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Mechanical Rotating Technical
11 – 15 Dec, 2016
SAHARA Petrochemical Company.
Developed and Presented by: Mr. Barrak Al Bogami
Experience the Differe
nce
Coral Hotel / Al-Jubail, Saudi Arabia 8: 00 am. To 3: 00 pm.
Break Time
Mobile Silent Status
Attendance
Participation
Understanding Others
Ground Rules
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Participants’ Introduction
• Name
• Company / Dept. / Div.
• Job Title
• No. of Service Years
• How can you describe your self?
Proposed Daily Schedule
Session # 1 08:00 – …….
Break
Session # 2
Short Break
Session # 3
Prayer/Lunch Break
Session # 4
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ROTATING EQUIPMENT OPERATION&MAINTENACE.
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Introduction
• Steam turbines work by converting external heat into more useful energy.
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Steam cycle
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Purpose
Used to drive a generator or mechanical machinery
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Energy Conversion
• Steam turbines convert steam pressure energy
into blade velocity energy
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Impulse Stage Reaction Stage Velocity –Compound Stage and Reaction Stages
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Types
• 1. Condensing
• 2. Non-Condensing (Backpressure)
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Condensing steam turbines
• Are used in most large power plants. Used steam goes from the turbine into a condenser or series of condensers to ensure that the maximum amount of heat can be extracted.
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Condensing steam turbines
• Advantage:
The most efficient steam turbine cycle
• Disadvantage:
The most expensive
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Dual Containing Condensing & Non-Condensing
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Backpressure systems
• Function by using high pressure steam to drive a turbine, leaving
lower pressure steam or hot water that can be used for other
processes.
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Non- Condensing (Backpressure)
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Backpressure systems
• Advantage:
Low Cost
• Disadvantage:
Less efficient
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Applications
• Steam turbines are widely used in utility central power stations and industrial process plants
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Strength
• Highly reliable design.
• Produces very high efficiencies when combined with combustion turbines.
• Can utilize waste heat to become a zero emissions generation source.
• Can use many different fuel sources for heat input
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Limitation
• Low cycle efficiency in traditional design where a boiler is fired by fossil fuels.
• Fuel source must be able to produce high levels of heat.
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Types
• Single Stage Turbines
• Multi-Stage Steam Turbines
• DUAL
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SINGLE
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SINGLE • Designed to make electricity by reducing steam
pressure (Preferably for mechanical drive)
• Used where high pressure steam is available but low pressure steam can be used for process or space heating,
• Can be used to replace large pressure reducing valves and thereby convert normally wasted energy potential into valuable electricity.
• Surplus boiler capacity is not required.
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Multi-Stage
Advantage:
• low fuel consumption
• High Efficiency
• Reliability
• Installation requirements
• Additional horsepower
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Multi-Stage (small steam turbine)
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Fifteen Different Basic Steam Turbine types:
Condensing
&
Non Condensing
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Dual
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STEAM TURBINE COMPONANTS
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Drawings
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COMPONANTS:
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Blades (rotating and stationary)
COMPONANTS :Nozzles
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COMPONANTS :Nozzles
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COMPONANTS: Rotor
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COMPONANTS: Rotor
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COMPONANTS: Impulse Wheel Bucket
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COMPONANTS: Combined Steam Governor Valve
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COMPONANTS: Steam Turbine Housing
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COMPONANTS: Steam Outlet
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COMPONANTS: Overspeed Mechanism
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Automatic Throttle, Stop, Check & Steam Chest Governing valves
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COMPONANTS: Bearings
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Components: Thrust Collar
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Governor-System Designs
• To minimize needed force, the steam valve is a balanced double-seated design.
• Both governor weights pivot on rolling surfaces with circular sections. To the left of the governor head a spring-loaded unbalanced pin acts as the overspeed trip..
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Governor-System Designs
• When shaft speed exceeds the safe limit, centrifugal force snaps the pin to an outer position so it trips a lever that closes the turbine stop valve.
• A speed-changer knob on the upper end of the governor lever tightens springs to shift the unit’s drop curve
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Controls
And
Instrumentation
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To control load automatically we depend on:
1-Speed Governors
2-Overspeed Trip
3-Pre—Emergency Speed Governor
4-Load-Limiting Meter
5-Initial, Pressure Regulator
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Lubrication and Hydraulic Systems
Lubrication is needed to minimize turning friction &
cools the bearings and gears.
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Large-Turbine Hydraulic Systems
6- Main pump mounted on the turbine shaft
7-Turning Gear Oil Pump.
8-Emergency Lube Oil pump.
9-Jacking Oil Pump
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Gas turbine Gas turbines convert the thermal energy in hot , expanding gases into the mechanical energy to drive generators and other process equipment . Although they come in a variety of sizes and designs , all gas turbines work the same way . In this part of the introduction you will review : • the parts of a gas turbine • how gas turbines work • types of gas turbines • gas turbine speed control • gas turbine efficiency
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EXHAUST
GAS
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AIR INLETFILTERAIR INLETFILTER
GASTURBINEGASTURBINE
EXHAUSTBYPASSSILENCER
EXHAUSTBYPASSSILENCER
GENERATORGENERATOR
DIVERTERVALVEDIVERTERVALVE
SUPPLE-MENTARYBURNER
SUPPLE-MENTARYBURNER
HEATRECOVERYSTEAMGENERATOR(HRSG)
HEATRECOVERYSTEAMGENERATOR(HRSG)
EXHAUSTSILENCEREXHAUSTSILENCER
PROCESSSTEAMPROCESSSTEAM
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Required Developments Market Pressures for : Lower Emissions
Water or Steam Injection Dry Low Emissions Combustion
Fuel Flexibility New combustion and fuel systems New coatings
Improved Reliability & Availability Longer Component Lives Intelligent Control Systems Condition Monitoring
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Improved Efficiency •Improved individual component efficiencies : Tighter tolerances, improved aerodynamics More complicated to manufacture
Higher Firing Temperatures : More exotic materials Reaching firing temperature limits effectiveness
Reduced Costs : Increased Power Density Higher firing temperatures & new component designs
More compact turbomachinery with lower component costs More highly loaded components
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Combined Cycle (Brayton & Rankine Cycles)
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Uses GT exhaust gases to produce steam for Steam
Turbine generator :
Approximately 40 - 50% additional power
13MW gas turbine gives c.18.5MW in CCGT
configuration
Approximately 15 - 20% points increase in fuel
efficiency
13MW GT of 35% electrical efficiency gives 50%
efficient CCGT
Increased Capital Costs
High pressure HRSG, Steam Turbine etc.
Increased Space Requirements
Combined Cycle
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Heat Recovery Methods
Direct Heating
Fluid Heating / Hot Water
Steam Production
Absorption Chilling
Preheated Combustion Air
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Food Processing
Pharmaceutical
Pulp and Paper
Manufacturing
Refinery
Hospitals
Universities
Industries using Gas Turbine Cogeneration
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Pump INTRODUCTION : PUMPS DEFINATION
PUMPS HISTORY
PUMPS APPLICATIONS
PUMPS TERMINOLGY
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MAIN TOPICS
PUMPS CLASSIFICATION PUMPS APPLICATION MAJOR COMPONENTS OF CENERIFUGAL & RECIPROCATING PUMPS CALCULATION & PERFORMANCE OPERATION & TROUBLESHOOTING
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PUMPS
Pumps are machines that are used to move liquids from one place to anther through pipelines. Pumps handle all kinds of liquids. Pumping rates can vary from a few gallons to a million/day
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Pumps are made of
different materials in
different sizes and
shapes
Pumps are the
second common
machine in the world
Pumps are used in
all power plant
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Pumps applications
Examples of pumps application in
power plants:
Boiler circulation
Feed water
Fuel oil
Chemical Feed
Condensate
Circulation water
Vacuum
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PUMPS CLASSIFICATION
Dynamic pump
Displacement
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CENTERIFUGAL PUMP
OPERATE ON THE PRINCIPLE OF CENTERIFUGAL FORCE :
DRIVEN BY •ELECTRIC MOTOR •STEAM TURBINE •GAS TURBINE
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MAJOR COMPONENTS OF CENTERIFUGAL PUMP
SUCTION INLET IMPELLER SHAFT CASING(HOUSING) DISCHARGE OUTLET BEARINGS SEALS
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IMPELLER & SHAFT
Impeller is the main part of a centrifugal
pump.
It move the liquid through the pump
It is vary considerably in design
It can be classified according to specific
speed
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IMPELLER TYPES
There are three types, depend upon the pump size or type of liquid and required discharge pressure:
Open Partially open
Enclosed
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IMPELLER CAVITATION
Cavitation : The formation and collapsing of bubbles inside the pump casing
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COLLAPSE OF VAPOR
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PUMP CASING
•Centrifugal pump casing (Housing) encloses the rotating parts •The suction and discharge nozzles are usually in the lower casing •The upper have can be easily lifted for inspection •There are many types of casing, ex. Volute and split.
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SEALS
•All pumps developed pressure to pump the liquid. The
pressurize liquid must be contained by a seal to prevent
leakage around the drive shaft .
•There are many types of seals that are used in many
types of pump. Ex
•Wearing ring
•Packing
•Mechanical seal
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DISPLACEMENT PUMPS
Introduction Displacement pump types Reciprocating & Rotary Pumps
•Major parts •Describe the operation •Advantages & Disadvantages •Drawing symbol
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INTRODUCTION
Rotary &Reciprocating pumps are positive displacement pumps. Positive displacement pump can be classified by the type of motion of internal elements The motion may be either rotary or reciprocating
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Major Parts of Rotary Pumps
The major parts of rotary pumps are the: Suction Inlet Pumping Element/Drive shaft* Housing Discharge Outlet * The pumping elements in each of the four types are different.
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Gear pumps
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External pumps
•The pumping element in external pump consist of two gear wheels inside the housing. •One gear is driven by the motor (Drive gear) •The driven gear connected directly to the drive shaft
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External Pumps Operation
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External Pumps Operation
From the figure : Liquid enters the pump through the suction inlet. As the gears rotate, liquid is trapped between the gear teeth and the housing. In suction side, volume expand In discharge, volume decrease When the gear teeth mesh, the liquid is squeezed out through the discharge outlet
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Internal Gear Pumps
•This design consist of internal spur gear and external housing. •As a power is applied to either gear, the motion of the gears draws fluid from tank and forced it around both sides of the crescent seal (seal between S & D)
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Lobe Pumps
•The pumping element in this pump consists of two close-fitting parts, which are called rotors. •The lobe trap the liquid and carry it around to the discharge outlet.
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Reciprocating Pumps
•Introduction •Major Parts •Pump Operation •Main types •Drawing Symbol •Advantages & Disadvantages
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Introduction
•Reciprocating pumps, like rotary pumps, are positive displacement pumps. •Reciprocating means to move with a back and forth motion. •The main parts are piston and cylinder •The main types :
•Axial design •Radial design
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Major Components
Main Parts •Suction Inlet Valve •Cylinder •Piston •Discharge Outlet Valve •Housing
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COMPRESSOR
Introduction
Compressors can be divided into two general categories: positive displacement compressors and dynamic, or centrifugal compressors. Positive displacement compressors work by trapping a certain amount of gas and forcing it into a smaller volume. A common type of positive displacement compressor is a reciprocating compressor. Two of the main parts of a reciprocating compressor are a cylinder and a piston. In the compressor used as an example, gas enters the cylinder and is trapped inside the cylinder. The gas is then forced into a smaller space by the action of the piston. Forcing the gas into a smaller space increases the pressure of the gas. The compressed gas is then discharged.
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Positive displacement compressor: A compressor that works by trapping a certain amount of gas and forcing it into a smaller volume. Centrifugal compressor: A compressor that operates by accelerating a gas to give it energy that is converted into pressure as the gas stream is slowed down. Reciprocating compressor: A compressor that compresses gas with one or more devices that move in a back and forth motion.
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All compressors are require some form of drive mechanism. Electric motors are commonly used to drive compressors. Other drive mechanisms include gasoline engines and steam or gas turbines. Compressors are used in many different types of compressed Compressed Air Systems Gas systems, and a particular facility may have several compressed gas systems. A compressed air system may also be referred to as a pneumatic system. The compressor in the system used as an example is a reciprocating compressor with two cylinders and two pistons. The example system also includes an intercooler, an aftercooler, a demister, a safety valve, and a receiver.
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Intercooler: A heat exchanger that cools compressed gas between stages of a multistage compressors
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After cooler: A heat exchanger that cools compressed gas after the compression process is complete
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Demister: A device used to remove moisture from gas
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Receiver: A tank that is used to store compressed gas
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Stage: Each area in a compressor in which gas is compressed In the first stage, the compressor increases the pressure of the air to approximately 25 psi. As the air is compressed, its temperature increases. The air that leaves the first stage of the compressor is routed to the intercooler. The intercooler is a shell and tube heat exchanger. As the air passes through the tubes in the intercooler, it is cooled by water flowing around the tubes. The cooled air from the intercooler is routed to the second stage of the compressor.
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In the second stage of the example compressor, the air's pressure is increased to approximately 120 psi. From the second stage, the compressed air is sent to the aftercooler, which is another shell and tube heat exchanger. As the compressed air passes through the tubes in the aftercooler, it is cooled by water flowing around the tubes. During the cooling process, any water vapor that is in the air condenses. As a result, there may be moisture in the compressed air. Moisture must be removed to prevent it from damaging equipment that uses the compressed air. From the aftercooler, the compressed air is sent to the demister, which removes moisture from the compressed air.
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COMPRESSOR MAINTENENCE
Components and Operation
Centrifugal compressors use an impeller, or several stages of impellers, to move air or gas. The impeller, or impellers, rotates at a very high speed inside a casing. The centrifugal force generated by the impeller forces the air or gas away from the impeller, toward an expanding area of the casing. There the air or gas slows down, expands, and gains pressure. The compressed air or gas can then be routed elsewhere to drive tools or machinery.
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All centrifugal compressors operate at very high speeds, often in excess of fifty thousand RPMs. At those speeds if there is something wrong with the compressor, it could very easily destroy itself in a matter of seconds. Another common characteristic among centrifugal compressors is that they all have extremely close tolerances. Nearly every component is machined to near perfection. So any maintenance work done on these units must be done
with extreme caution. Even a simple mistake made during a repair on one of these compressors could have devastating results. Although all centrifugal compressors operate on the same basic
principles, they come in many shapes and sizes. For example, compressors that have a single impeller are called single-stage compressors. Those with two or more impellers are known as multistage compressors.
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