Fundamentals of Rotating Equipment in Industry: Engineering, Operation and Maintenance

Fundamentals of Rotating Equipment in Industry: Engineering, Operation and Maintenance

Date/Time: Date(s) - 11/07/2022 - 13/07/2022( 8:00 am - 5:00 pm )
Location: Malaysia, Kuala Lumpur


Overview

It is extensive work, in a few days, covering the main Rotating Equipment used on sites of industrial engineering. They are mainly, pumps, compressors, and gas turbines. Mechanical seals and dry gas seals are also covered. The course is addressing the fundamentals of Rotating Equipment technology, in a practical approach, that is essential to understand the operation and maintenance of such critical equipment. Several selected case studies of failure analysis are included at the end of each topic. Through the course, high-quality short video clips are presented with comments and clarifications made by the instructor, enhancing the addressed concepts. Whenever relevant, reference is made to API standards, as applied to Rotating Equipment in industrial engineering. It is an interactive course as everyone is sharing his problems on site. Accordingly, the participants are encouraged to bring to class any supporting materials for detailed discussions. Considerable time is allocated for this activity. Each participant shall receive printed slides, in addition to a soft copy of the course materials. All of them shall be added to our rotating equipment group in WhatsApp for future sharing of interesting issues.

Who Should Attend?

  • Mechanical engineers who are involved in the selection, operation, maintenance, and failure analysis of Rotating Equipment.
  • Process and control engineers.

Objectives

A) Centrifugal Pumps

  • A clear understanding of hydraulic principles applied to centrifugal pumps, which enable the participant to improve the operation and maintenance of pumping systems
  • Understanding of classification of centrifugal pumps as per API 610 international standards.
  • Provide the participants with the essential tools in order to successfully select and size the suitable pump for a specific application.
  • Provide the participants with the methods required to calculate the net positive suction head, and how to improve it on-site to assure smooth operation and avoid pump cavitation.
  • Provide the participants with practical methods used for pump performance test on-site.

B) Centrifugal Compressors

  • Understanding the design features of critical components of compressors. That will provide the participants with a tool to understand failure mechanisms of such components, and hence they can carry out a conclusive Root Cause Analysis (RCA).
  • Understanding of characteristic curves of centrifugal compressors, and effect of changes on gas molecular weight, suction, and discharge conditions.
  • A clear understanding of anti-surge systems, and how to improve the compressor operating range.
  • Review typical Process Flow Diagrams (PFD) and Process and Instrumentation Diagrams (P&ID).

C) Gas Turbines

  • Review the basics of thermodynamics applied in gas turbines and review different types of gas turbines and their application.
  • A Clear understanding of the design features of the main components of gas turbines, focusing on aeroderivative and light industrial machines used offshore.
  • Highlighting the function of each system supporting gas turbine packages, including fuel system, lube, and hydraulic systems, air system, and a brief overview of control and protection system.
  • Understanding of performance parameters of the gas turbine.
  • Enhance the capabilities of troubleshooting and failure analysis through discussion of case studies.

D) Mechanical Seals and Dry Gas Seals

  • Understanding the basics of mechanical seals.
  • Detailed demonstration on a typical seal system, Plan 53B, used in hydrocarbon application.
  • Understanding of the basics of dry gas seal used in centrifugal compressors, including seal systems.
  • Review typical failures of dry gas seals and how to avoid them

Course Outlines

Module 1: Centrifugal Pumps

Basics of Centrifugal Pumps

  • Hydraulic Principles
  • Impeller Types
  • API 610 Pump Types
  • Double Volute Casing
  • Axial Thrust
  • Pump Characteristic Curve and System Curve
    • Best Efficient Point (BEP)
    • Shut off Point
    • Operating Point
    • System Curve Calculation
  • Pump Selection and Sizing

Centrifugal Pump Operation

  • Minimum Flow
  • Allowable Operating Range
  • Preferable Operating Range
  • Cavitation
  • Unstable Pump Curve
  • Starting Up Procedures
  • Pumps in Parallel and in Series

Net Positive Suction Head (NPSH)

  • Definition
  • Vapour Pressure
  • NPSH Required (NPSHR) Calculation
  • NPSH Available (NPSHA) Calculation
  • Improving NPSHA

Module 2: Centrifugal Compressors

Basics of Centrifugal Compressors

  • Compressor Arrangement
  • Impeller types
  • Axial thrust
  • Balance Drum
  • Tilt pad thrust and journal bearings

Performance of Centrifugal Compressors

  • Characteristic curves and operating range
  • Surge line
  • Chock line
  • Effect on performance due to changes of:
    • Gas molecular weight
    • Suction conditions
    • Discharge conditions

Anti-surge System

  • How it works
  • Typical PIDs and FDs

Lube Oil System

  • Main components
  • Overhead run-down tank

Failure Analysis and the Troubleshooting

  • High thrust bearing temperature

Module 3: Gas Turbines

Basics of Gas Turbines

  • Thermodynamics.
  • Comparison with reciprocating engines.
  • Design features of main Components.
  • Types of gas turbines, heavy industrial, light industrial, and aero-derivative gas turbines.

Performance of Gas Turbines

  • Performance parameters.
  • Compressor wash.
  • Borescope inspection.

Gas Turbine Supporting Systems

  • Air intake system.
  • Lube and hydraulic system.
  • Fuel system.
  • Control and protection system.
  • Startup sequence.

Typical Failure Analysis

  • Hot corrosion of turbine blades.

Module 4: Mechanical and Dry Gas Seals

  • Mechanical Seal Plan 53B for Hydrocarbon.
  • Basic Principles of Dry Gas Seals.
  • Tandem Seal Arrangement.
  • Failure analysis.
  • Seal Hang up.

Training Methodology

  • Case Studies.
  • Individual and group discussions and exercises.
  • Intensive training by using templates, diagrams, and charts.
  • Planning activities and presentations.
  • Self-assessments.
  • Action plan.

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This course is fully booked.

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