintenance and easy, practical methods to troubleshoot turbomachinery problems. Improving plant production and reducing maintenance costs.

Who Should Attend:
The people attending the course should be technical personnel interested in better understanding turbomachinery (operators, engineers & technicians, reliability specialists, project engineers, equipment specialists and planning engineers).

Course Content Details:
PART 1: THE TURBOMACHINERY WORLD.
Introduction to Turbomachinery: Definition of turbomachinery. Driver and driven machines. Applications.
Steam Turbines: Different type of steam turbines. Casing and stationary components. Rotors. Auxiliary systems: Speed control systems. Over speed protection systems. Steam Condensers. Vacuum systems.
Gas Turbines: Industrial and Aero derivative Gas Turbines. Air compressor. Combustors. Gas generator and power turbine. Auxiliary Systems.
Turbocompressors: Turbocompressors purpose. Head, work and efficiency. Axial compressors. Centrifugal compressors. Aerodynamic components: Impellers, diaphragms, guide vanes. Interstage seals. Balance piston seal. Impeller thrust. Internal compressor configuration: Straight thru, double flow, back to back, multi-stage iso-cool, side-load.
Journal and Thrust Bearings: Different type of journal bearings: plain, pressure dam and tilting pad. Tilting pad thrust bearings. Bearing installation. Bearing instrumentation. Bearing damage.
Shaft End Seals: Different type of seals: Labyrinth, restrictive (carbon), mechanical contact and dry gas seals. Wet seals problems. Dry gas seals problems. Operational cares.
Couplings: Different type of couplings. Lubricated versus non lubricated couplings. Coupling installation. Coupling failures.
Lube and Seal Oil Systems: Oil systems. Components details: Oil reservoir, pumps, relief valves, transfer valves, oil coolers, filters, regulators, instrumentation, accumulators, rundown tanks, mist eliminators, degassing tank. Lube and seal oil system common problems.
Turbomachinery Instrumentation: Pressure, temperature and flow measurements. Anti-surge control strategies.

PART 2: TURBOMACHINERY RELIABILITY.
From Statistics to Practical Turbomachinery Reliability: Probabilistic Approach. Failure Rates. Mean time between Failures (MTBE). Availability. Maintainability. Turbomachinery Maintenance Philosophies: Run to failure, Preventive Maintenance, Predictive Maintenance, Condition Based Maintenance, Proactive Maintenance. Failure Mode and Effect Analysis (FMEA). Example: FMEA of a Turbocompressor.
How to establish an Optimized Turbomachinery Maintenance Plan. Turbomachinery Health Analysis and Monitoring.
Specific Problems of Turbomachinery: Steam Turbines: Steam deposits problems. Foreign Objects Damage (FOD). Erosion. Corrosion. Stress Corrosion Cracking. Gas Turbines: Recoverable and Non-Recoverable Losses. Compressor, Combustor and Power Turbine degradations. FOD. Contaminants. Fouling. Erosion. Corrosion. Hot corrosion. Oxidation. Creep. Ageing. Fatigue. Common failures of gas turbine blades. Centrifugal Compressors: Aerodynamic components fouling. Impeller damage due to operation in choke. Liquid slug. Erosion.

PART 3: TURBOMACHINERY INSPECTION, MAINTENANCE AND REPAIR.
Turbomachinery Inspection and Maintenance: Disassembly, inspection, maintenance and assembly of a turbocompressor.
Steam and Gas Turbines Inspection. Checks to be done. Remaining life prediction and life extension of gas turbines.
Turbomachinery Repair: Rotor repair (API 685). Casing repair. Repair of hot gas path components.
Turbomachinery modernization strategies: Presentation of the state of the art of turbomachinery hardware associated with optimum performance. Copper backed journal and thrust bearings. Dry gas seals. Aerodynamic hardware. Coatings. Non lubricated couplings. Anti-surge controllers and valves.

PART 4: TURBOMACHINERY DESIGN AUDITS
Machinery Design Audits: How to conduct a review of design/operational values & compare to max allowable values and how to establish those upper limits. Turbomachinery Vibration: Rotordynamics, Instability and its vibrational behavior, Torsional & lateral critical speeds & analysis, interference maps, Campbell diagrams, Field vibration operating limits. Review of component stress & frequency analysis. Bearing & seal operating parameters and limits. Nodal analysis techniques. Aero path design & evaluation. Understanding FEA & CFD vs. other calculation methods and how to relate all of this to the long term reliability of your machinery.