Rotating Equipment Design, Selection, Operation & Maintenance

The rotating equipment (turbomachinery) are very important facilities in many industries, power plants, sea ships, air crafts and military applications. Turbomachinery family includes centrifugal/axial pumps, centrifugal/axial compressors and gas/steam turbines, where all are based on the principle of turbo-action where a shaft with blades is rotating to impart or extract energy to or from a fluid (gas or liquid). This course will present a scientific & practical background/knowledge to refresh and correlate the theory with the practical applications regarding design basis, operation, maintenance & troubleshooting showing the possible and potential reasons behind the energy losses and problems may face the operation staff and how to analyze them to define the proper solutions and troubleshooting based on science, experience and recommended practices.

Audience

This course is designed for:

Professionals dealing with the operation and maintenance of rotating equipment
New technicians who wish to improve knowledge and skills
Those who are involved in condition monitoring of machines
Maintenance technicians who are in charge of correcting the turbomachinery problems.
Engineers and maintenance planners involved in turbomachinery design and machine’s condition monitoring.

Course objectives

By the end of the training, participants will be able to:

Understand the basics of design, selection of turbomachinery
Understand how power imparted or extracted to/from a turbomachinery
Classify the turbomachinery families
Deep understanding of centrifugal & axial pumps basics and reasons behind losses and possible troubles and how to deal with them scientifically
Deep understanding of centrifugal & axial compressors basics and reasons behind losses and possible troubles and how to deal with them scientifically
Understanding roto-dynamic pump cavitation
Understanding roto-dynamic compressor surge
Understanding topping & bottoming
Understanding steam turbine thermodynamic cycle, latent heat & useful work taken from the steam
Understanding the gas turbine thermodynamic cycle, useful work taken from the combustion hot gases
Heat recovery in steam & gas turbines

Course contents

Day-1

Pretest
Review of important fluid mechanics, first & second laws of thermodynamics
Introduction & turbomachinery equipment families
Theory of centrifugal pump
Classification of centrifugal pump family
Momentum and velocity triangles
Euler’s power equations
Single stage centrifugal pump components & construction
Radial & axial loads in centrifugal pump
Losses in centrifugal pump that change H-Q curve from linearity to curved shape
Multistage centrifugal pump & axial loads reduction techniques (holes, back vanes, balancing drum,…etc)
Centrifugal pump performance & pump operation optimization
Centrifugal pump maintenance & troubleshooting scientific practical way

Day-2

Theory of centrifugal compressor
Classification of centrifugal compressor family
Single stage centrifugal compressor components & construction
Radial & axial loads in centrifugal compressor
Multistage centrifugal compressor & axial loads reduction techniques
Surge & how to deal with it
Centrifugal compressor performance & compressor operation optimization
Centrifugal compressor maintenance & troubleshooting scientific practical way

Day-3

Steam turbine cycle
Types of steam turbines
Topping & bottoming & thermal/electrical ration concept
Steam turbine in power generation
Steam turbine as pump & compressor prime-mover
Steam turbine in sea ship liners for propelling purpose
Cogeneration & waste heat recovery
Steam turbine maintenance & troubleshooting

Day-4

Gas turbine cycle
Types of gas turbines
Gas turbine in power generation
Gas turbine as pump & compressor prime-mover
Gas turbine in air crafts
Gas turbines in military applications
Gas turbine impulse & reaction
Gas turbine maintenance & troubleshooting

Day-5

Couplings overview
Bearings overview
Equipment failure modes (bathtub curve)
Maintenance policies & which is suitable for our turbomachine
An application of a centrifugal pump design (piping diameters, impeller dimensions, blade angles, pump shaft & pump electric motor HP)

Posttest

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