Centrifugal Compressor and Steam Turbine Design, Operations, Performance, Maintenance and Troubleshooting

Introduction

Centrifugal Compressors and Steam Turbines of several types that have widely varying configurations and applications are used extensively in the process industries. These compressors and steam turbines represent a significant part of the capital and operating costs of most plants so that optimizing selection has become of major economic importance.

The course is devoted to design features, efficiencies, operating characteristics, reliability and maintenance implications of centrifugal compressors and steam turbine drivers.

This course will cover the operating principles of centrifugal compressors and steam turbines, specifications, their design, thermodynamics, effects of efficiency on operating costs, energy usage, the effect on plant costs, special materials of construction, selection, troubleshooting, and maintenance.

The course will also cover plant run-length extension surveys, organizing for successful turnarounds and on-going reliability improvement, and preventive vs. predictive maintenance strategy decisions.

The course will provide the participant with a basic as well as advanced centrifugal compressor and steam turbine technology inventory required to successfully select, apply, troubleshoot and maintain compression and steam turbine equipment

Objectives

Upon completion of this course, participants will have gained a thorough understanding of the various centrifugal compressor and steam turbine:

Configurations available to virtually every industrial user, including mechanical design features, sizing and application criteria, maintainability, reliability, vulnerability and troubleshooting issues. Participants will learn simple techniques and short-cut methods of machinery selection, which can take the place of tedious hand calculations and will serve as rapid means to determine the sensitivity or influence of parameter changes on equipment performance. Participants will be able to determine the most appropriate and efficient matching of the compressor to steam turbine drivers. Participants will also acquire knowledge of operating and maintenance issues by getting to know mechanical design, machinery components, piping design as well as proven approaches to monitoring, troubleshooting and maintenance of compressor installations.

Training Methodology

This is a highly interactive training course with opportunities to advance your opinions and ideas. Participation is encouraged in a supportive environment. To ensure the concepts introduced during the program are understood, they will be reinforced through a mix of learning methods, including lecture-style presentations, open discussion, case studies, simulations, and group work.

Who Should Attend?

This application and the component course is intended to be of direct use by persons in staff Senior Technicians, Operators, Supervisors, Superintendents) and corporate engineering, plant planning and design, systems design, equipment selection and evaluation, and equipment maintenance areas. It should also be of value to equipment and systems specialists in engineering contractor firms. This course should also be valuable to managerial and supervisory individuals responsible for operations and maintenance functions. The industries most directly involved with the subject matter are those producing chemicals, petrochemicals, petroleum products, natural gases, manufacturing gases, steel and other metals, and plants requiring process refrigeration. Throughout the course, participants will have ample opportunity to have equipment-related questions answered by the Course Director.

Course Outline

  Day:1

• Introduction to Compressor Types: Centrifugal; Axial; Reciprocating; Helical Screw; Ranges of Application and Limitations
• Mechanical Design of Centrifugal Compressors: Compressor Side Streams, Rotors, Balancing, Rotor Dynamics, Impellers, Casings
• Mechanical Design of Centrifugal Compressors (continued): Bearings, Seals, Couplings, Controls
• Alignment Techniques and Support Criteria: Review of Dial Indicator Methods; Laser Optic Cold Alignment; On-Stream (Hot) Alignment Verification Techniques

Day 2 :     

• Basic Compressor Parameters: Thermodynamics; Capacity; Power; Efficiencies; Gas Properties; Intercooling
• Selection of Centrifugal Process Compressors: Calculation Methods
• Selection of Centrifugal Process Compressors (continued): Characteristic Curves; Stability

Compressor Train Inspection, Maintenance, Overhaul and Repair – IMO&R: IMO&R Planning, Execution, Documentation

Day 3 : Compressor Maintenance, Inspection, Overhaul and Repair –IMO&R (Continued):

• IMO&R Q & As, Troubleshooting
• Steam Turbines:
• Operating Principles, Impulse Turbines, Reaction Turbines
• Steam Turbines (Continued):
• Application Ranges, Configurations, Application Constraints

Turbine Components:

Turbine Rotors, Blading, Diaphragms, Nozzles, Steam Chests, Glands     and Gland Systems, Bearings

Day 4 : 

• Turbine Components (Continued):
• Balancing, Rotor Dynamics, Governing Systems, Lube Oil Management

Overview of Selection and Sizing of Steam Turbines for Reliability:

• Thermodynamics, Steam (Water) Rates, Condensing and nbsp; Backpressure Turbines, Single and Multistage Types, Process Considerations
• Operation and Maintenance of Steam Turbines:
• Commissioning, Startup, Run-In and Shut-down, Surveillance and Health Monitoring, Performance Measurement, Monitoring and Tracking
• Operation and Maintenance of Steam Turbines (Continued):
• Steam Turbine Washing, Steam Turbine Inspection, Maintenance, Overhaul and Repair (IMO&R)

Day 5 :      

• Basic Approaches to Machinery Troubleshooting: Examples from Recent Failure Incidents Attributed to Design Defects, Processing and Manufacturing Deficiencies, Assembly Errors, Off-Design or Unintended Service Conditions, Maintenance Deficiencies, etc.
• Predictive vs. Preventive Maintenance Techniques: Determination of Which Method to Use
• Machinery Reliability Audits and Reviews: Overview; Reliability Impact on Plants
• Written Test (Optional)