Course Details

Objective

By end of course participants will be able to understand

• Understand the various types of turbines (steam, gas, and combined cycle) and their operational principles.
• Identify the critical components of turbines and their functions in the overall system.
• Plan and prepare for a major turbine inspection and overhaul.
• Conduct a thorough inspection of turbine components, including rotors, stators, bearings, and seals.
• Diagnose common turbine faults (mechanical, thermal, electrical) and understand troubleshooting techniques.
• Follow safety protocols and best practices during turbine maintenance and overhaul.
• Perform detailed measurements and testing to assess turbine health and performance.
• Understand the overhaul procedures, including disassembly, part replacement, reassembly, and post-overhaul testing.
• Optimize turbine performance post-overhaul through adjustments and recalibrations.

Content

Day 1: Introduction to Turbines and Inspection Fundamentals

• • Overview of turbine types (steam, gas, and combined-cycle turbines).
  • Key turbine components and their functions: rotors, stators, blades, bearings, seals, and more.
  • Basic principles of turbine operation: thermodynamics, fluid dynamics, and mechanical systems.
  • Common causes of turbine failures and the need for regular inspection.
  • Overview of turbine inspection processes.
  • Types of inspections: routine, major, and emergency inspections.
  • Documentation and reporting for turbine inspections.
  • Safety considerations during turbine inspection and maintenance.

Day 2: Major Inspection and Diagnostic Techniques

• • Preparing for a major turbine inspection: pre-inspection procedures and planning.
  • Inspection of mechanical components: blades, rotors, casings, and nozzles.
  • Inspection of thermal components: temperature monitoring, expansion, and heat distribution.
  • Visual inspections, ultrasonic testing, and non-destructive testing (NDT) methods.
  • Diagnostic tools and techniques: vibration analysis, oil analysis, and thermography.
  • Inspection of seals, bearings, and lubrication systems.
  • Troubleshooting common mechanical and thermal issues.

Day 3: Turbine Overhaul Procedures

• • Steps in the turbine overhaul process: disassembly, cleaning, inspection, and part replacement.
  • Guidelines for dismantling turbine components safely and efficiently.
  • Cleaning and restoring turbine parts: rotor blade maintenance, seal replacement, and bearing inspection.
  • Common problems encountered during turbine disassembly.
  • Reassembly of turbines: ensuring correct alignment, proper torque, and sealing.
  • Quality checks during reassembly: tolerances, surface finishes, and component inspection.
  • Post-overhaul testing: performance testing and load testing.

Day 4: Performance Testing and Post-Overhaul Adjustments

• • Performance tests to assess turbine efficiency: vibration monitoring, temperature, and pressure checks.
  • Balancing and alignment of rotating components.
  • Post-overhaul adjustments: fine-tuning for optimal performance.
  • Troubleshooting turbine malfunctions after overhaul.
  • Commissioning procedures for newly overhauled turbines.
  • Startup procedures: key considerations during turbine start-up and shutdown.
  • Data logging and monitoring during performance tests.

Day 5: Safety, Best Practices, and Industry Standards

• • Safety procedures and standards during turbine overhaul (e.g., lockout/tagout, personal protective equipment).
  • Industry standards for turbine inspections and overhauls (API, ASME, ISO standards).
  • Environmental factors affecting turbine performance: temperature, humidity, and vibration.
  • Developing a turbine maintenance strategy: preventive vs. corrective maintenance.
  • Review of the course content and key takeaways.
  • Q&A and course wrap-up.

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

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Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences.  Tests of the multiple-choice type will be made available daily to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions