Centrifugal Compressors Maintenance & Failure Analysis
Centrifugal Compressors Maintenance & Failure Analysis
OBJECTIVES
- Learn the principles of the centrifugal compressors and gas turbine.
- Familiarize the participants with various types of centrifugal compressor & gas
- Understand the operation principles of the centrifugal compressor and gas
- Learn the maintenance procedure of the centrifugal compressor and gas turbine.
- Discuss the troubleshooting and failure analysis of the centrifugal compressor and gas turbine
WHO SHOULD ATTEND?
Turbine & compressor maintenance engineers of relatively short experience and senior technicians of medium experience who have the ability to improve & develop their capabilities. Members of the following departments: Engineering, Planning, Procurement, Operation, Maintenance or Inspection and those who are engaged in or intend to be familiar with compressor systems. Also senior staff should update and refresh their knowledge by attending this course and their solutions.
COURSE OUTLINE
- Introduction.
- What is a compressor?
- Compressor terminology
- Compressor classification
- (Centrifugal – axial – reciprocating –helical- screw, ranges of application)
- Compressor finite-life parts (bearings-mechanical seals-couplings…..)
- Compressor Drivers
- Overview of maintenance function and objectives.
- Maintenance job standards.
- Maintenance types & strategies.
- Common problems associated in the rotating equipment in general.
PRINCIPLES OF CENTRIFUGAL COMPRESSORS
- Theoretical H-Q curve.
- Theoretical Power-Q curve.
- Performance curves.
- Centrifugal compressor classification
- Basic components and their function
- The effect of outlet blade angle
- Function of the diffuser
CENTRIFUGAL COMPRESSOR OPERATION
- Compressor start-up and shut down.
- Speed limits.
- Required speed calculations
- System Resistance
- Inlet conditions Effects
- Parallel and series operation
CENTRIFUGAL COMPRESSOR MAINTENANCE
- Maintenance strategies
- Lubrication Systems
- Inlet Filtration
- Sealing Systems
- Shaft Deflection
- Rotor Balancing
- Shaft Alignment
CENTRIFUGAL COMPRESSOR TROUBLESHOOTING AND FAILURE ANALYSIS
- Troubleshooting procedure
- Site inspection
- Monitoring systems
- Surge line and stonewall.
- Anti-surge control system
- Excessive vibration
- Check list of compressor problems
PREDICTIVE MAINTENANCE PROGRAM
- Building a system
- Equipment data
- Failure data
- Maintenance data
- Data format
- Failure and maintenance notations
- Failure descriptors
- Failure causes
- Method of detection
- Maintenance activity
DATA REQUIREMENTS FOR VARIOUS APPLICATIONS OF GAS TURBINES
- Industrial heavy duty gas turbines
- gas turbine theory and systems
- Major gas turbines components
- Applications
PRINCIPLES OF GAS TURBINE
- Gas Turbine Components (Compressor-Turbine-Combustor-Ancillary & Auxiliary Systems)
Gas Turbine Components
- Axial-flow compressor
- Radial-inflow turbines
- Combustors, construction types
- Igniters Day 3
- Hot path components
- Firing concept and emission control
- Fuel nozzles
- Air standard cycles and other famous cycles.
- Turbine performance characteristics.
- Main requirements of a gas turbine engine
GAS TURBINE OPERATIONS
- Pre Start Checks
- Starting Sequence
- Loading/Unloading Operations
- Shutdown Sequence
GAS TURBINE CHECKS
- Inlet filter
- Lubricating oil
- Hydraulic and control oil
- Cooling water
- Cooling and sealing air
- Fuel system(s)
- Starting means
- Heating and ventilation
- Fire protection
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. Vibration analysis