Gas Turbines 24-27

Telephone: +65 6506 0965 | Fax: +65 6749 7293 | Email: [email protected] aeg trainings

Gas Turbine Reliability Management

Ensuring Effective Operational Management of Gas Turbines in Power Plants and LNG Trains

24th – 27th May 2010, Kuala Lumpur

The Course

The introduction of high-temp gas turbines has been anything but trouble-free, with models from all manufacturers falling short of reliability and durability expectations. However, it is still an operational imperative for you to ensure reliability in your gas turbines to maximise performance to your operations. Join us for a comprehensive 4 day interactive training seminar in order to give yourself an edge in effective operational management of your Gas Turbines. Gas Turbine Reliability Management is designed to give you an comprehensive understanding of the latest reliability management strategies to help you:

• Examine the performance and life assessments for gas turbines aimed at improving gas turbine operational performance and maintenance practices• Minimize the likelihood of failures• Ensure higher reliability to prolong asset life and reduce maintenance costs• Integrate performance of Gas Turbines, HRSG, Steam Turbines in Combined Cycle Power Plant

At Course Completion

Upon successful completion of this course, participants will be able to:• Understand Gas Turbines Basics and Applications. • Develop a detailed knowledge on material systems employed in gas turbines.• Understand degradation mechanisms and how to predict them.• Trend / Condition Monitoring of Gas Turbines.• Performance Analysis, Thermal, Mechanical etc.• Determine optimal linkages between condition assessments, including mechanical and NDT, fracture mechanics and stress analysis using simulation.• Examine recent advances in the ability to model the creep and fatigue behaviour of advanced turbine materials.• Systematic and Practical management of gas turbine components.• Risk management mechanisms in relation to repair and maintenance.• Key competencies for management decision making on overhaul scheduling and condition assessment techniques.• Work-scoping in Gas Turbine Power Plant, with emphasis on cost reduction.• Integrating Gas Turbine, HRSG , Steam Turbine in Combined Cycle Power Plant.• Warranty and Insurances related to Gas Turbine Operation.

Who Should Attend

• Power Plant Managers / Engineers• Power Plant Performance Managers / Engineers• LNG Gas Turbine Engineers• Turbine Operators / Engineers• Mechanical Engineers• Airlines Power Plant Managers / Engineers• Rotating Engineers• Vibration Analysts• Maintenance Engineers• Operations Engineers• Mechanical Supervisors• Reliability Engineers

BONUS! Focused Case Study on GT24/GT26Trainer Write-up

Mr S.Nadeem Ahmed has more than 20 years of engineering experience in different industrial sectors with his career as a Mechanical Engineer with manufacturing and process industry . For the past 15 years he is working with Pakistan International Airlines Engineering MRO facility on Maintenance Repair, Overhaul, Testing and Evaluation of turbo machinery. The facility is fully equipped for General Electric, Rolls Royce, Snecma and Pratt & Whitney Turbo Machines and its static and rotating equipment as accessories.He has been Trained by and has Diversified Experience on GE , Rolls Royce and Pratt & Whitney Machines. His present assignments also include the Business Development of Aero Gas Turbine / Aero derivative Gas Turbine Repair, Refurbishment and Overhaul. This requires customer interface between OEM and existing MRO setups globally.In addition Mr S.Nadeem Ahmed is an international conference speaker and workshop facilitator in events globallyaddressing Gas Turbine Power Plants, Rotating equipment, Reliability Engineering, Six Sigma and Lean Six Sigma. He has trained a number of professionals in the same area within and outside his organisation. He provisioned process companies (Fertilizer, Glass, Power Generation, Oil and Gas etc) Effective Reliability Improvement Programs, Maintenance Management Strategies, Lean Maintenance and Six Sigma Process Improvement Strategies integrating the same with reliability solutions.





Condition and Life Assessment • Condition and life assessment.• Condition Monitoring / Trend Monitoring • Life assessment of Parts and how to achieve.• Assessment Procedure to Facilitate Optimisation of Component Life and Repair cycles• Life assessment analysis (Use of Six Sigma Techniques)• Condition Assessment of Gas Turbine Blades ( Stages 1, 2 ------ )

Repair Techniques for Gas Turbine Components / Parts• Repair of hot gas path components.• What components can be repaired or reclaimed success fully.• Understand 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 / LLP’s ( Life Limited Parts )• Understand 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• Communicating policy to all stakeholders for buy-in

Agenda: Day 2

GT24 / GT26 Gas Turbine Design features and Fleet Operating History• What is experience with Mature Fleet • What Advantages are already demonstrated in the field • What Improvements are Available Today

• Overview of EPRI Systems• Measurement units• Characteristics of Advanced Industrial Gas Turbines GT24 / GT26• GT24 Fleet History from Various Sites• Surprises• Commissioning History • Technical Problems • Technical Problems—General Fleet• Problem Resolution• Life-Cycle Costs • Running Units• Service Hours Accumulated • Market Acceptance

Agenda: Day 1

Gas Turbine Basics• Types & Applications • Layout of Systems o Pneumatic, Hydraulic, Fuel, Oil, Electrical, Control o Videos• Modular Concepts for Maintenance / Design Philosophy • Gas Turbine Manuals o Specific Operating Instructions Manual o Maintenance / Trouble Shooting Manual o Overhaul Manual o Standard Practices Manual o NDT ( Non Destructive Testing )

Gas Turbine Systems & 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• Understand the operation and failure mechanism 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 • Create an easy to use management system for effective parts tracking• Discover the advantages of performance trending• Optimizing maintenance scheduling





Agenda: Day 2

EPRI Monitoring and Analysis Systems • Optical Pyrometer - Blade Temperature Monitoring System (BTMS )• BTMS Technology Advancements Since 1992• Data Evaluation and Display System (DEDS)• Optical Fiber Thermometers - Hot-Gas-Path Monitoring• Vibration Monitoring System • Data Collection Connectivity• Flexible Configuration• Data Manipulation and Archive• Startup / Shutdown Features• Efficiency-MAP

Thermal Performance Monitoring in GT24 / GT26 Power Plant • Performance Degradation• Degradation — Recoverable by Washing/Cleaning• Degradation — Recoverable from Icing• Degradation — Non recoverable by Washing/Cleaning• Degradation — Non recoverable Miscellaneous Degradation• Turbine Blade Duty • Turbine Blade Cooling

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

Agenda: Day 3

Fundamentals of Combustion • Model Specific 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• Confirmation 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 • Procedure to Correct Performance Parameters to Standard Conditions • Corrected Power Output (MW)• Corrected Exhaust Gas Temperature (EGT)• Corrected Air Mass Flow Rate (Exhaust)• Corrected Compressor Efficiency (%)• Filtering of Non-Full-Load Operating Conditions

Turbine Base Line Performance and Degradation• Baseline Performance - Power Output• Baseline Performance - Exhaust Gas Temperature• Baseline Performance - Air Mass Flow Rate• Baseline Performance - Heat Rate • Performance Degradation Analysis of Vibration Data• Vibration Monitoring • Initial Vibration Data Analysis Conclusions .

LTSAs ( Long Term Service Agreements ) • Understanding the common pitfalls in LTSA’s• LTSA from a Technical perspective• Insurance view on GT technology, risk and LTSAs• Warranty related issues on Gas Turbine Parts • Discussions on LTSA experience

Tendering For Repair/Replacement Of Parts• Understand the importance of the information gathering process• Assess what is critical information and what is good to have• How do you ensure quality assurance requirements?• Developing a knowledge of the selection process• Learn how to produce technically proficient tenders• Comparing different tenders – key factors to look for

Auditing Gas Turbine Overhauls• Components of effective audits.• Benefits 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





Agenda: Day 4

Steam Turbine • Basic thermodynamics of Steam turbines.• Expansion-impact and reaction stages.• Types and Applications with design features .• Materials for construction• Steam Turbine controls a. Speed b. Temperature control. c. Ramping rate d. Barring gear, critical speed-back.• Condensers• Turbine blades• Profile difference in stages maintenance• Steam turbine Design. Blade angles, Rotor design.• Metallurgy, Improvements, Current Trends • Steam Turbine performance Evaluation. e. Performance deterioration f. Application software for performance monitoring. g. Online condition monitoring. h. Steam Turbine operation Over Life Cycle. i. Failure Analysis, Lean and Six Sigma Applications in RCA• Governing, Bearings, Journal bearings and Thrust bearings.• Lubrication system, Installation of Steam Turbines, Commissioning Issues.• Inspection procedures during and Off Operation. j. Periodic Inspection k. Precise Inspection l. Life Assessment m. Class A, B and C Inspection. i. Rotor ii. Nozzle Diaphragms iii. Blades iv. Casings, HP, IP and LP v. Discs , Bolts vi. Turning Device vii. Valves / control Governor n. Blades , Wear limits , Twist o. Corrosion Issues, Laser Alignment p. Vibration Analysis, Steam Leakages q. NDT Techniques, i. VT: Visual Test ii. PT: Dye Penetrating Test iii. MT: Magnetic Particle Test iv. UT: Ultrasonic Test v. DM: Dimension Check

Heat Recovery Steam Generator • Heat Consumption Vs Temperature Design of HRSG• COM GAS Codes • Efficiency Calculations for GT 26 o With Gasification o 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 condition • Using Minitab for Analysis and Model Building for Performance • Reliability Factors for GT26• Excercises

Conclusion & Questions

Email: [email protected]: +65 6506 0965Fax: +65 6749 7293Post: All Events Group Pte Ltd 221 Henderson Road, Unit 01-01C Henderson Building Singapore 159557

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Documents

Gas Turbines 24-27