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Ensuring Effective Operational

Management of Gas Turbines in Power Plants and LNG Trains

Gas Turbine
Reliability Management
24th – 27th May 2010, Kuala Lumpur

The Course
The introduction of high-temp gas turbines has been anything but Focused Case Study on GT24/GT26
trouble-free, with models from all manufacturers falling short of reliability and
durability expectations. However, it is still an operational imperative for you to Trainer Write-up
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 Mr S.Nadeem Ahmed has more than 20 years
• Ensure higher reliability to prolong asset life and reduce maintenance costs of engineering experience in different
• Integrate performance of Gas Turbines, HRSG, Steam Turbines in
industrial sectors with his career as a
Combined Cycle Power Plant
Mechanical Engineer with manufacturing and
process industry . For the past 15 years he is
At Course Completion
working with Pakistan International Airlines
Upon successful completion of this course, participants will be able to:
Engineering MRO facility on Maintenance
• Understand Gas Turbines Basics and Applications. Repair, Overhaul, Testing and Evaluation of
• Develop a detailed knowledge on material systems employed in gas turbo machinery. The facility is fully equipped
turbines. for General Electric, Rolls Royce, Snecma and
• Understand degradation mechanisms and how to predict them. Pratt & Whitney Turbo Machines and its static
• Trend / Condition Monitoring of Gas Turbines. and rotating equipment as accessories.
• Performance Analysis, Thermal, Mechanical etc. He has been Trained by and has Diversified
• Determine optimal linkages between condition assessments, including Experience on GE , Rolls Royce and Pratt &
mechanical and NDT, fracture mechanics and stress analysis using
Whitney Machines. His present assignments
• Examine recent advances in the ability to model the creep and fatigue
also include the Business Development of
behaviour of advanced turbine materials. Aero Gas Turbine / Aero derivative Gas
• Systematic and Practical management of gas turbine components. Turbine Repair, Refurbishment and Overhaul.
• Risk management mechanisms in relation to repair and maintenance. This requires customer interface between
• Key competencies for management decision making on overhaul scheduling OEM and existing MRO setups globally.
and condition assessment techniques. In addition Mr S.Nadeem Ahmed is an
• Work-scoping in Gas Turbine Power Plant, with emphasis on cost reduction. international conference speaker and
• Integrating Gas Turbine, HRSG , Steam Turbine in Combined Cycle Power workshop facilitator in events globally
addressing Gas Turbine Power Plants,
• Warranty and Insurances related to Gas Turbine Operation.
Rotating equipment, Reliability Engineering,
Who Should Attend Six Sigma and Lean Six Sigma. He has trained
a number of professionals in the same area
• Power Plant Managers / Engineers within and outside his organisation. He
• Power Plant Performance Managers / Engineers provisioned process companies (Fertilizer,
• LNG Gas Turbine Engineers Glass, Power Generation, Oil and Gas etc)
• Turbine Operators / Engineers Effective Reliability Improvement Programs,
• Mechanical Engineers Maintenance Management Strategies, Lean
• Airlines Power Plant Managers / Engineers Maintenance and Six Sigma Process
• Rotating Engineers Improvement Strategies integrating the same
• Vibration Analysts
with reliability solutions.
• Maintenance Engineers
• Operations Engineers
• Mechanical Supervisors
• Reliability Engineers

Telephone: +65 6506 0965 | Fax: +65 6749 7293 | Email: aeg trainings
Ensuring Effective Operational
Management of Gas Turbines in Power Plants and LNG Trains

Gas Turbine
Reliability Management
24th – 27th May 2010, Kuala Lumpur

Agenda: Day 1 Condition and Life Assessment

• Condition and life assessment.
Gas Turbine Basics • Condition Monitoring / Trend Monitoring
• Types & Applications • Life assessment of Parts and how to achieve.
• Layout of Systems • Assessment Procedure to Facilitate Optimisation of
o Pneumatic, Hydraulic, Fuel, Oil, Electrical, Control Component Life and Repair cycles
o Videos • Life assessment analysis (Use of Six Sigma Techniques)
• Modular Concepts for Maintenance / Design Philosophy • Condition Assessment of Gas Turbine Blades
• Gas Turbine Manuals ( Stages 1, 2 ------ )
o Specific Operating Instructions Manual
o Maintenance / Trouble Shooting Manual Repair Techniques for Gas Turbine Components / Parts
o Overhaul Manual • Repair of hot gas path components.
o Standard Practices Manual • What components can be repaired or reclaimed success
o NDT ( Non Destructive Testing ) fully.
• Understand the main processes used for repair
Gas Turbine Systems & Design • The various Re-Coating options available
• Control Systems ( Typical Aero / Aero Derivatives ) • Examining which repairs extend life and which don’t.
• Bearing Seals and Drives. • Auditing the repair process
• Concepts of Bearing Sumps Philosophy
• Turbine Mechanical Design Turbine Disc Life Assessment
• Turbine Aero Overview • Turbine discs / LLP’s ( Life Limited Parts )
• Combustor Aero Design • Understand LLP Damage Mechanisms
• Compressor Mechanical Design • Contained / Uncontained Failures
• Static Structures • Importance of Thermo-Mechanical Stress Analysis
• Typical Failure Modes / Trouble shooting / Diagnostics • Time based versus condition based remaining life
• NDT requirements – what techniques should be used
Hot Gas Path Materials and Degradation Mechanisms • Step by Step analysis of the Disc Life Assessment
• Hot Gas Path Process
• History of alloy development for gas turbines • Life assessment of a turbine disc
• Understanding the metallurgy of hot gas path components • Communicating policy to all stakeholders for buy-in
• Thermal Barrier Coatings, what are they and why are they
used? Agenda: Day 2
• Main types of materials degradation mechanisms
• Understand the operation and failure mechanism of hot gas GT24 / GT26 Gas Turbine Design features and Fleet
path components Operating History
• What is experience with Mature Fleet
Hot Gas Path Parts Management • What Advantages are already demonstrated in the field
• Achieving best practice performance and life from hot gas • What Improvements are Available Today
components • Overview of EPRI Systems
• Repair Vs Replace decision • Measurement units
• Create an easy to use management system for effective • Characteristics of Advanced Industrial Gas Turbines
parts tracking GT24 / GT26
• Discover the advantages of performance trending • GT24 Fleet History from Various Sites
• Optimizing maintenance scheduling • Surprises
• Commissioning History
• Technical Problems
• Technical Problems—General Fleet
• Problem Resolution
• Life-Cycle Costs
• Running Units
• Service Hours Accumulated
• Market Acceptance

Telephone: +65 6506 0965 | Fax: +65 6749 7293 | Email: aeg trainings
Ensuring Effective Operational
Management of Gas Turbines in Power Plants and LNG Trains

Gas Turbine
Reliability Management
24th – 27th May 2010, Kuala Lumpur

Agenda: Day 2
EPRI Monitoring and Analysis Systems • Results and Conclusions from Initial Test Data
• Optical Pyrometer - Blade Temperature Monitoring System • Baseline Pyrometer Data , Second-Stage Pyrometer Traces,
(BTMS ) Third-Stage Pyrometer Traces
• BTMS Technology Advancements Since 1992 • Winter and Summer Peaking Data, Second-Stage Pyrometer
• Data Evaluation and Display System (DEDS) Traces, Third-Stage Pyrometer Traces
• Optical Fiber Thermometers - Hot-Gas-Path Monitoring
• Vibration Monitoring System Methodology for Gas Turbine Performance Analysis
• Data Collection Connectivity • ISO Conditions and ISO-Rated Values of Performance
• Flexible Configuration Parameters
• Data Manipulation and Archive • Procedure to Correct Performance Parameters to Standard
• Startup / Shutdown Features Conditions
• Efficiency-MAP • Corrected Power Output (MW)
• Corrected Exhaust Gas Temperature (EGT)
Thermal Performance Monitoring in GT24 / GT26 Power Plant • Corrected Air Mass Flow Rate (Exhaust)
• Performance Degradation • Corrected Compressor Efficiency (%)
• Degradation — Recoverable by Washing/Cleaning • Filtering of Non-Full-Load Operating Conditions
• Degradation — Recoverable from Icing
• Degradation — Non recoverable by Washing/Cleaning Turbine Base Line Performance and Degradation
• Degradation — Non recoverable Miscellaneous Degradation • Baseline Performance - Power Output
• Turbine Blade Duty • Baseline Performance - Exhaust Gas Temperature
• Turbine Blade Cooling • Baseline Performance - Air Mass Flow Rate
• Baseline Performance - Heat Rate
Fundamentals of Vibration Analysis • Performance Degradation Analysis of Vibration Data
• Vibration Data Analysis • Vibration Monitoring
• Vibration Sensor Types • Initial Vibration Data Analysis Conclusions .
• Selection Criteria for Vibration Sensors
• Vibration Characteristic Basics for Typical Mechanical LTSAs ( Long Term Service Agreements )
Problems • Understanding the common pitfalls in LTSA’s
• Vibration Severity Limits • LTSA from a Technical perspective
• Insurance view on GT technology, risk and LTSAs
Agenda: Day 3 • Warranty related issues on Gas Turbine Parts
• Discussions on LTSA experience
Fundamentals of Combustion
• Model Specific Combustion Tendering For Repair/Replacement Of Parts
• Sequential Combustion • Understand the importance of the information gathering process
• Combustion Analysis • Assess what is critical information and what is good to have
• How do you ensure quality assurance requirements?
EPRI Monitoring and Analysis Systems • Developing a knowledge of the selection process
• Blade Temperature Measurement System (BTMS) • Learn how to produce technically proficient tenders
• Data Collection • Comparing different tenders – key factors to look for
• Blade Temperature Scans
• Peak Blade Surface Temperature Auditing Gas Turbine Overhauls
• Difference in Peak Blade Surface Temperature within a Stage • Components of effective audits.
• Valley of Blade Surface Temperature • Benefits for the operator in auditing and managing major gas
• Typical Plant Operating modes turbine overhauls
• Blade Temperature Monitoring • Determining key outcomes for overhauls
• Confirmation of Blade Temperature Uniformity between Gas • Advantages of assessing overhauls – before, during and after
Turbine Stages • Major aims of the audit process
• Initial Test Pyrometer Data , Second-Stage Pyrometer Traces,
Third-Stage Pyrometer Traces

Telephone: +65 6506 0965 | Fax: +65 6749 7293 | Email: aeg trainings
Ensuring Effective Operational
Management of Gas Turbines in Power Plants and LNG Trains

Gas Turbine
Reliability Management
24th – 27th May 2010, Kuala Lumpur

Agenda: Day 4 Heat Recovery Steam Generator

• Heat Consumption Vs Temperature Design of HRSG
Steam Turbine • COM GAS Codes
• Basic thermodynamics of Steam turbines. • Efficiency Calculations for GT 26
• Expansion-impact and reaction stages. o With Gasification
• Types and Applications with design features . o Sequential Combustion
• Materials for construction
• Steam Turbine controls Integrating the Performance Together
a. Speed • GT, HRSG and Steam Turbine
b. Temperature control. • Combustion Analysis as CCPP for GT24/26
c. Ramping rate • Performance Curves and Interpretation.
d. Barring gear, critical speed-back. • Achieving Optimum Point for all Loads condition
• Condensers • Using Minitab for Analysis and Model Building for
• Turbine blades Performance
• Profile difference in stages maintenance • Reliability Factors for GT26
• Steam turbine Design. Blade angles, Rotor design. • Excercises
• Metallurgy, Improvements, Current Trends
• Steam Turbine performance Evaluation. Conclusion & Questions
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

Telephone: +65 6506 0965 | Fax: +65 6749 7293 | Email: aeg trainings
Ensuring Effective Operational
Management of Gas Turbines in Power Plants and LNG Trains

Gas Turbine
Reliability Management
24th – 27th May 2010, Kuala Lumpur


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Telephone: +65 6506 0965 | Fax: +65 6749 7293 | Email: aeg trainings