Best Training on Operation, Maintenance & Troubleshooting

Venue	Starting Date	Duration	Fees	Join Now
Online - Virtual ,	20230404 04 - Apr - 2023	2 Hrs X 8 Sessions	$1,750	Register
Kuala Lumpur - Malaysia ,	20230612 12 - Jun - 2023	5 - Day	$5,750	Register
Dubai - UAE ,	20230828 28 - Aug - 2023	5 - Day	$4,750	Register
Online - Virtual ,	20231031 31 - Oct - 2023	2 Hrs X 8 Sessions	$1,750	Register
Dubai - UAE ,	20231113 13 - Nov - 2023	5 - Day	$4,750	Register

COURSE OVERVIEW

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

Module 1 - Introduction and Basics of Centrifugal Pump

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

Module 2 - Operations, Trouble Shooting & Maintenance of Pumps

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

Module 3 - Thermodynamics, Compressor Basics & Operations

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

Module 4 - Centrifugal Compressor Control, Operations & Troubleshooting

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

Module 5 - Steam Turbines Basics, Components & Operation

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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