Compressor, Steam Turbine And Pumps Technology: Design, Operation, Control, Troubleshooting And Maintenance
This course introduces participants to turbomachinery equipment, (compressors, steam turbines, and pumps), fundamentals, and their principles of operation. The participants will review the various models of compressors (centrifugal and axial), different types of steam turbines, and different types of pumps as well. It provides in-depth coverage of all existing support systems such as lube oil, seal oil, dry gas seal systems, and mechanical seal as well.
The participants will learn the control systems required to keep these units in operation.
The participants will learn the correct procedures to perform routine maintenance, preventive and predictive maintenance. Also a complete tear-down and re-assembly for scheduled overhauls for different types of compressors, steam turbines, and pumps as well.
Each attendee will have pre & post-tests in order to check what we gained during the course.
At the end of the course participants will be able to:
- An understanding of what is turbomachinery equipment?
- Identify typical applications for each of the equipment.
- Identify the different types of lubrication for rotating equipment.
- Identify the different sealing systems for rotating equipment.
- Define the performance and efficiency of rotating equipment.
- Describe the function of pumps, compressors, and steam turbines.
- Identify types of pumps, compressors, and steam turbines.
- Identify the different components of pumps, compressors, and steam turbines and operation constraints.
- Identify the auxiliaries such as seals, lube oil, and cooling system.
- Implement proper techniques and procedures for turbo machinery maintenance and troubleshooting
- Implement systematic techniques for selection, sizing, application, operation, testing, troubleshooting, and maintenance of various industrial equipment and turbo machines
- Illustrate the operation and characteristics of centrifugal and axial compressors as well as compressor systems calculations
- Illustrate vibration instrumentation and analysis, the cause of vibration, and predictive maintenance.
- List types of bearings and explain the statistical nature of bearing
- To enable the attendees to grasp the advanced information in preventive as well as predictive maintenance of rotating equipment
- To present the advanced condition monitoring technologies stressing vibration and oil analysis.
All the technical staff who are involved in the operation, design, selection, maintenance & troubleshooting of pumps, compressors, and steam turbines.
A highly interactive combination of lectures and discussion sessions as well as case studies will be managed to maximize the amount and quality of information, knowledge and experience transfer. The course will be intensive but practical and highly interactive. Course material through power point equipped with necessary animation, learning videos, and general discussions will be provided.
The course participants shall be evaluated before, during, and at the end of the course.
Course Outline
- Pretest
- Discuss course objectives and outlines.
- Introduction to turbo machinery equipment.
- Compressors
- Centrifugal compressor classifications based on :
- Number of stages
- Casing type
- Seal type
- Impeller’s arrangement.
- Centrifugal and axial compressors applications
- Compressor characteristics
- Positive displacement and dynamic compressors.
- Centrifugal compressor mechanical design.
- Casing and internals:
- Impellers (types and arrangement)
- Diffusers
- Diaphragms
- Balance drum and balance line
- Bearings, types and function
- Compressor operation in process systems.
- Compressor performance:
- Performance curves
- Surge and stonewall
- Effect of gas composition
- Compressor fouling
- Affinity Laws for centrifugal impellers
- Calculating effect of speed change
- Calculating effect of impeller changes
- Startup and shutdown procedures
- Pre-start Checks
- Vibration Survey
- Run-up / Rundown Analyses
- Centrifugal compressor control and surge protection
- Anti-surge control valve
- Safety devices and logic control.
- Critical speed.
- Capacity Control Methods
- Speed Change
- Inlet Guide Vanes
- Startup /shutdown procedures of Centrifugal compressor
- Compressor seals
- Seal types: labyrinth, wet and dry seal.
- Main cause of failure of compressor seals
- Compressor preventive, predictive maintenance, and troubleshooting
- Case Study & Videos
- Recap of day1
- Lube oil system including:
- Lube oil tank
- Lube oil pumps
- Filters and coolers
- Rundown tank and accumulators.
- High vibrations, surge, high axial thrust, high bearing temperature, bearing failure, seal failure…
- Steam Turbines
- Introduction to steam turbines
- Steam turbine classifications
- Turbine Construction & Maintenance
- Construction and System
- Casings
- Diaphragms
- Stator
- Blades
- Bearings & Seals
- Rotor, journal and thrust bearings
- Internal and shaft seals
- Coupling
- Rotor Dynamics
- Balance
- Critical speeds
- Associated Systems
- Lubrication system
- Seal systems
- Condensate &condenser system, ejectors, and condensate pumps
- Turbine Characteristics
- Speed
- Specific consumption
- Efficiency
- Steam Conditions
- Influence of inlet steam state
- Effects of exhaust steam
- Control Systems
- Speed governor
- Pressure & temperature control systems
- Safety devices
- Over speed
- Overpressure
- Steam turbines preventive, predictive maintenance, and troubleshooting.
- Case Study & Videos
- Pumps
- Introduction to pumps
- Pump types and application.
- Pump classifications
- Recap of day2
- Important characteristics of pump systems
- Energy and head in pump systems
- Static Head & Total Head (NPSH)
- Pump cavitation
- Main cause of cavitation
- Pump Characteristic Curve
- Pipe Friction Calculation
- Pump Start Up and Shut Down
- Priming of Centrifugal Pumps
- Parallel and Series Operation
- Abnormal Operation
- Capacity Regulation
- Overview of Maintenance Practice
- Pump Maintenance Procedure
- Lubrication
- The role of condition monitoring in pump and
- Centrifugal Pump: Construction Performance
- Impellers
- Diffusers
- Shaft
- Bearings
- Minimum flow control
- FCV
- Yarway valve
- Pumps preventive, predictive maintenance, and troubleshooting.
- Case study and videos
- Post test