Oil and Gas treatment processes require specialized equipment to provide the energy to move large quantities of the liquids and gases through piping and pipelines designed for those purposes. This movement occurs from the oil and gas fields through refining and processing plants, and onwards to the storage and sales points. The equipment used for to move the fluids are termed rotating equipment. These types of equipment are used extensively and provide an increase in pressure for both liquid and gas streams to enable the passage of fluids to the required destination.
This training course will introduce delegates to different types of pumps, compressors, turbines and their associated equipment, such as bearings, seals, filters, separators, etc. The focus in this training course will be on the start-up and operation of these machines and their optimal diagnostics and troubleshooting techniques.
The training course will also enhance the technical knowledge of the operation and maintenance staff to build confidence level in start-up, follow-up, shut down and troubleshooting. The course defines the systems and subsystems that form the turbine, the potential problems with these systems and subsystems, monitoring techniques for early detection of problems, and methods to analyze the monitored variables to detect potential problems or reconstruct reasons for failures.
This training course will also cover the efficient and trouble-free operation of pumps, compressors, and turbines along with their ability to control the main operational parameters and will include an emphasis on physical principles and clear technical reasoning. Case studies are used throughout the course.
LEARNING OBJECTIVES
Attendance at the Pumps, Compressors and Turbines training course will enable participants to:
familiarize with the fundamentals of pumps, compressors and gas turbines
understand the principles of pump, compressor, and gas turbine theory of operations
understand different types of pumps, compressors and gas turbines
explain the functions and principles of operation of each of the major components of these machines and systems components
monitor pump, compressor and gas turbine reliability, availability and cost-effectiveness
know how to measure and control of performance and efficiency of these machines
understand the principles of pump, compressor, and gas turbine start-up procedures and to introduce standard operating procedures for the package
know the procedure of how to maintain and inspect the pumps, compressor and gas turbine to improve skills in executing activities in a safe and right manner
know how to inspect and diagnose the root cause of the problems
learn troubleshooting techniques for operational problems of pumps, compressors and gas turbines
define gas turbine engine
understand the GT thermodynamic cycle and engine theory
identify gas turbine parts
know the function of major package components
demonstrate the support and auxiliary systems
classify the different types of compressors
study the different types of combustion chamber and turbines
learn the recommended operating procedures
develop skills in troubleshooting
acquire knowledge of repair, inspection, and diagnosis
explore systems maintenance procedures
follow-up key performance variables and means to monitor
Evaluate turbine performance parameters during start-up and normal operation
Analyze common turbine problems, such as vibration, temp/pressure operation, and surge
TARGET AUDIENCE
The Pumps, Compressors and Turbines training course is designed to benefit all levels of Technical Personnel in the oil and gas industry as well as in chemical and process industries but will greatly benefit:
Engineering Personnel
Technical Personnel in Charge of Operations and Maintenance
Maintenance and Operation Engineers
Supervisors
Operators
TRAINING METHODOLOGY
The Pumps, Compressors and Turbines training course will utilize a variety of proven learning techniques to ensure maximum understanding, comprehension and retention of the information presented. This includes a lecture with active delegate participation including discussions, real-life problems, and case studies.
Through an active participation in the group work and class discussions, the delegates will get a lot of opportunities to increase their experience and knowledge of techniques available for equipment troubleshooting.
Pre & Post course assessments will be used to measure the effectiveness of this training.
COURSE CONTENTS
DAY 1
KeyTopics:
Pump Introduction
Hydraulics – A Few Basics
Vapor Pressure
Pump Classification
Centrifugal Pump Basics
Principle of Operation,
Pump Classifications
Mixed Flow Pumps
Axial Flow Pumps
Low-pressure & High-pressure pumps
Single-suction & Double-suction pumps
Single-stage and Multi-stage pumps
Volute & Diffuser pumps
Closed impeller, open, impeller or Semi-open impeller
Casing Construction (Radially Split, Axially Split, Double Casing)
Impeller Shrouds (Open, Partially Open, Closed)
Shaft Position (Horizontal, Vertical)
Wear Ring Running Clearances
Pump Bearings
Antifriction bearings
Journal bearings
Range of applications
Lubrication of bearings
DAY 2 – Effective Communication with Customers
KeyTopics:
Pumps Operation Procedures
Operating conditions
Pump curve against piping system curve
System curve calculation
NPSH available and required
Suction system configurations
NPSH measurement
Normal operating range
Best operating condition
The minimum flow rate limit
The maximum capacity limit
Off-design operation
Operation difficulties
Pump Troubleshooting
Pump Installation, Startup and Operation Guidelines
Pump Inspection and Performance Control
Pump Maintenance Based on Daily Observations of Pump Operation,
Diagnoses of Pump Troubles and Records of Inspections and Repairs
Control of Lubrication System
Mechanical Seals, Bearings and Couplings
Vibration Control and Analysis
Cavitation in pumps
Net Positive Suction Head
Available against required NPSH
Symptoms of cavitation
Effects of Cavitations
Avoidance of cavitation
Water Hammer Problems and Troubleshooting
General Troubleshooting Checklist
Shaft deflection
Critical speed and shaft deflection
Parameters affecting shaft deflection
Effects of shaft deflection on Mechanical seals and Bearings
Failure or Deviation Symptoms
Pump does not deliver
Insufficient capacity delivered
Insufficient discharge pressure developed
Pump loses prime after starting
Pump requires excessive power
Stuffing box / mechanical seal leak excessively
Packing / mechanical seal has short life
Pump vibrates or noisy
Bearing have short life
Pump overheats and seizes
Introduction to Compressors
First Law of Thermodynamics
Second Law of Thermodynamics
Compressor Types and Applications
Introduction to the compressor types
How a centrifugal compressor works
How a positive displacement compressor works
Different between dynamic and positive displacement compressor
How screw compressor works
DAY 3 – Handling Customer Complaints
KeyTopics:
Centrifugal Compressor Configurations and Components
Casing Configuration
Horizontally Split Compressor Casings
Vertically Split Compressor Casings
Axially vs. Radially Split
Compressor Impellers
Impeller Arrangements on Compressor Shafts
Impeller Thrust
Balance piston
Diffusers
Diaphragms
Compressor Bearings
Radial Bearings
Thrust Bearings
Compressor seals (Labyrinths, carbon rings, liquid films and dry gas seals)
Dry Gas Seals and Support Systems:
Comparison of Dry Gas Versus Wet Sealing Systems
Principles of Dry Gas Seals and Construction Features
Centrifugal Compressor Control
Performance Characteristics
The performance curves
Limits of operating speed: First and second critical speed
Effect of speed variation
Effect of inlet conditions
Effect of gas molecular weight
Performance of different types of compressors
Limits of flow rates: Surge line and stonewall line
Surge and Surge Control
Stonewall
Off-design Operation
Vibration control system
Alarm and trip system
DAY 4 - Setting and Managing Customer Expectations
KeyTopics:
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 Troubleshooting
Guidelines for trouble-free centrifugal compressor operation
Examples from recent failure incidents attributed to design defects, processing and manufacturing deficiencies, assembly errors, off-design or unintended service conditions, maintenance deficiencies, etc.
Liquid Entrainment
Compressor fouling
Cleaning Centrifugal Compressors
Compressor off-design performance, low rotational speeds, high rotational speeds
Performance degradation
Excessive vibration
Gas Turbine Basics and introduction
What’s the gas turbine?
Historic tips on gas turbines invention
Brayton thermodynamic cycle
Gas turbine as a continuous ICE
Advantages and disadvantages of a gas turbine over a diesel engine
Categories of gas turbines
Main factors affecting gas turbine performance
General package description
Core engine main components
Engine support systems
Turbine Ancillary components
Core Engine Components
Axial air compressor
Principle of operation of axial flow compressors
Characteristics of axial flow compressor
Compressor definition and function
Axial flow compressor performance
Stall and bleed valve
Compressor washing
DAY 5 – Development Plan for Improving Service
KeyTopics:
Air inlet system
Air filter
Inlet air conditioning system
Primary and secondary air
Combustion chamber
Combustion process
Combustion chamber construction and design
Combustor arrangements (tubular, can annular & annular)
Combustor chamber performance
Combustor components
Turbine stages and Exhaust
Gas turbine configuration
Blades arrangement and design
High pressure and power turbines
Turbine nozzles and blades cooling
Exhaust duct
Engine support systems
Starting system
Lube oil system
Fuel system
Control and monitoring system
Turbine Ancillary components
Acoustic enclosure
Coupling
Battery Charger
Gas and flame detectors
Firefighting system
Gas Turbine Operation and follow-up
Pre-start preparation
Start up procedures
Steady state operation follow-up
Performance evaluation
Shut down types and procedures
Alarms investigation
Gas Turbine Troubleshooting
Simplified troubleshooting flow chart
Main troubles possible causes
Gas Turbine Inspection and Overhaul
Maintenance definition and policies
Preventive maintenance PM program
Condition monitoring and diagnosis
Predictive maintenance PdM program (oil analysis, vibration analysis, boroscope inspection)
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