A DIVISION OF IIR MIDDLE EAST
Learn Practical Methods To Improve The Performance Of Your Gas Turbines
Gas Turbine Reliability Management 28 February – 3 March 2010 • Villa Rotana Hotel, Dubai, UAE
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3 Learning Objectives:
Understand the effective operational management of gas turbines in power plants and LNG trains utilising focused case studies of GT24 / GT26 Examine the performance perfor mance and life assessments for gas turbines to improve operational performance and maintenance practices Assess how to minimise the likelihood of failures, ensure higher reliability and longer asset life reducing maintenance costs per hour of operation
Who Should Attend?
Course Leader
Nadeem Ahmed Senior Power Plant Engineer PK MRO (Maintenance, Repair & Overhaul) Pakistan International Airlines (PIA)
Anyone involved with industrial gas turbines – their procurement, installation, operation and maintenance maintenance including: • Power Plant Managers / Engineers • Rotating Engineers • Power Plant Per formance Managers / Engineers • Vibration Analysts • LNG Gas Turbine Engineers • Maintenance Engineers • Turbine Operators / Engineers • Operations Engineers • Mechanical Engineers • Mechanical Supervisors • Airlines Power Plant Managers / Engineers • Reliability Engineers Organised By
Ofcial Regional Recruitment Partner
www.iirme.com/gasturbine
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WAREHOUSING ADVANCED MAINTENANCE MASTERCLASS PRACTICAL MAINTENANCE PLANNING, SCHEDULING AND CONTROL PHYSICAL ASSET MANAGEMENT OPTIMISING MAINTENANCE BULK LIQUID STORAGE TANKS ELECTRICAL ENGINEERING HV SWITCHGEAR EMERGENCY RESPONSE PLANNING FLEET PLANNING, MAINTENANCE AND MANAGEMENT PUMPS DUE DILIGENCE IN OIL AND GAS PROJECT ANALYSIS FOR THE OIL & GAS INDUSTRY
Gas Turbine Reliability Management Course Timings: Registration will be at 07:30 on Day One. Each day will start promptly at 08:00 and nish at 15:30 with breaks for refreshments and lunch at appropriate intervals.
Introduction Gas Turbine Reliability Management is a comprehensive four day training course which will give you the knowledge and skills to effectively manage the reliability of gas turbines. During the course you will examine the performance and life assessment of gas turbines with an aim to improve their operational and maintenance practices, minimise the likelihood of failures and ensure higher reliability.
The knowledge you take away will help you prolong asset life and reduce maintenance costs per hour of operation. The four day course will include a mix of presentations, case studies and small breakout sessions to transform theory into practice.
Day One Gas Turbine Basics • Types and applications • Layout of systems - Pneumatic, hydraulic, fuel, oil, electrical, control - Videos • Modular concepts for maintenance/design philosophy • Gas turbine manuals - Specic operating instruction manual - Maintenance/troubleshooting manual - Overhaul manual - Standard practices manual - NDT (Non Destructive Testing)
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28 February – 3 March 2010 • Villa Rotana Hotel, Dubai, UAE
Gas Turbine Systems And Design • Control systems (typical aero/aero derivatives) • Bearing seals and drives • Concepts of bearing sumps philosophy • Turbine mechanical design • Turbine aero overview • Combustor aero design • Compressor mechanical design • Static structures • Typical failure modes/trouble shooting/diagnostics Hot Gas Path Materials And Degradation Mechanisms • Hot gas path • History of alloy development for gas turbines • Understanding the metallurgy of hot gas path components • Thermal barrier coatings: what are they and why are they used? • Main types of materials degradation mechanisms • Understanding the operation and failure mechanisms of hot gas path components Hot Gas Path Parts Management • Achieving best practice performance and life from hot gas path components • Repair vs replace decision • Creating an easy to use management system for effective parts tracking • Discovering the advantages of performance trending • Optimising maintenance scheduling Condition And Life Assessment • Condition monitoring/trend monitoring • Life assessment of parts and how to achieve longer life • Assessment procedure to facilitate optimisation of component life and repair cycles
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• Life assessment analysis (use of Six Sigma techniques) • Condition assessment of gas turbine blades (stages 1 and 2) Repair Techniques For Gas Turbine Components/Parts • Repair of hot gas path components • Which components can be repaired or reclaimed successfully? • Understanding the main processes used for repair • The various re-coating options available • Examining which repairs extend life and which don’t • Auditing the repair process Turbine Disc Life Assessment • Turbine discs/LLPs (Life Limited Parts) • Understanding LLP damage mechanisms • Contained/uncontained failures • Importance of thermo-mechanical stress analysis • Time based versus condition based remaining life • NDT requirements – what techniques should be used? • Step-by-step analysis of the disc life assessment process • Life assessment of a turbine disc
Day Two GT24 / GT26 Gas Turbine Design Features And Fleet Operating History • What is the experience with a mature eet? • What advantages are already demonstrated in the eld? • What improvements are available today? • Overview of EPRI systems • Measurement units • Characteristics of advanced industrial gas turbines GT24 / GT26 • GT24 eet history from various sites • Commissioning history • Technical problems – general eet • Life-cycle costs • Running units, service hours accumulated • Market acceptance EPRI Monitoring And Analysis Systems • Optical pyrometer – Blade Temperature Monitoring System (BTMS) • BTMS technology advancements since 1992 • Data Evaluation and Display System (DEDS) • Optical bre thermometers – hot-gas-path monitoring • Vibration monitoring system • Data collection connectivity • Flexible conguration • Data manipulation and archive • Startup/shutdown features • Efciency – MAP Thermal Performance Monitoring In GT24 / GT26 Power Plant • Performance degradation • Degradation - Recoverable by washing/cleaning - Recoverable from icing - Non-recoverable by washing/cleaning - Non-recoverable miscellaneous degradation • Turbine blade duty • Turbine blade cooling
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Fundamentals Of Vibration Analysis • Vibration data analysis • Vibration sensor types • Selection criteria for vibration sensors • Vibration characteristic basics for typical mechanical problems • Vibration severity limits
Day Three Fundamentals Of Combustion • Model specic combustion • Sequential combustion • Combustion analysis EPRI Monitoring And Analysis Systems • Blade Temperature Measurement System (BTMS) • Data collection • Blade temperature scans • Peak blade surface temperature • Difference in peak blade surface temperature within a stage • Valley of blade surface temperature • Typical plant operating modes • Blade temperature monitoring • Conrmation of blade temperature uniformity between gas turbine stages • Initial test pyrometer data, second-stage pyrometer traces, third-stage pyrometer traces • Results and conclusions from initial test data • Baseline pyrometer data, second-stage pyrometer traces, third-stage pyrometer traces • Winter and summer peaking data, second-stage pyrometer traces, third-stage pyrometer traces Methodology For Gas Turbine Performance Analysis • ISO conditions and ISO-rated values of performance parameters • Procedures to correct performance parameters to standard conditions • Corrected power output (MW) • Corrected Exhaust Gas Temperature (EGT) • Corrected air mass ow rate (exhaust) • Corrected compressor efciency (%) • Filtering of non-full-load operating conditions Turbine Base Line Performance And Degradation • Baseline performance - Power output - Exhaust gas temperature - Air mass ow rate - Heat rate • Performance degradation Analysis Of Vibration Data • Vibration monitoring • Initial vibration data analysis conclusions Long Term Service Agreements (LTSAs) • Understanding the common pitfalls in LTSAs • LTSA from a technical perspective • Insurance view on GT technology, risk and LTSAs • Warranty related issues on gas turbine parts • Discussions on LTSA experience
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Tendering For Repair/Replacement Of Parts • Understanding the importance of the information gathering process • Assessing what is critical information and what is good to have • How do you ensure the quality assurance requirements are met? • Developing a knowledge of the selection process • Learning how to produce technically procient tenders • Comparing different tenders – key factors to look for Auditing Gas Turbine Overhauls • Components of effective audits • Benets for the operator in auditing and managing major gas turbine overhauls • Determining key outcomes for overhauls • Advantages of assessing overhauls – before, during and after • Major aims of the audit process
Day Four Steam Turbines • Basic thermodynamics of steam turbines • Expansion – impact and reaction stages • Types and applications with design features • Materials for construction • Steam turbine controls - Speed - Temperature control - Ramping rate - Barring gear, critical speed-back • Condensers • Turbine blades • Prole difference in stages maintenance • Steam turbine design, blade angles, rotor design • Metallurgy, improvements, current trends • Steam turbine performance evaluation - Performance deterioration - Application software for performance monitoring - Online condition monitoring - Steam turbine operation over a life cycle - Failure analysis, lean and Six Sigma applications in RCA • Governing, bearings, journal bearings and thrust bearings • Lubrication systems, installation of steam turbines and commissioning issues
Meet Your Course Leader Nadeem Ahmed is a Senior Power Plant Engineer, PK MRO (Maintenance, Repair & Overhaul) at Pakistan International Airlines (PIA). He has more than 20 year’s experience, including six years in manufacturing and fourteen years with a power plant overhaul division involving the area of gas turbine power plant overhauling its operations, repair, testing and evaluation.
He has extensive experience in gas turbine power plant assembly lines, quality systems procedures, overhauling and maintenance work scope preparation including mini, performance and full overhaul. Nadeem is an experienced trainer in gas turbines power plants, rotating equipment, lean and Six Sigma, process improvements and reliability asset management. He has a Masters in Mechanical Engineering from the University of Engineering and Technology, Lahore, Pakistan with a major in thermal power systems engineering. He is also a Six Sigma Master Black Belt and specialises in the use of Six Sigma quality management methodology in performance/process improvement of gas turbines power plant and their systems.
Heat Recovery Steam Generator (HRSG) • Heat consumption vs temperature design of HRSG • COM GAS codes • Efciency calculations for GT 26 - With gasication - Sequential combustion Integrating The Performance Together • GT, HRSG and steam turbine • Combustion analysis as CCPP for GT24/26 • Performance curves and interpretation • Achieving optimum point for all loads conditions • Using minitab for analysis and model building for performance • Reliability factors for GT26 • Exercises Conclusion And Questions
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Gas Turbine Reliability Management 28 February – 3 March 2010 • Villa Rotana Hotel, Dubai, UAE
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Gas Turbine Reliability Management 28 February – 3 March 2010
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Course fees include documentation, luncheon and refreshments. Delegates who attend all sessions will receive a Certificate of Attendance.
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