Rotating Equipment Troubleshooting and Simulation Software Training

Day 1

Section 1: Rotating Equipment

• Theory of the Gas Turbine.
• Comparison with the four-stroke cycle internal combustion operation, Efficiency comparison of both.
• Cycle of operation. Effects of ambient temperature and altitude on performance.
• General description of engine and systems.
• Gas generator – compressor blades and staging, combustion chambers, CT discs & blades.
• Starting systems – types of starter – air turbine, hydraulic, electric and diesel engine starter motors
• Fuel system types – gas, liquid & dual fuel. Igniters, burners, filters and demisters.
• Lubricating oil systems. Pumps, filters and thermostatic valves and coolers etc.
• Air Systems – cooling and sealing air. Types of air intake filtration systems.
• Anti-surge systems – bleed valves, blow off valves and variable inlet guide vanes.
• Servicing – boroscope inspections, compressor cleaning etc.
• Maintenance Types- PM -PDM-RCM.

Section 2: Alignment. – An Aid to Equipment Reliability & Optimization

• Rim and face.
• Reverse.
• Universal.
• Laser – Optalign / Permalign.
• Shim correction calculations.
• The cold offset.
• Effects of temperature on alignment – process conditions, dynamic conditions, sun swing etc.
• Case Studies
• Group Studies
• Self-Assessment Questions

Section 3: Couplings

• Mechanical couplings – types and applications.
• Flexible coupling design, types, application and installation.

Section 4: Bearings

• Types – radial – sleeve, rolling element. Thrust – Tilt pad & back-to-back rolling element.
• Advantages and disadvantages of sleeve and rolling element bearings.
• Effects of oilwhirl.
• Oilwhirl – reduction of – tilt pad, pocketed and lemon bore bearings.

Section 5: Pumps

• Types and application – positive displacement/ centrifugal types – performance data – pump curves.
• Hydraulic disturbance in centrifugal pumps – cavitation – lack of N.P.S.H.
• Hydraulic balance of rotating assemblies – minimizing of axial forces – impeller arrangements – balancing drums/discs and balancing lines.
• Mechanical design – vertical/horizontal, single, multi-stage, volute/diffuser, impeller arrangements.
• Pump maintenance and trouble shooting.

Day 2

Section 6: Mechanical Seals

• Balancing of seals – meaning of and effect.
• Function, materials of construction – suitability.
• Common causes of failure.
• Sealing systems – flushing and quenching of seal faces.
• Seal face refurbishment

Section 7: Compressors

• Types – Centrifugal, Axial and Positive Displacement.
• Centrifugal types – horizontal split case, barrel, back to back side stream.
• Concept of fluid head.
• Performance relationships.
• Effects of gas density change.
• Surge and stonewall. Anti-surge methods.
• Compressor design overview – ceramic coating of wheels/ impellers and diaphragms/diffusers.
• Rotor axial thrust forces – minimizing – balancing pistons.
• Compressor sealing systems overview and types.
• Labyrinth seals – function. Wet seals, dry gas seals.
• Buffer gas and seal oil systems – heater and vacuum degassing systems.
• Process gas cooling and scrubbing systems.
• Positive displacement compressors.
• Types – reciprocating piston- single or double acting, rotary compressors, sliding vane, liquid ring, screw, and lobe.
• Principle of operation.
• Reciprocating compressors – major components – pistons and rods, x- heads, crankshafts, packing
• boxes and packing.
• Cylinder liners- wet and dry types.
• Head end / crank end clearance ratio.
• Packing – pressure breaker, radial and tangentially cut.
• Piston rod run-out, monitoring of, effect on packing
• Piston rings & rider rings, dry and lubricated liners. Monitoring rider ring wear rate.
• Valves – types. Plate, spring and channel. Suction valve unloading mechanisms.
• Lubrication systems.

Day 3

Section 8: Lubrication -Essential for Equipment Reliability

• Lubricate moving parts to minimize wear
• Lubricate to minimize power loss from friction
• Lubricate to remove heat from engine parts
• Lubricate to absorb shocks between bearing and other engine parts thus reducing engine noise and extending engine life.

Section 9: Vibration & Other Troubleshooting Techniques

• Vibration Analysis
• Thermography
• Tribology
• Process Parameters
• Visual Inspection
• NTD – Techniques
• Sorting out Imbalance and finding the Resultant Vector to insure proper Balance of Equipment