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Rotating Equipment Troubleshooting and Simulation Software Training

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Course Information

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

Rotating Equipment Troubleshooting and Simulation Software Training Course

The course will introduce participants to a wide range of rotating equipment, pumps, turbines, compressors and associated equipment. The course will be supported by 3D Simulated Software programs which explains every detail. Each session will be followed by a number of self-assessment questions, answers will eventually be provided.

After completing this training, delegates will:
• Understand different types of pumps, compressors, and turbines.
• Operate pumps, compressors and turbines close to the design efficiency
• Monitor pump, compressors and turbine reliability and cost effectiveness
• Select the best operation and maintenance strategy
• Troubleshoot pump, compressor and turbine problems.

Operations, Technical Personnel in charge of production, Supervisors, Maintenance and Operation Engineers, Instrumental Engineers and Engineering Managers

Continuing Professional Development