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Steam Turbine Technology

Selection, Applications, Operation, Inspection, Diagnostic Testing, Maintenance, Refurbishment, Performance Monitoring, Rotor Dynamic Analysis, and Computer Simulation of Steam Turbine Rotor Dynamics

Upcoming Courses

This seminar will cover all aspects of steam turbines including design and features of modern turbines, material, rotor balancing, features enhancing the reliability and maintainability of steam turbines, rotor dynamic analysis, Campbell, Goodman and SAFE diagrams, Blade failures: causes and solutions, maintenance and overhaul of steam turbines, and modeling of steam turbines. This seminar will also cover in detail all the components of these turbines, instrumentation, control systems, governing systems, and selection criteria. The main focus of this seminar will be on the failure modes of steam turbine components, causes and solutions for component failure, maintenance, refurbishment and overhaul, rotor dynamic analysis of steam turbines, and computer simulation of steam turbine rotor dynamics. All possible failure modes of steam turbine components and the maintenance required to prevent them will be discussed in detail. Examples of rotor dynamic analysis, and stability criteria will be covered thoroughly. This seminar will also provide up-dated information in respect to all the methods used to enhance the availability, reliability, and maintainability of steam turbines, increase the efficiency and longevity of steam turbines, and improve the rotor dynamic stability.

Who should attend

  • Engineers of all disciplines
  • Managers
  • Tchnicians
  • Maintenance personnel
  • Other technical individuals

Seminar outcome

  • Steam Turbine Components and Systems: Learn about all components and systems of the various types of steam turbines such as: stationary and rotating blades, casings, rotor, seals, bearings, and lubrication systems
  • Steam Turbine Failure Modes, Inspection, Diagnostic Testing, and Maintenance: Understand all the failure modes of steam turbine components, causes and solutions of steam turbine component failure, inspection, diagnostic testing, and all maintenance activities required for steam turbines to minimize their operating cost and maximize their efficiency, reliability, and longevity.
  • Steam Turbine Instrumentation and Control Systems: Learn about the latest instrumentation, control systems, and governing systems of steam turbines
  • Steam Turbine Reliability and Maintainability: Increase your knowledge about all the methods used to enhance the reliability and maintainability of steam turbines as well as the predictive and preventive maintenance required for steam turbines
  • Steam Turbine Selection and Applications: Gain a detailed understanding of the selection considerations and applications of steam turbines in steam power plants, co-generation, combined-cycle plants, and drivers for compressors pumps, etc.

Training methodology

The instructor relies on a highly interactive training method to enhance the learning process. This method ensures that all the delegates gain a complete understanding of all the topics covered. The training environment is highly stimulating, challenging, and effective because the participants will learn by case studies which will allow them to apply the material taught to their own organization.

Special feature

Each participant will receive a copy of the following materials written by the instructor:

  • STEAM TURBINE MANUAL (includes practical information about steam turbines - 350 pages)
  • Relevant material from POWER PLANT EQUIPMENT OPERATION AND MAINTENANCE GUIDE authored by Phil Kiameh, published by McGraw-Hill in 2012

Program outline

Day 1 - Steam Power Plants, Steam Turbine Components, Steam Turbine Auxiliaries, Impulse and Reaction Turbines, Rotor Balancing, Features of Advanced Steam Turbines, and Features Enhancing The Reliability and Maintainability of Steam Turbines

  • Review of thermodynamics principles, efficiency and heat rate
  • Steam power plants, steam turbines
  • Mechanisms of Energy Conversion in a Steam Turbine, Steam balance considerations
  • Steam turbine types (straight noncondensing, automatic extraction noncondensing, automatic extraction condensing
  • Steam turbine controls, Automatic extraction condensing controls
  • Geared and direct-drive steam turbines, modular design concepts
  • Turbine components, Rotating and stationary blades
  • Steam Turbine casing and major stationary components: casing design, steam admission sections, steam turbine diaphragms and labyrinth packing
  • Steam turbine bearings: journal bearings for industrial turbo-machinery, fixed-geometry journal bearing stability, tilted-pad journal bearings, advanced tilting-pad journal bearings, lubrication-starved tilting pad bearings, key design parameters, thrust bearings for turbo-machinery, active magnetic bearings
  • Rotors for impulse turbines: long-term operating experiences, pitch diameter and speed, steam turbines, built-up construction, materials of construction for multi-stage steam turbines, solid construction, shaft ends, turbine rotor balance methods, at-speed rotor balancing, advantages and disadvantages of at-speed balancing, balance tolerance
  • Rotors for reaction turbines: solid rotors, finite element analysis for steam turbines, materials for solid rotors, welded rotor design, welded rotor materials
  • Thrust bearings, labyrinth seals
  • Steam turbine blade design: blade material, blade root attachments, types of airfoils and blading capabilities, guide blades for reaction turbines, low-pressure final stage blading, Campbell diagram
  • Turbine auxiliaries lube systems, barring or turning gears, trip-throttle or main stop valves, overspeed trip devices, gland seal systems, lube oil purifiers
  • Testing of Turbine blades
  • Quality Assurance of Turbine Generator Components
  • Assembly and testing of turbine components
  • Turbine Types, Compound Turbines
  • Turbine Control Systems
  • Steam Turbine Maintenance
  • Power Station Performance Monitoring
  • The Turbine Governing Systems
  • Steam Chests and Valves
  • Turbine Protective Devices
  • Turbine Instrumentation
  • Lubrication Systems
  • Gland Sealing System
  • Features of Advanced Steam Turbines
  • Constant and sliding pressure operation of steam turbines
  • Frequently Asked Questions about Turbine-Generator Balancing, Vibration   Analysis and Maintenance
  • Steam turbine rotor failures: causes and solutions: rotor rubs, blade rubs causing bending, rotor and casing misalignment, bearing problems, alignment of diaphragms, achieving precise alignment, rotor imbalance, corrosion causing rotor imbalance, failures due to poor maintenance, casing problems
  • Steam Turbine Deposition, Erosion, and Corrosion
  • Features Enhancing The Reliability and Maintainability of Steam Turbines: steam turbine design, measures of reliability, availability, and maintainability, design attributes enhancing reliability, overall mechanical design approach, modern steam turbine design features, design attributes enhancing maintainability, maintainability features, maintenance recommendations, cost/benefit analysis of high reliability, availability, and maintenance performance, reliability, availability, and maintainability value calculation     

Day 2 - Steam Turbine Rotor Dynamic Analysis, Campbell, Goodman, and SAFE Diagrams, Advanced Steam Turbine Design, Materials and Coatings, Steam Turbine Blade Failures, Causes and Solutions, Maintenance and Overhaul of Steam Turbines

  • Steam turbine rotor dynamic technology: rotor model, dynamic stiffness, effects of damping on critical speed prediction, bearing-related developments, refinements, bearing support considerations, foundations, impedance, partial arc forces, design procedure, rotor response, instability mechanisms, sub-synchronous vibration, service examples, labyrinth and cover seal forces, rotor stability criteria, experimental verification
  • Campbell, Goodman, and SAFE Diagrams for Steam Turbine Blades: Goodman diagram, Goodman-Soderberg diagram, Campbell diagram, exciting frequencies, SAFE diagram-evaluation tool for packeted bladed disk assembly, definition of resonance, mode shape, fluctuating forces, SAFE diagram for bladed disk assembly, mode shapes of a packeted bladed disk, interference diagram beyond N/2 limit, explaining published data by using SAFE diagram
  • Frequency Evaluation of Steam Turbine Rotors: natural frequency and mode shape, vibratory forces, resonance, Campbell diagram, SAFE diagram
  • Reaction vs impulse type steam turbines: impulse and reaction turbines compared, efficiency, design, impulse type, reaction type, critical speed, blading, vibration, control stage, full-admission stages, blade damage, blade clearances, erosion, axial thrust, maintenance, design features of modern reaction turbines, deposit formation and turbine water washing
  • Shortcut graphical methods of turbine selection: estimating steam rates, steam turbine selection procedure, examples of steam turbine selection, quick reference information to estimate steam rates of multivalve multistage steam turbines
  • Elliott shortcut selection method for multivalve, multistage steam turbines: approximate steam rates, stage performance determination, examples of steam turbine selection process, extraction turbine performance
  • Rerates, Upgrades, and Modifications of Steam Turbines: performance and efficiency upgrade, brush seals and labyrinth seals, wavy face dry seals, replacing carbon rings with wavy dry seals, design goals and available technologies, seal design specifics, installation of seals, installation sequence, cost vs. benefit analysis, buckets, reliability upgrade, electronic controls, monitoring systems, life extension, modification and reapplication, casing, flange sizing, nozzle ring capacity, steam path analysis, rotor blade loading, thrust bearing loading, governor valve capacity, rotor, shaft and reliability assessment, speed range changes, auxiliary equipment review, oil mist lubrication for general-purpose steam turbines, wet sump (purge mist) vs. dry sump (pure mist) application, control and application of oil mist, header temperature and header size, experience and conducting comments, problem solving
  • Advanced Ultra Supercritical Steam Turbine Materials: design of ultra supercritical steam turbines, steam oxidation, creep resistance, rupture ductility, nickel-based alloys, creep curves of different steam turbine materials, yield strength of different steam turbine materials, temperature capabilities of nickel-based superalloys for high pressure and intermediate pressure steam turbines, composition of various high-temperature superalloys considered for advanced ultra supercritical steam turbines, advanced ultra supercritical turbine designs using nickel-based superalloys
  • Advanced Steam Turbine Design, Materials, and Coatings: materials used in advanced steam turbines, design and materials used in high pressure steam turbine rotors, intermediate pressure rotors, steam turbine casings, and bolting, rotor materials - advanced processing of current alloys, nickel-base rotors, welding of udimet 720 and Inconel 617, isothermally forged nickel-base rotors, high temperature disc materials, rotor blade materials - advanced processing of current alloys, erosion resistant coatings, casing materials and large scale nickel castings, bolting - high temperatures bolt alloy, high strength pipe materials, efficiency improvement of steam turbines, characteristics of 50 and 60-inch last stage blades, fluid performance design, development of supersonic turbine blades, structural reliability design, vibration design, conclusions
  • Steam Turbine Blade Failures, Causes and Solutions, failure investigation
  • Steam turbine risk assessment - a tool for optimizing inspection and overhauls of steam turbines: outage planning factors
  • Maintenance and Overhaul of Steam Turbines: steam turbine component characteristics, failure mechanisms, arrangements and applications, monitoring, operations, maintenance, and training infrastructure, steam turbine availability and failure experience, scheduled maintenance and overhaul practices, approaches/methodologies/criteria for establishing longer time intervals between major overhauls, issues with new steam turbine technologies and applications
  • Methods of Strategic Oil Flushing Program; high-velocity turbine lube oil flushing using pulse-induced wave technology
  • Turbine Blasting
  • Steam Turbine Rotor Dynamic Analysis: comparative analysis of different components of rotor dynamic stability, Bode plot of rotor dynamic analysis
  • Steam Turbine Rotor Dynamics and Vibration Diagnostics
  • Modeling of Steam Turbine Rotor Dynamics: understanding rotor dynamics, solid model rotor dynamics, modeling methods, results
  • Advanced Water Treatment Technology: reverse osmosis systems, nanofiltration, ultrafiltration and microfiltration, electrodeionization (EDI), activated carbon filtration, multimedia filtration, ozonation systems, ultraviolet irradiation, steam turbine water treatment
  • Glossary of turbo-machinery and related equipment terms
  • Computer Simulation of Steam Turbine Rotor Dynamics: rotor equations, examples of computer simulation of rotor dynamic analysis