PROGRAM'S BACKGROUND

Maximum efficiency, reliability, and longevity of pumps, compressors, turbines, bearing and motors are of great concern to many industries. These objectives can only be achieved by understanding the characteristics, selection criteria, sizing calculations, sealing arrangements, common problems, troubleshooting, repairs techniques, preventive and predictive maintenance of those turbo-machineries. This program is a must for anyone who is involved in the selection, calculations, sizing, applications, troubleshooting or maintenance of pumps, compressors, turbines, bearings or motors. It covers how this equipment operates and provides the guidelines and rules that must be followed for a successful application. Their basic design, specification and selection criteria, sizing calculations as well as all maintenance issues including troubleshooting, vibration analysis, and used oil analysis are covered in detail.

This program is designed to provide delegates with a detailed and up-to-date overview of the fluid mechanic fundamentals and operating practice of pumps, compressors, turbines and motors. It will address aspects of both axial and centrifugal compressors. Upon the successful completion of this program, participants will have acquired the knowledge to enable them not only to choose the correct device for a particular application but also be in a position to resolve many commonly occurring operating problems.

This program is ideal for those personnel in the oil, gas, petrochemical, chemical, power and other process industries who require a wider and deeper appreciation of pumps, compressors, turbines and motors, including their design, performance and operation. No prior knowledge of the topic is required. Participants will be taken through an intensive primer of turbo-machinery principles, using the minimum of mathematics, and will learn how to solve the many and varied practical industrial problems that are encountered.

PROGRAM'S OBJECTIVES

This Program’s Attendees Will Be More Able To:

›       Apply an up-to-date knowledge and skills of the latest technologies in industrial equipment and turbo machines including pumps, compressors, turbines and motors and apply systematic techniques on selection, sizing, application, operation, testing, troubleshooting and maintenance of turbo machinery.

›       Identify the various types of compressors, performance measurements and preventive maintenance

›       Illustrate the operation and characteristics of centrifugal and axial compressors as well as compressor systems calculations

›       Define and categorize pumps and discuss centrifugal pump theory, general performance and basic components

›       List types of bearing and explain statistical nature of bearing life

›       Demonstrate viscosity of lubricants and oil analysis

›       Describe viscosity of lubricants and oil analysis

›       Describe the characteristics of induction motors including their speed control, maintenance, troubleshooting techniques and diagnostic testing for failures in three-phase stator windings

›       Illustrate vibration instrumentation and analysis, the cause of vibration and predictive maintenance

›       Implement the latest techniques and procedures of turbo-machinery maintenance and troubleshooting

›       Recognize the root causes of machine failure like the vibration and employ the proper steps to troubleshoot anomalies

›       Employ troubleshooting techniques in accordance with the turbo machinery API & ISO standards and specifications

PROGRAM'S ATTENDEES

›       Mechanical Engineers

›       Mechanical Technicians & Operators

›       Mechanical Foremen & Supervisors

›       Managers

›       Maintenance Personnel

›       Design and system Engineers

›       Inspectors, Project and Maintenance Engineers

›       Maintenance and Production Supervisors and Engineers who are dealing with industrial equipment, machinery and rotating equipment such as engineers, supervisors, foremen and other technical staff

PROGRAM'S OUTLINE

Introduction

›       Overview of maintenance function and objectives

›       Maintenance job standards

›       Maintenance types & strategies

›       Common problems associated in the rotating equipment in general

›       Definition of fluid, liquid & gas

›       Recap of basic thermodynamic laws and changes; PV, TS and other diagrams

›       Head & different types of heads, pressure, liquid power

›       Density, S.G, viscosity and their effect on performance of fluid machines

›       Basics of lubrication & lubricants

PUMPS

›       Pump definition, pump categories: dynamic and displacement reciprocating & rotary

›       Principle of operation

›       Centrifugal pumps: theory of operation of a centrifugal pump, casings and diffusers,

›       radial thrust, Impeller, axial thrust, axial thrust in multistage pumps

›       Centrifugal Pump general performance characteristics, cavitation, net positive suction head and requirements and wear ring types and function

›       Pump analysis and cavitation

›       Troubleshooting pump problems

›       Construction & installation variances such as casing design, single & multi stage; installation variances

›       Application & selection criteria

›       Performance characteristic & comparison between both types

›       Establishing the operating point and main operating parameters

›       Hydraulic disturbances, axial thrust, cavitation and NPSH

›       Affinity laws

›       Pump/system interaction

›       Flow/head control

›       Basic auxiliary equipment

›       Parallel & serial connection

OVERVIEW OF GAS TURBINES

›       Industrial heavy duty gas turbines

›       Gas turbine theory and systems

›       Major gas turbines components

›       Applications

GAS TURBINE COMPONENTS

›       Axial-flow compressor

›       Radial-inflow turbines

›       Combustors, construction types

›       Igniters

›       Fuel nozzles

›       Hot path components

›       Firing concept and emission control

MATERIALS OF CONSTRUCTION

›       General metallurgical behavior

›       Gas turbine blade materials

›       Turbine wheel alloys

›       Corrosion problem

TURBINE MAINTENANCE

›       GT operating principles, components and characteristics

›       Turbine operating checks & performance monitoring

›       Shaft, bearings and seals maintenance

›       Blades and nozzles maintenance

›       Shaft sealing system

›       Hydraulic and pneumatic systems maintenance

›       Cooling water system and water injection system maintenance

›       Starting system maintenance

›       Ducting and valves maintenance

›       Turbine troubleshooting, testing and reinstallation

CENTRIFUGAL GAS COMPRESSOR

›       Introduction

›       Types

›       Compression methods

›       Chart of compressor types

›       Compression ratio

›       Compressor

›       Compressor performance

›       Centrifugal compressor components

›       Casing

›       Impellers

›       Balancing piston

›       Guide vanes

›       Diffuser and volute

›       Diaphragms

›       Sealing

›       Shaft bearings

GAS COMPRESSOR MAINTENANCE

›       Types, application and lubrication

›       Compressor monitoring and fault diagnosis

›       Maintenance of shaft, bearings, blade and seals

›       Maintenance of filtration system

›       Gas compressor operating checks

›       Compressor installation & controls checks

›       Compressor inspection, troubleshooting practices

›       Common causes of gas compressor deterioration

FUNDAMENTAL MOTOR THEORY

›       Introduction to motors

›       Motors types

›       DC motors

›       AC motors

›       Induction motors

MAINTENANCE STRATEGIES

›       Corrective maintenance

›       Breakdown maintenance

›       Preventive maintenance

›       Predictive maintenance

›       Corrective maintenance

CAUSES OF MACHINERY FAILURE

›       Improper specifications

›       Improper sizing

›       Material deterioration

›       Overstressing

›       Material corrosion

›       Overheating

›       Fatigue failure

›       Brittlement failure

›       Misalignment

›       Cold versus hot alignment

›       Alignment tolerances

›       Imbalance

›       Causes of imbalance

›       Level of balancing

›       Vibration due to imbalance

›       Off-design operation

›       Range of acceptable operation

›       Limits of operation

›       Controlling systems

›       Loop oil systems

›       Bearings

›       Seals

›       Control systems

›       Installation problems

›       Piping stresses

ROOT CAUSE & TROUBLESHOOTING

›       Failure consequences

›       Failure Mode and Effect Analysis (FMEA)

›       Age-related failure

›       Failure which are not age-related

›       The failure process

›       The six failure patterns

›       Technical history data

›       Failure finding task

FAILURE PREVENTION

›       Failure investigation techniques

›       Proper specifications

›       Codes and standards

›       Proper operation

›       Protective and safety devices

›       Proper training

›       Monitoring systems

›       Maintenance planning

›       Problem solving & decision making techniques

APPLICATIONS & CASE STUDIES

›       Pumps

›       Fans and blowers

›       Compressors

›       Steam turbines

›       Gas turbines

ADDITIONAL DETAILS