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Advanced Gas Turbine Maintenance & Troubleshooting

Course Syllabus

SESSION 1 SESSION 2 SESSION 3 SESSION 4
GTE5 FOUNDATION GTE5 FOUNDATION GTE5 FOUNDATION GTE5 FOUNDATION
Introduction to GTE.
Format, Layout & Derivatives.
Otto & Brayton Cycles.
Pressure, Velocity & Temperature.
Divergent / Convergent Ducts.
Bernoulli's Principle.
Air intake, Compressor and Airflow. Combustion Section & Gas Flow.

SESSION 1 SESSION 2 SESSION 3 SESSION 4
GTE5 FOUNDATION GTE5 FOUNDATION GTE5 FOUNDATION GTE5 FOUNDATION
Turbine & Exhaust Systems.
Accessory Drives.
Practical Problem Solving Exercise. Investigating Intakes & Compressors.
Cold End Inspection.
Investigating Combustors, Turbines & Exhausts.
Hot End Inspection.

SESSION 1 SESSION 2 SESSION 3 SESSION 4
GTE5 ADVANCED GTE5 ADVANCED GTE5 ADVANCED GTE5 ADVANCED
Introduction to advanced GTE & Associated Systems.
GTE Industrial Applications & Comparative Equipment.
Compressor & Airflow Control. Shafts, Bearings & Seals.
Combustion Chambers.
Practical Problem Solving Exercise.

SESSION 1 SESSION 2 SESSION 3 SESSION 4
GTE5 ADVANCED GTE5 ADVANCED GTE5 ADVANCED GTE5 ADVANCED
Fuel System - Overview. Fuel System - Control. Lubrication System. Turbine.
Internal Air System.

SESSION 1 SESSION 2 SESSION 3 SESSION 4
GTE5 ADVANCED GTE5 ADVANCED GTE5 ADVANCED GTE5 ADVANCED
Exhaust.
Power Take Off Systems.
Accessory Drives.
Performance, Control & Testing. Condition Monitoring. Program conclusion and review.

Course Details

To appreciate how theoretical principles are met through varying design and construction techniques and how these affect operating parameters across differing types of Gas Turbine Engine and how this theory can be applied through practical problem solving to overcome common problems encountered with this type of equipment.
  • To investigate aerodynamic and mechanical design features.
  • To investigate major Gas Turbine Engine systems.
  • To undertake fault finding and problem solving of major Gas Turbine Engine systems.
  • To apply knowledge to undertake monitoring, inspection and maintenance methods.
  • To investigate Gas Turbine Engine performance characteristics.
 
In terms of gas turbine engine knowledge, maintenance and management. At the conclusion of this five-day program, learners should be able to:
  • Explain the mechanical and aerodynamic processes of a Gas Turbine Engine with regard to airflow and gas flow passing through an engine. In particular, the relationship between intake, compressor, combustor and exhaust.
  • Understand and fully describe major engine systems, such as fuel, lubrication, airflow control, seals and bearings, cooling air, starting, monitoring and control.
  • Conduct problem solving simulations and perform monitoring, inspection and maintenance tasks.
  • Explain engine performance characteristics and be able to fault diagnose performance anomalies.
 
The program is pitched at a level 3/4 format. That is, the average level of understanding and skill should be conducive with several years experience as a qualified technician (level 3) or that of a newly qualified or less experienced engineer or graduate (level 4).

Additionally, other engineers, managers/executives and support staff could benefit from this program as a means of an informative introduction and complementary overview to Gas Turbine Technology.

 
Assessment is conducted using a number of different methods. All methods are designed to be non-threatening and accurately measure understanding, which, in turn, assists with knowledge retention. These methods are commonly used:
  1. As an integrative and non obtrusive part of the learning process.
  2. In periodical assessment trigger points.
  3. As systematic reinforcement following topic conclusion.
  4. As a summative review of understanding and to consolidate value added knowledge.

A full report detailing an analytical performance profile is produced for each learner.

 
Portable visual aids, program notes, electronic images, problem solving exercises and all assessment material supplied. Ideally, access to a 'live' industrial gas turbine engine or a training derivative would be desirable.
 
Maximum of 6 recipients is recommended.
 
Five days.
 
Dates available on request.
 

PDF-course

Basic Vibration Analysis & Condition Monitoring (Gas Turbines)

Course Syllabus

SESSION 1 SESSION 2 SESSION 3 SESSION 4
GTECM GTECM GTECM GTECM
Introduction to the GTE.
Format and Layout of a Typical Engine.
Introduction to the GTE.
Format and Layout of a Typical Engine.
Introduction to Gas Turbine Engine Performance, Condition & Trend Monitoring. Introduction to Gas Turbine Engine Performance, Condition & Trend Monitoring.

SESSION 1 SESSION 2 SESSION 3 SESSION 4
GTECM GTECM GTECM GTECM
Properties of Air & the Atmosphere. Principles of Temperature, Pressure & Velocity. Performance Monitoring - Mass Airflow, Temperature & Power. Performance Monitoring - Exhaust Gas Temperature/Jet Pipe Temperature & Thermocouples.

SESSION 1 SESSION 2 SESSION 3 SESSION 4
GTECM GTECM GTECM GTECM
Performance Monitoring - Thrust & Rotational Speed.
Engine Pressure Ratios.
Performance Monitoring - Data Analysis.
Performance Trend Monitoring.
Practical Problem Solving. Practical Problem Solving.

SESSION 1 SESSION 2 SESSION 3 SESSION 4
GTECM GTECM GTECM GTECM
Condition Monitoring - Vibration Analysis. Condition Monitoring - Vibration Analysis. Condition Monitoring - Lubrication Systems. Condition Monitoring - Temperature Health Monitoring Systems.
Audiological Detection & Analysis Systems.

SESSION 1 SESSION 2 SESSION 3 SESSION 4
GTECM GTECM GTECM GTECM
Condition Monitoring - Data Analysis and Trend Monitoring. Practical Problem Solving. Practical Problem Solving. Program conclusion and review.

Course Details

To appreciate how theoretical and applied principles are met in relation to the parameters of both Gas Turbine Engine performance monitoring and condition monitoring and how this theory can be applied through practical problem solving to overcome common problems encountered with this type of equipment.
  • To investigate Gas Turbine Engine performance monitoring.
  • To investigate Gas Turbine Engine condition monitoring.
  • To undertake fault finding and problem solving of major Gas Turbine Engine trend monitoring systems.
  • To apply knowledge to undertake monitoring, inspection and maintenance tasks.
  • To analyse Gas Turbine Engine reliability programs.
 
In terms of gas turbine engine management - at the conclusion of this five-day program, candidates should be able to:
  • Explain the mechanical and electrical principles of a basic Gas Turbine Engine performance monitoring systems with particular regard to: mass airflow, temperature and power output; types of thermocouple and positioning, exhaust gas temperature (EGT) and jet pipe temperature (JPT), thrust and rotational speed, engine pressure ratio (EPR) and integrated engine pressure ratio (IEPR), data analysis and performance trend monitoring.
  • Explain the mechanical and electrical principles of a basic Gas Turbine Engine condition monitoring systems with particular regard to: vibration analysis, lubrication systems, temperature health monitoring outputs, audio logical detection and analysis, data analysis and performance trend monitoring.
  • Understand and fully describe typical integrated engine trend monitoring and control systems, their function and health & safety implications.
  • Conduct problem solving simulations and perform monitoring, inspection and maintenance tasks.
  • Explain engine performance and monitoring characteristics and demonstrate informed comparisons between particular systems.
 
Successful completion of a GTE five-day program or extensive post-qualification, first-hand experience within gas turbine engines and the maintenance or operating environment.
 
Assessment is conducted using a number of different methods. All methods are designed to be non-threatening and accurately measure understanding, which, in turn, assists with knowledge retention. These methods are commonly used:
  1. As an integrative and non obtrusive part of the learning process.
  2. In periodical assessment trigger points.
  3. As systematic reinforcement following topic conclusion.
  4. As a summative review of understanding and to consolidate value added knowledge.

A full report detailing an analytical performance profile is produced for each candidate.

 
Portable visual aids, program notes, electronic images, problem solving exercises and all assessment material supplied. Ideally, access to a 'live' industrial gas turbine engine or a training derivative would be desirable.
 
Maximum of 6 recipients is recommended.
 
Five days.
 
Dates available on request.
 

PDF-course

Gas Turbine Maintenance Course

Course Syllabus

The typical Gas Turbine Systems Maintenance course covers the following topics:

  • Gas Turbine Introduction
    • Explanation of how a gas turbine works
    • Introduction to the customer-specific unit
  • Gas Turbine-Generator Arrangements
    • Site turbine and accessory base arrangements and enclosures
  • Support Systems Operation and Routine Maintenance
    • Inlet and exhaust systems including inlet bleed heat (if applicable)
    • Lube oil system
    • Hydraulic oil system
    • Trip oil system
    • Seal oil system (if applicable)
    • Inlet guide vanes
    • Cooling water system
    • Cooling and sealing air system
    • Fuel system(s)
    • Atomizing air system (if applicable)
    • Water/steam injection (if applicable)
    • Purge air system(s) (if applicable)
    • Starting system, including slow-roll / cooldown function
    • Heating and ventilation systems
    • Fire protection system

Course Details

To introduce operators and maintenance personnel to the routine preventative maintenance procedures to attain high levels of availability and reliability of the gas turbine.
 
Personnel with some working knowledge of Gas Turbine operation and maintenance.
 
Video, demonstration software, training manuals.
 
Assessment is carried out on an on-going basis throughout the course and delegates will be given a written examination on completion.
 
The optimum number of the maintenance course is seven.
 
Ten days for maintenance personnel.
 

PDF-course

Gas Turbines Operation, Inspection & Maintenance, Troubleshooting

Course Syllabus

The typical Gas Turbine Systems Maintenance course covers the following topics:

  • Gas turbine general overview, operating principles, installation layout
  • Description of Gas Turbine components - air compressor, combustion chamber and principles of emission reduction, journal and thrust bearings and oil, air sealing systems, cooling and sealing air systems
  • Main Gas Turbine auxiliary systems - lube oil system, control and hydraulic oil system, starting system, gas fuel system, liquid fuel system, atomizing air system, gas detection system, fire fighting system, ventilation system, turbine inlet and exhaust air system
  • Gas Turbine control system - control and protection systems and description of gas
  • turbine start-up and shut-down sequences
  • Key parameters during Gas Turbine start-up and operation - operating parameter monitoring and operating parameter evaluation
  • Turbine performance curves
  • Gas Turbine assembly
  • Maintenance overview - operating factors affecting maintenance intervals
  • Scheduled maintenance - scheduled inspection, bore-scope inspection, disassembling and reassembling procedures and component acceptability criteria
  • Emergency maintenance
  • Spare parts required for inspections
  • Troubleshooting

Course Details

To introduce operators and maintenance personnel to the routine operation, inspection, maintenance and troubleshooting procedures required to attain high levels of availability and reliability of the gas turbine.

 
At the end of the course, the delegates will be able to:
  • Describe the principles of thermodynamics of gas turbine.
  • Identify the types of gas turbines based on its technology.
  • Describe the Gas Turbine performance.
  • Describe gas turbine principles of operation.
  • Identify major components/assembly and their function.
  • Differentiate between single-shaft and two-shaft gas turbines.
  • Describe key parameters affecting gas turbine performance.
  • Describe basic controls used in gas turbines.
 
Personnel with some working knowledge of Gas Turbine operation and maintenance.
 
Each delegate will receive a handout of the course notes plus a course CD.
 
Participants will receive an end of course assessment, if required by the client. If required, this process will be agreed with the client in advance of the course delivery.
 
The maximum number of participants is 20.
 
Five days.
 

PDF-course

Gas Turbines Operations

Course Syllabus

  • Gas Turbine Fundamentals
    • Basic theory of operation
    • Base and Machine arrangement
  • Support Systems Operation and System Checks
    • Inlet filter
    • Lube oil
    • Hydraulic and control oil
    • Cooling water
    • Cooling and sealing air
    • Fuel systems
    • Starting means
    • Heating and ventilation
    • Fire protection
  • Control System
    • Arrangements
    • Control functions and operating sequences
    • Protection functions
  • Operator Responsibilities
    • Data taking and evaluation
    • Operating limits
    • Required operator action on various annunciation indications
  • Unit Operation
    • Start-up
    • Normal operation
    • Shutdown
    • Emergency procedures

Course Details

This course is designed to enable engineers, supervisors, operations and maintenance personnel to safely operate GE designed heavy duty gas turbine units. It develops a background in gas turbine operation that will enable participants to properly analyze operating problems and take the necessary corrective action.

Emphasis is placed on the operator's responsibilities with regard to auxiliary systems, operational data taking, and data evaluation. Operators are instructed in how to interpret fault annunciation and how to determine if the annunciate fault can be remedied by operator action or by the assistance of instrumentation and/or maintenance personnel. The course focuses on the starting, loading, and specific operator checks of the various turbine support and auxiliary systems to ensure safe and reliable operation of the gas turbine unit. Also covered is the effect of operation on major mechanical maintenance.

 
Personnel with a basic knowledge of turbine technology.
 
PowerPoint and information handouts.
 
Maximum of 10 delegates per course.
 
Five days.
 
Dates available on request.
 

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Speedtronic Mark V <HMI> Operations

Course Syllabus

  • Hardware Modification and Interface
  • Revision of SPEEDTRONIC Fundamentals
    • Introduction to control function
    • Redundancy, Hardware and Security
    • Startup, Speed, Temperature and Controls
    • Fuel Systems
    • Protection Systems
  • SPEEDTRONIC Mark V HMI Control Documentation
    • Function
    • Interpretation and Use
  • Operator Interface <HMI>
    • Operation
    • Data Retrieval
    • Display Modification
  • Backup Operator Interface <BOI>
    • Operation
    • Data Recovery
  • Startup and Shutdown Sequences

Course Details

This course is designed to instruct a qualified gas turbine operator to the modifications made to upgrade the unit to a SPEEDTRONIC Mark V Control System. This course covers major topics in the fundamentals of the Gas Turbine Mark V Control System and related systems, documentation, backup operators interface <BOI> and the operator's control interface <HMI>.

Emphasis is placed on enabling operators and supervisors to confidently operate and monitor the gas turbine using the SPEEDTRONIC Mark V Control System.

 
GT operators and supervisors with a basic knowledge of turbine technology.
 
PowerPoint, information handouts, TV and video.
 
Maximum of 10 delegates per course.
 
Three days.
 
Dates available on request.
 

PDF-course

Gas Turbine Driven Centrifugal Compressors

Course Syllabus

The typical Gas Turbine Operation course covers the following areas:

  • Gas Turbine Fundamentals
    • Basic theory of operation
    • Base and machine arrangement
  • Support Systems Operation and System Checks
    • Inlet filter
    • Lube oil
    • Hydraulic and control oil
    • Cooling water
    • Cooling and sealing air
    • Fuel system(s)
    • Starting means
    • Heating and ventilation
    • Fire protection
  • Control System
    • Arrangements
    • Control functions and operating sequences
    • Protection Functions
  • Operator Responsibilities
    • Data taking and evaluation
    • Operating limits
    • Required operator action on various annunciation indications
  • Unit Operation
    • Start-up
    • Normal operation
    • Shutdown
    • Emergency procedures
    • Gas Compressor Loading and unloading
  • Anti Surge
    • Function of the anti surge system
    • Surge characteristics
    • Surge control

Course Details

This site-specific course is designed to enable engineers, supervisors, operations, and maintenance personnel to safely operate GE designed heavy duty gas turbine units. It develops a background in gas turbine operation that will enable participants to properly analyze operating problems and take the necessary corrective action.

Emphasis is placed on the operator's responsibilities with regard to auxiliary systems, operational data taking, and data evaluation. Operators are instructed in how to interpret fault annunciation and how to determine if the annunciate fault can be remedied by operator action or by the assistance of instrumentation and/or maintenance personnel. The course focuses on the starting, loading, and specific operator checks of the various turbine support and auxiliary systems to ensure safe and reliable operation of the gas turbine unit. Also covered is the effect of operation on major mechanical maintenance.

 
This course is not intended for experienced plant operation and maintenance personnel.
 
PowerPoint presentation.
 
Maximum of 10 delegates per course.
 
Five days.
 
Dates available on request.
 

PDF-course

Introduction To Heavy Duty Gas Turbine

Course Syllabus

  • Introduction Video (Major Components of the Gas Turbine)
    • The basic cycle
    • Thermo-Dynamics
    • General observations
  • Assembly and Construction
    • Turbine base and supports
    • Compressor section
    • Combustion section
    • Turbine section
    • Accessory gear assembly
    • Flexible couplings
    • Main turbine bearings
    • Starting system
  • Operating systems
  • Auxiliary systems
  • Summary and review

Course Details

This course is designed specifically for power plant personnel unfamiliar with GE Heavy Duty Gas Turbines. The program will cover Gas Turbine construction, auxiliary systems and maintenance overview.
 
On completion of the course, delegates shall be able to:
  • Understand basic gas turbine operating cycle.
  • Understand gas turbine construction features, axial flow compressor, combustion system, turbine section and accessories.
  • Understand gas turbine auxiliary systems such as lube oil system, fuel systems, starting means, etc.
  • Identify operating factors affecting maintenance intervals.
 
This course is designed for delegates with little experience in power generation but useful for personnel involved in the operation and maintenance of GE Heavy Duty Gas Turbines.
 
PowerPoint and information handouts.
 
Maximum of 5 delegates per course.
 
Two days.
 
Dates available on request.
 

PDF-course

Speedtronic Mark II Maintenance

Course Syllabus

  • GT Speedtronic Control Principles
    • Digital control elements
    • Analogue control elements
    • Fuel control
    • Gas fuel control
    • Speed control
    • Temperature control
    • Master protection
    • Digital set point (Governor)
    • Liquid fuel control
  • Gas Turbine Control Sequencing
    • On-base permissive signals
    • MCC sequencing
    • Input and output signal
    • Turbine start sequencing
    • Master protection
    • Turbine starting means and ratchet
    • Turbine control sequencing
    • Atomising and fuel purge
  • GT Control Calibration
    • Speed control
    • Temperature control
    • Fuel splitter
    • Liquid fuel control
    • Gas fuel control
    • Start-up control
    • Ground fault detection
    • Vibration protection
    • Flame detection
  • GT Control Troubleshooting
    • Introduction
    • Speedtronic power modules
    • Control function
    • Protection systems
    • Power supply systems
    • Panel field energising
    • Troubleshooting

Course Details

This course is designed to enable engineers and competent technicians to confidently calibrate the controls and diagnose problems in Gas Turbine SPEEDTRONIC Mark II control systems. The course provides a solid background in turbine governing system circuitry. Participants increase their skills in relating machine operating requirements to the SPEEDTRONIC control which establishes the vital parameters of a gas turbine prime mover.
 
Personnel with a basic knowledge of turbine technology.
 
PowerPoint and information handouts.
 
Maximum of 8 delegates per course.
 
Ten days.
 
Dates available on request.
 

PDF-course

Speedtronic Mark IV Maintenance

Course Syllabus

  • Mark IV Speedtronic Control Principles - Level 1
    • Introduction to Mark IV terminology
    • Hardware
    • Elementary diagrams and control specifications
    • System support software
    • Mark IV processor structure
  • Mark IV Speedtronic Control Principles - Level 2
    • Sequencing function
    • Control algorithm representation
    • Control application software
    • Liquid fuel control system
    • Gas Fuel control system
    • Mark IV Speedtronic control sequencing
    • On-base permissive signals
    • Input signals
    • Control system sequencing
  • Mark IV Speedtronic Control Calibration
    • Introduction
    • Speed control calibration
    • Temperature control calibration
    • Start-up/shutdown control
    • Gas fuel control
    • IGV control
    • Protection
  • Mark IV Speedtronic Control Troubleshooting
    • Introduction
    • Recommended practices
    • Installation procedures
    • Troubleshooting
    • Diagnostic fault techniques
    • Hardware test
    • Using CRT display

Course Details

This site-specific course is designed to introduce operations and maintenance personnel to the routine preventative maintenance procedures of the turbine support systems required to attain high levels of availability and reliability from the gas turbine. It does not cover the turbine-generator disassembly inspections required for major mechanical maintenance. Operating and maintenance personnel should attend this course together to develop a working relationship regarding the routine maintenance requirements of the unit.

The training includes detailed descriptions of the turbine support systems. This includes a functional description of the system was well as the routine maintenance requirements of the system. If the course is held at the customer's location it will include site visits to familiarise personnel with the location of the various system components and to allow personnel to correlate the system piping schematics to the system hardware.

 
Control and Instrumentation Technicians and Engineers with a basic knowledge of turbine technology.
 
PowerPoint and information handouts.
 
Maximum of 7 delegates per course.
 
Ten days.
 
Dates available on request.
 

PDF-course

Speedtronic Mark V <HMI> Operations

Course Syllabus

  • Gas Turbine Control Fundamentals
    • Gas turbine principles of operation
    • Governing system requirements
  • Introduction to SPEEDTRONIC Fundamentals
    • Introduction to control function
    • Redundancy, hardware, security
    • Start up, speed, temperature, controls
    • Fuel systems
    • Protection systems
    • User's manual
  • SPEEDTRONIC Control Documentation
    • Function
    • Interpretation and use
  • Operator Interface <I>
    • Operation
    • Data retrieval
    • Alarm management
    • Display modification
    • Operating system
  • Backup Operator Interface <BOI>
    • Operation
    • Alarms
    • Data Recovery
  • Start up and Shutdown Sequences
  • Troubleshooting
    • Gas turbine process alarms
    • Mark V panel diagnostic alarms

Course Details

Emphasis is placed on enabling operators and supervisors to confidently operate and monitor the gas turbine using the Speedtronic Mark V Control System.
 
Personnel with a basic knowledge of turbine technology and personal computers.
 
PowerPoint and information handouts.
 
A competence based assessment can be applied.
 
Maximum of 10 delegates per course.
 
Five days.
 
Dates available on request.
 

PDF-course

Speedtronic Mark V Maintenance

Course Syllabus

  • Gas Turbine Control Fundamentals Revision
    • Gas turbine principles of operation
    • Governing system requirements
  • Mark V Panel Hardware
    • Panel layout
    • Cores, I/O Card, Terminal Boards
    • Troubleshooting
    • Wiring diagram
  • Gas Turbine Control
    • Startup/speed/temperature/other controls
    • Protection
  • Control Displays
    • User's manual
  • Control System Software
    • IDOS
    • File descriptions
  • Software Tools
    • Modifying and downloading control configuration
    • Data acquisition on Mark V interface
    • Software backup
    • CSP and Big Block Language
  • Troubleshooting
    • Gas Turbine process alarms
    • Mark V panel diagnostic alarms
    • Rung display
  • Calibration Procedures (Manual and Auto)
    • GCV, SRV and IGV

Course Details

The Mark V Maintenance Course offers a curriculum that emphasises a hands-on approach to learning the process of monitoring, maintaining, improving the availability of the Mark V Control System. Upon the successful completion of the course, the participants will be able to:
  • Have a good knowledge of the Mark V Control System components.
  • Carry out troubleshooting and maintenance using the operator interface.
  • Have a good knowledge of the Mark V documentation.
  • Understand the flow of control signals in and out of the Mark V.
  • Carry out calibration and maintenance of servo valve regulators and feedback devices.
  • Use the control sequence program to understand the control system.
  • Understand the synchronizing system for generator drive turbines.
  • Manage alarms and customise alarm messages.
  • Understand the operator interface displays, edit and create displays.
 
Control and instrumentation technicians and engineers with a basic knowledge of turbine technology and personal computers.
 
PC projector, information handouts, TV and video.
 
Maximum of 6 delegates per course.
 
Ten days.
 
Dates available on request.
 

PDF-course

 
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