By the end of this programme, participants will:
- Understand the different types and terminology of pumps and turbines.
- Gain knowledge of bearings, coupling alignment, and their maintenance.
- Learn the components, systems, and configuration of turbines, including disassembly and inspection.
- Explore steam turbine valves and auxiliary systems for effective maintenance.
- Understand the application of Reliability-Centered Maintenance (RCM) to gas turbines.
- Develop skills in condition monitoring and maintenance of positive displacement pumps and gas turbines.
DAY 1
Introduction to Pump & Turbine Fundamentals
- Overview of pump and turbine fundamentals, including basic principles of fluid mechanics and energy transfer.
- Exploration of different pump types (centrifugal, diaphragm, peristaltic, etc.) and their specific uses in various industries.
- Understanding of pump terminology, such as flow rate, head, pressure, and efficiency.
- Pump and turbine operations: Review of the key functions, working principles, and performance characteristics of pumps and turbines, including basic system integration and energy conversion.
DAY 2
Positive Displacement Pumps and Mechanical Components
- In-depth focus on positive displacement pumps, their operation, advantages, and applications in various industries like oil and gas, water treatment, and chemical processing.
- Comprehensive study of bearings: Different types (ball, roller, sleeve) and their role in supporting rotating equipment, along with maintenance practices.
- The importance of coupling alignment in ensuring efficient transmission of torque and preventing misalignment-related issues in pumps and turbines.
- Case Study: Hands-on analysis of real-world pump and turbine failures, diagnosing causes, and applying corrective measures.
DAY 3
Turbine Components and Safety Management
- Detailed breakdown of turbine components, including rotors, stators, governors, seals, and bearings, with an emphasis on their construction and function.
- Hazards associated with turbines and pumps: Identification of operational risks such as mechanical failure, overheating, pressure buildup, and vibration. Strategies for minimizing safety risks during maintenance and operation.
- Condition Monitoring techniques and tools: Vibration analysis, temperature monitoring, and oil analysis, used to assess the health of pumps and turbines.
- Understanding turbine auxiliary systems, such as lubrication systems, cooling systems, and fuel supply systems, and their importance in turbine efficiency and longevity.
DAY 4
Turbine Configuration, Disassembly, and Inspection
- Insights into turbine configuration, including single and multi-stage designs, and their impact on performance.
- Hands-on practice in turbine disassembly: Step-by-step procedures for dismantling turbines for inspection or repair, emphasizing safe practices and precision.
- Turbine inspection: Identifying wear and tear, measuring tolerances, and determining the need for part replacement or repair.
- Examination of packaging and mechanical seals: The role of seals in preventing leaks, contamination, and the importance of selecting appropriate sealing materials.
DAY 5
Human Factors, Gas Turbine Maintenance, and Component Reuse
- Discussing the impact of human factors on turbine and pump maintenance, emphasizing training, teamwork, and safety protocols to reduce human error.
- Detailed overview of gas turbine maintenance: Procedures, challenges, and specialized maintenance requirements for gas turbines, with focus on inspection, cleaning, and repair.
- Establishing criteria for re-use and repair of combustion components: Understanding when to repair, replace, or recondition components like burners, combustors, and nozzles based on wear, performance, and cost considerations.
