A wide range of configurations and applications are extensively utilized in the process industries. Compressors and steam turbines, in particular, constitute a substantial portion of the capital and operational expenses for most plants. As a result, the optimization of equipment selection has become a matter of significant economic importance.

Course 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 driver. 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.

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 Outlines:

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

Basic Compressor Parameters: Thermodynamics; Capacity; Power; Efficiencies; Gas Properties; Intercooling
Selection of Centrifugal Process Compressors (continued): Characteristic Curves; Stability
Compressor Train Inspection, Maintenance, Overhaul and Repair – IMO&R: IMO&R Planning, Execution, Documentation
Selection of Centrifugal Process Compressors: Calculation Methods

Compressor Maintenance, Inspection, Overhaul and Repair –IMO&R (Continued)
Operating Principles, Impulse Turbines, Reaction Turbines
Application Ranges, Configurations, Application Constraints
Turbine Rotors, Blading, Diaphragms, Nozzles, Steam Chests, Glands and Gland Systems, Bearings

Balancing, Rotor Dynamics, Governing Systems, Lube Oil Management
Overview of Selection and Sizing of Steam Turbines for Reliability:
Thermodynamics, Steam (Water) Rates, Condensing and 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)

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)

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