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Mechanical Courses

M1: Pumps types, operation and maintenance

M2: Compressors Design, Operation, Maintenance, and Troubleshooting

M3: GAS TURBINE FUNDAMENTALS

M4: Shaft to shaft alignment and measurement tools

M5: Vibration analysis and condition monitoring

Course (1)

M1: Pumps types, operation and maintenance

Module (01) pumps introduction
1.1     pumps function and application 
1.2     pumps classification
1.3     positive displacement pumps
1.4     dynamic pumps
1.5     pumps selection chart

Module (02) centrifugal pumps classification
2.1   pump selection charts  
2.2   pump main components and function 
2.3   centrifugal pump classification
2.4   types of impellers 
2.5   bearing selection and position
2.6   volute design

Module (03) centrifugal performance curve 
3.1   relations between head and capacity
3.2   effect of specific gravity on head     
3.3   system curve and operating point  
3.4   wear ring types and effect in pump performance
3.5   impeller balancing holes and it`s function


Module (04) factors affecting pump performance 
4.1   NPSH required and available 
4.2   cavitation and how to avoid it
4.3   internal circulation
4.4   proper piping arrangement
4.5   pumps arrangement in parallel and in series


Module (05) multistage centrifugal pumps
5.1    application and function
5.2    axial thrust force generation and it`s compensation 
5.3    balancing drum function
5.4    minimum flow controls
5.5    specific speeds

Module (06) mechanical seal
6.1   sealing technology introduction
6.2   shaft seal classification 
6.3   shaft mounted and cartridge seal types 
6.4   seal arrangement
6.5   seal flushing plans 

Course(2)

M2: Compressors Design, Operation, Maintenance, and Troubleshooting

Module (01) compressors introduction 
1.1     compressors function and application 
1.2     compressors classification
1.3     positive displacement compressors
1.4     dynamic compressors
1.5     compressors selection chart

Module (02) centrifugal compressor classification
2.1    centrifugal compressor selection charts  
2.2    compressor main components and function 
2.3     centrifugal compressor classifications
2.4     types of impellers 
2.5     centrifugal compressor arrangements  
2.6     compressor construction components

Module (03) centrifugal compressor operation and performance   
3.1     compressor chart
3.2     surge phenomena introduction  
3.3     Compressor Protection & Anti-Surge Control
3.4     balancing drum function   
3.5     startup procedure and shut down 

Module (04) compressor auxiliary  
4.1    compressor bearings
4.2    lubrication circuit
4.3    dry gas seal fundamentals 
4.4    seal gas filtration.
4.5    protection systems 


Module (05) positive displacement compressors
5.1    operation fundamentals
5.2     reciprocating compressor  
5.3     lobe compressor
5.4     sliding vane compressor 
5.5     screw compressor

Module (06) dry gas seal 
6.1     sealing technology introduction
6.2     shaft seal classification 
6.3     shaft mounted and cartridge seal types 
6.4     seal arrangement
6.5     seal flushing plans 

Course(3)

M3: GAS TURBINE FUNDAMENTALS
 

Module (01) Introduction
Module (02) Types of Gas Turbine and Gas Turbine Applications

2.1   Heavy Duty Gas Turbines

2.2   Aero-Derivative Gas Turbines

2.3   Two-shaft Gas Turbines

2.4   Simple Cycle/Combined Cycle/ Combined Heat and Power Applications

Module (03) Major Components of a Gas Turbine

3.1  Compressor Component

  3.1.1 Compressor Design/Effects on Performance

  3.1.2 Compressor Washing Techniques/Philosophies

3.2  Combustion Components

  3.2.1 Combustion Liner Design/Type

  3.2.2 Combustion Liner Materials/Repair

  3.2.3 Fuel Nozzle Design/Repair

  3.2.4 Environmental Control for Combustion System

  3.2.5 Types of Environmental Control

  3.2.6 Installation/Retrofitting Environmental Control Systems

3.3 Hot Gas Path Components

  3.3.1 Blade Materials/Design

  3.3.2 Nozzle Materials/Design

  3.3.3 Blade/Nozzle Inspection Techniques (Dye Penetrate, Eddy Current)

  3.3.4 Blade/Nozzle Defects (Corrosion, Erosion, Oxidation)

  3.3.5 Coatings and Coating Application Techniques

  3.3.6 Evaluating Components for Repair

  3.3.7 Repair Techniques and Materials

Module (4) Gas Turbine Systems

4.1  Lubrication Systems

  4.1.1 Lube Oil Types

  4.1.2 Oil Monitoring and Cleaning

4.2  Fuel Systems

  4.2.1 Fuel Properties and Selection

  4.2.2 Fuel Measurement

4.3 Supply Systems

  4.3.1 Heavy Fuels and Fuel Dosing

  4.3.2 Fuel Performance Impacts

  4.3.3 Environmental Considerations

4.4 Bearings

  4.4.1Types of Bearing

  4.4.2 Bearing Materials and Repairs

4.5 Additional System

  4.5.1 Starting Systems

  4.5.2 Inlet Air Systems/Filtering

4.6 Control System

  4.6.1 Evaluating/Collecting Control System Data  

  4.6.2 Evaluating Control System Retrofits/Upgrades

  4.6.3 Pressure, Temperature and Vibration Monitoring

Course(4)

M4: Shaft to shaft alignment and measurement tools

Module (01) introduction
1.1     What is shaft alignment?
1.2     benefits from shaft alignment
1.3     machines failure categories
1.4     wears in mechanical components


Module (02) measurement tools 
2.1    direct measurement tools 
2.2    using micrometer
2.2.1 internal micrometer
2.2.2 external micrometer
2.2.3 depth micrometer
2.3    using Vernier
2.4    using dial gages


Module (03) pre-alignment check  
3.1     soft foot detection and correction
3.2     pipe strain check
3.3     shaft and coupling runout
3.4     thermal growth consideration


Module (04) alignment process
4.1     types of misalignment
4.2     filler and straight peace alignment method
4.3     sag calculation
4.4     true alignment rules  
4.4.1  validity rule
4.4.2  total indicator readings
4.4.3  true position sensing


Module (05) reverse and cross alignment method
5.1     dial brackets arrangement
5.2     graphical method
5.3     calculation method                    
5.4     correct vertical and horizontal misalignment readings


Module (06) rim and face alignment method
6.1     dial brackets arrangement
6.2     using one dial and two dials in face readings
6.3     calculation method
6.3     graphical method

Course (5)

M5: Vibration analysis and condition monitoring

Module (01)condition monitoring introduction
1.1     maintenance strategy and types
1.2     source of vibration
1.3     infra thermography technique overview 
1.4     oil analysis technique overview
Module (02) principles of vibration analysis
2.1     vibration amplitude
2.1.1  vibration displacement
2.1.2  vibration velocity
2.1.3  vibration acceleration
2.2     data acquisition technique
2.3     measurement point’s identification 
2.4     phase concept and measurement
Module (03) vibration measurement sensors
               3.1     proximity report theory and operation
3.2     velocity transducer theory and operation
3.3     accelerometer theory and operation
3.4     sensor selection criteria
3.5     sensors fixation methods and effect       

Module (04) vibration analysis fundamentals
4.1     converting from time wave form spectrum.
4.2     free vibration concept
4.3     forced vibration
4.4     resonance phenomena identification and problem solving           
4.5     critical speed identification
4.6     non, sub and synchronous frequencies

Module (05) Rotor unbalance fault detection and solving
5.1     unbalance defect reasons
5.2     unbalance detection using vibration analysis
5.2.1  Detection using spectrum and timewaveform
5.2.2  Detection using phase analysis
5.2.3  Detection using orbit analysis 
5.3     unbalance correction method
5.4     unbalance impact on machinery health

Module (06) misalignment defect detection and solving
6.1      misalignment sources
6.2      misalignment detection using vibration analysis
6.2.1   Detection using spectrum analysis
6.2.2   Detection using timewave form analysis
6.2.3   Detection using phase analysis
6.2.4   Detection using orbit analysis
6.3      misalignment solving problem
6.4      alignment using dial gages
6.5      alignment using laser alignment devise
6.6      belt alignment
Module (07) bearing defects detection and solving
7.1        bearing failure sources
7.2        bearings failure stages
7.3        bearing failure detection
7.4        bearing failure effect on machinery health
7.5        proper bearings installation methods
Module (08) other common machinery defects
8.1        rotor eccentricity detection
8.2        belt defects detection
8.3        bent shaft detection
8.4        looseness defect detection
8.4.1     Internal looseness
8.4.2     External looseness

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