zArchive – ATP Industry Summit Short Courses

Materials in Centrifugal Compressor and Steam Turbines: Selection, Processing and Repair

Presented by: Derrick Bauer, David Dowson (Elliott Company)

Location: Hyatt – Grand Residence 103

Materials selection is significant with respect to performance, reliability, and longevity of turbomachinery, particularly given the increasing severity of the process environments. The trends are that the selection is becoming a cooperative effort between the OEM’s and the customers and it is vital that all parties understand the implications of the materials selection and necessary manufacturing processes. This course reviews the material selection for major components for centrifugal compressors and steam turbines coving topics such as materials of construction, heat treatments, properties, fabrication and manufacturing methods, inspection methods, and compliance with industry specifications such as API and NACE along with other special requirements. Going beyond new equipment, the course will touch on the identification of damage mechanisms through root cause analysis and then delve into the procedures and documentation required to restore the components to operating condition. The course will end with a discussion of various coatings and surface treatments that can also be used to enhance the performance and/or longevity of the equipment.

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Outline:

• Introduction
• Basic Materials Engineering Concepts
  • Materials and Structures
  • Ferrous Metallurgy
    • What is Steel?
    • What is the Purpose of Alloying Elements?
    • What is Stainless Steel?
• Centrifugal Comperssors
  • Review of Material Selection, Properties and Manufacturing Methods for
    • Rotating Components
      • Impellers
      • Shafts
    • Stationary Components
      • Casings
      • Diaphragms
      • Bolting
      • Piping
      • Interstage and Balance Piston Seals

• Steam Turbines
  • Review of Material Selection, Properties and Manufacturing Methods for
    • Rotating Components
      • Rotor Forgings
      • Blades
    • Stationary Components
      • Casings
      • Nozzles and Diaphragms
      • Bolting
      • Piping
      • Seals

• Turbomachinery Repairs
  • Root Cause Failure Analysis
  • Non-Destructive Evaluation Procedures
  • Welding Processes
    • Standard Procedures, Electron Beam, Laser
  • Repairs to Centrifugal Compressors
    • Casings and Diaphragms
    • Shafts
    • Impellers
  • Repairs to Steam Turbines
    • Casings and Diaphragms
    • Rotors
  • Case Studies of Repairs

• Surface Enhancements
  • Available Coating and Welding Overlay
    • Corrosion and Fouling
    • Wear Resistance
    • Liquid Droplet Erosion

Best Practices in Turbomachinery Maintenance & Reliability

Presented By: Arun Kumar (HMEL)

Location: Hyatt – Grand Residence 100

Turbo machinery in process industry is business critical equipment and in number of cases it is a single line equipment (without any stand by). Undesired stoppage of turbomachinery in between maintenance intervals can cause a severe limitation such as throughput reduction or complete stoppage of unit/ complex. This calls for a strong and focused approach towards maintenance strategizes. The maintenance work is to be completed in limited time , should be well planned , of high quality , with no rework so as to achieve high reliability & uninterrupted operation of machine afterwards with sustained efficiency for prolonged time.

For single line supercritical turbomachines the only opportunity available for maintenance and servicing is a planned turnaround. Normally, turnaround in refineries are scheduled at an interval of 4-5 years of operation. It has financial impact due to both ‘loss of production’ and ‘shutdown expenses’. At the same time, it results in increase in asset reliability, continued production, inspection and reduction in the risk of unscheduled outages or catastrophic failures.

Hence the turbomachinery maintenance has to be done with best planning & execution so that the machine performs well, as required, minimum till next turnaround cycle. Methods are being thought of to increase the span between two turnarounds which places a challenge to ensure reliability of turbomachinery for a prolonged / extended period. This can be achieved by adopting best practices in machines maintenance and reliability. The future calls for predictive analytics and early detection of faults in turbomachinery so that action can be planned and executed instead of surprise. This call for digital transformation in area of turbomachinery maintenance and
reliability.

The subject short course compiles the practical aspect of maintenance and reliability practices out of experience, learnings and facts so as to achieve the high expectation in asset safety, integrity & reliability.

The content of short course is systematically placed taking care of the attendees’ requirement and easy grasping of the practices step by steps, supported by success stories and highlights of take away at the conclusion of the short course. More coverage has been made on maintenance during turnaround as major overhauls happen during the turnaround period.

Table of content:

Section 1: Safety during Turbomachinery Maintenance (JSAs-job safety analysis, pre start safety reviews (PSSRs)

Section 2: Turbomachinery Maintenance & Reliability Challenges- Drafting the Best Maintenance Strategies. Maintenance/ Overhauling Intervals (Minor and major overhauls).

Section 3: Turbomachinery Maintenance Best Practices:

3(a): Routine/ regular maintenance practices (Daily checks, PMs on auxiliary machinery, monitoring.

3(b): Turnaround maintenance practices:
“Turbomachinery turnaround work is a specialized approach integrated with the refinery turnaround. Most of the times it is also in critical path of Turnaround”. The available duration for refinery turbo machinery mechanical work is only 15 to 18 days. Hence safe and successful completion of turbo machinery work in Turnaround depends on good planning, scheduling, spare parts management, high quality execution and monitoring.

(Job identification and scope finalization, Formation of turnaround turbo-machinery core team, Roles, responsibility and ownership matrix, best planning , scheduling , execution and tracking practices, Key reasons of success, Turnaround planning milestones for turbomachinery work, Major contracts to be awarded for turnaround turbomachinery work, close out activities)

Section 4: Standard Maintenance Procedures (SMPs), documentation, work packs, Maintenance checklists.

Section 5: Avoiding rework after Turbomachinery Maintenance. What can go wrong? , Why it happens? , How it can be avoided? (Expected results after the safe and successful turbomachinery overhauling, Rework definition, Impact & causes, typical maintenance errors and ways to avoid).

Section 6: Turbomachinery Reliability Best Practices:

6(a): Reliability Tools: RCA, FMEA, reliability risk register, Maintenance and reliability Key Performance indicators- KPIs (MTBF, MTTR, availability etc.). Condition monitoring: vibrations, performance parameters, Lube oil analysis, and frequency of monitoring.

6(b): Integrating reliability tools. Asset performance management (APM) to integrate equipment data at single location for ease in analysis, troubleshooting & selecting best maintenance strategy for asset.

6(c): Look- listen-feel -smell (LLFS), Joint rounds. Joint meetings: reliability, operation and maintenance (TRIPOD meetings) – the strong reliability strategy. Operator driven reliability.

Section 7: Powerful Execution Philosophies:
Maintenance & reliability organograms, Ensuring high performance and skill of Turbomachinery service engineers, craftsman and contractors manpower (trainings & validation).

Best Working Models – Contract v/s In-House Turbomachinery Maintenance.

Best practices in Capability of in-house maintenance: workshop, mechanical seal refurbishing shop, insitu-machining, scrapping & blue matching, dry gas seal maintenance philosophy.

Spares part Philosophies- Best practices. (What and how much to keep in stock? – Spare rotor and assemblies, dry gas seals, elastomers, capital/ insurance spares philosophies , spare warehouse rotor preservation, spare parts interchangeability)

Section 8: Looking ahead – Digital transformation of Turbomachinery Maintenance and reliability. Why transformation, IIOT solutions, Artificial intelligence (AI) and Machine learning (ML) based solutions.

Section 9: Leaning from incidents- Case studies of safe & successful turbomachinery maintenance.

Who should attend the short course?
As Turbomachinery prolonged high reliability is challenging day by day with higher expectations from business and assets? New technologies & new processes providing long run of units without stoppages ask for the alignment with best maintenance practices & enhanced reliability of turbomachinery.

The attendees of this short course can be: Turbomachinery users, OEMs, Managers / Engineers from areas:
maintenance, reliability, planning, turnaround, condition monitoring, asset integrity, operation etc.

Compressors 101

Presented By: Manoj Gupta (Guroomed), Mayank Dave (Siemens)

Location: KLCC – Boardroom 1

Introduction to Compressors

Agenda:

• Selection Process
  • Aerodynamic Selection
  • Mechanical Design
  • Rotordynamic Design
• Impellers
  • Design Basics
• Stationary Aero Components
  • Inlet, inlet guide
  • Diffuser, vaned and vaneless, LSD
  • Volute and collector
  • Return bend/Return channel
• Compressor Performance
  • Nomenclature
  • Impact of Operating Conditions
  • Internal Leakage
  • Surge Control
• Rotordynamics
• Stress analysis
• Acoustics
• Seals
  • Gas seals
  • Oil film seals
  • Laby
• Testing
• Vibration signatures of classic problems
• Materials considerations
  • NACE
  • Typical compressor materials
  • Effects of blockage and fouling

Machinery Applications in O&G

Presented By: Rainer Kurz (Solar Turbines), Klaus Brun (Elliott Group)

Location: KLCC – Boardroom 2

Outline:

• Introduction and Welcome
• Oil and Gas Applications
  • Upstream
  • Midstream and LNG
  • Downstream
• Turbomachinery
  • Gas Turbines
  • Centrifugal Compressors
  • Power Generation
  • Packaging Systems
    • Air Filtration
    • Off Shore
• Control
  • System Behavior and Process Control
  • Surge Control
• Testing of Turbomachinery
  • Concepts
  • Factory Test
    • ASME Power Test Codes
  • Field Performance Test
• Questions and Conclusion