Learn Practical Methods To

Improve The Performance Of

A DIVISION OF
IIR MIDDLE EAST Your Gas Turbines

Gas Turbine Reliability

Management
28 February – 3 March 2010 • Villa Rotana Hotel, Dubai, UAE

Top 3 Learning Objectives:

1  nderstand the effective operational management
U
of gas turbines in power plants and LNG trains
utilising focused case studies of GT24 / GT26

2 Examine the performance and life assessments for

gas turbines to improve operational performance
and maintenance practices

3 Assess how to minimise the likelihood of failures, Course Leader

ensure higher reliability and longer asset life Nadeem Ahmed
reducing maintenance costs per hour of operation Senior Power Plant Engineer
PK MRO (Maintenance, Repair &
Overhaul)
Pakistan International Airlines (PIA)
Who Should Attend?
Anyone involved with industrial gas turbines – their procurement,
installation, operation and maintenance including:
• Power Plant Managers / Engineers • Rotating Engineers
• Power Plant Performance 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 Official Regional Recruitment Partner

www.iirme.com/gasturbine
 AA DDI IVVI ISSI IOONN OOF F
I II IRR M
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Industrial 2010 Calendar JAN FEB MAR APR

3 10 17 24 31 7 14 21 28 7 14 21 28 4 11 18 25 2
MAY JUN JUL
9 16 23 30 6 13 20 27 4 11 18 25 1
AUG SEP OCT NOV DEC
8 15 22 29 5 12 19 26 3 10 17 24 31 7 14 21 28 5 12 19 26

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 28 February – 3 March 2010 • Villa Rotana Hotel, Dubai, UAE

Course Timings: Gas Turbine Systems And Design

Registration will be at 07:30 on Day One. Each day will • Control systems (typical aero/aero derivatives)
start promptly at 08:00 and finish at 15:30 with breaks for • Bearing seals and drives
refreshments and lunch at appropriate intervals. • Concepts of bearing sumps philosophy
• Turbine mechanical design
Introduction • Turbine aero overview
• Combustor aero design
Gas Turbine Reliability Management is a comprehensive • Compressor mechanical design
four day training course which will give you the • Static structures
knowledge and skills to effectively manage the reliability • Typical failure modes/trouble shooting/diagnostics
of gas turbines. During the course you will examine the
performance and life assessment of gas turbines with Hot Gas Path Materials And Degradation Mechanisms
an aim to improve their operational and maintenance • Hot gas path
practices, minimise the likelihood of failures and ensure • History of alloy development for gas turbines
higher reliability. • Understanding the metallurgy of hot gas path
components
The knowledge you take away will help you prolong asset • Thermal barrier coatings: what are they and why are
life and reduce maintenance costs per hour of operation. they used?
The four day course will include a mix of presentations, • Main types of materials degradation mechanisms
case studies and small breakout sessions to transform • Understanding the operation and failure mechanisms of
theory into practice. hot gas path components

Hot Gas Path Parts Management

Day One • Achieving best practice performance and life from hot
gas path components
Gas Turbine Basics • Repair vs replace decision
• Types and applications • Creating an easy to use management system for
• Layout of systems effective parts tracking
- Pneumatic, hydraulic, fuel, oil, electrical, control • Discovering the advantages of performance trending
- Videos • Optimising maintenance scheduling
• Modular concepts for maintenance/design philosophy
• Gas turbine manuals Condition And Life Assessment
- Specific operating instruction manual • Condition monitoring/trend monitoring
- Maintenance/troubleshooting manual • Life assessment of parts and how to achieve longer life
- Overhaul manual • Assessment procedure to facilitate optimisation of
- Standard practices manual component life and repair cycles
- NDT (Non Destructive Testing)

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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 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
• Commissioning history
• Technical problems – general fleet
• 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 fibre 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
- 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 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
• Procedures 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
- Exhaust gas temperature
- Air mass flow 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 Meet Your Course Leader
• Understanding the importance of the information
gathering process
• Assessing what is critical information and what is good Nadeem Ahmed is a Senior Power Plant
to have Engineer, PK MRO (Maintenance, Repair &
• How do you ensure the quality assurance requirements Overhaul) at Pakistan International Airlines
are met? (PIA). He has more than 20 year’s
• Developing a knowledge of the selection process experience, including six years in
• Learning how to produce technically proficient tenders manufacturing and fourteen years with a
• Comparing different tenders – key factors to look for power plant overhaul division involving the area of gas
turbine power plant overhauling its operations, repair,
Auditing Gas Turbine Overhauls testing and evaluation.
• Components of effective audits
• Benefits for the operator in auditing and managing He has extensive experience in gas turbine power plant
major gas turbine overhauls assembly lines, quality systems procedures, overhauling
• Determining key outcomes for overhauls and maintenance work scope preparation including
• Advantages of assessing overhauls – before, during and mini, performance and full overhaul.
after
Nadeem is an experienced trainer in gas turbines
• Major aims of the audit process
power plants, rotating equipment, lean and Six Sigma,
process improvements and reliability asset
management.
Day Four
He has a Masters in Mechanical Engineering from the
Steam Turbines
University of Engineering and Technology, Lahore,
• Basic thermodynamics of steam turbines
Pakistan with a major in thermal power systems
• Expansion – impact and reaction stages engineering. He is also a Six Sigma Master Black Belt
• Types and applications with design features and specialises in the use of Six Sigma quality
• Materials for construction management methodology in performance/process
• Steam turbine controls improvement of gas turbines power plant and their
- Speed systems.
- Temperature control
- Ramping rate
- 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
- 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

Heat Recovery Steam Generator (HRSG)

• Heat consumption vs temperature design of HRSG
• COM GAS codes
• Efficiency calculations for GT 26
- With gasification
- 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
IIR Middle East certified by

28 February – 3 March 2010 • Villa Rotana Hotel, Dubai, UAE

ISO 9001 : 2000

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P.O Box 21743 P.O Box 13977
Dubai, UAE Muharraq
971-4-3352438 Kingdom of Bahrain

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Event Early Bird Discounts WEB BC3660

Gas Turbine Reliability Management Price before 17 January 2010 Final Price
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