Training SessionTurbomachine System Training Courses

FLOWCARE Engineering offers an extensive range of training courses covering all aspects of the fan, pump and blower industry. The courses are taught by experienced professionals with hands on experience in the subjects being taught. The following are some of the training courses offered by FLOWCARE Engineering Inc:

All of these courses can be tailored and packaged into various groupings depending on overall training objectives.

Introduction to Turbomachines (Fans, Pumps and Blowers):
This will provide an overview of the componentry involved with fan, pump and blower systems. The objective will be to simply ensure that each course participant is familiar with the terminology and purpose of the electromechanical hardware.
Fundamentals of Turbomachines:
To successfully select and apply turbomachines requires a fundamental understanding of the equipment and how it operates. This section covers flow, pressure and power parameters, performance curves and affinity laws.

Application Theory:
Each turbomachine installation should be suitable for the system requirements and the environment to which it is applied. This may be difficult for conditions which involve erosion, corrosion or other hazardous environmental considerations (both internal and external to the turbomachine). For each application there is generally a "correct" design which can mitigate the difficulties encountered. This session will examine special design features, auxiliary hardware and control strategies that allow tailoring the equipment to suit the application. Emphasis will be placed on exotic materials, high temperature, material handling and other issues pertinent to decisions on turbomachine selection.

Design Principles:
This session will provide an overview of the step by step process followed by the design engineer as a custom turbomachine is taken from sales order to completed design.

Fundamentals of Systems:
There are four fundamental system types as dictated by the characteristics of the flow and pressure requirements. Each will be reviewed along with the suitable turbomachine control options that match each type.

Identifying Good Performance Optimization Candidates:
Approximately 60% of all motors drive turbomachine systems. Optimizing these systems has consistently proved to be the best target in attaining electrical energy reduction for typical industrial plants. This presentation will focus on four primary elements:

Optimization Techniques:
Options suitable for optimizing turbomachine systems will be reviewed for a variety of inefficient conditions. Application considerations relevant to each will be reviewed. (Application considerations for variable speed drives is a stand-alone issue covered under a separate heading.)

Troubleshooting:
Various problems unique to turbomachines will be elaborated on with specific reference to noise, vibration, capacity, control and failure issues. These will be discussed in the context of design principles, methods for mitigation and the cost of excess consumption of energy should the problems not be treated properly. (Each of the problems referred to in the foregoing can be expanded to standalone sessions should it be requested to elaborate on these.)

System Benefits of Proper Turbomachine Selection and Operation:
This presentation will detail the overall package of benefits provided by optimization. It will deal with both the system and specific electro-mechanical components (ie. maintenance, vibration, noise, process and equipment control, reliability, capacity).

Application Considerations for Variable Speed Drives:
Not all turbomachines are good applications for variable speed. Understanding both system and equipment characteristics and limitations is essential to avoiding future problems (ie. energy savings may be minimal, system may not be suited for variable speed control or problems can be created with the driven electro-mechanical componentry). This presentation explores the application considerations and provides solutions for those that can be mitigated or eliminated as a concern.

Data Acquisition and Field Performance Testing:
In order to conduct a suitable evaluation of a turbomachine, operating data must be collected. Obviously, accurate and thorough data will yield more precise predictions of savings, payback or other impact that modifications will have on the system. The available information may range from very little to an overload of data. This session deals with the issue of how to collect data for completion of a feasibility study analysis.

Test Equipment:
A brief overview will be undertaken of the type of test equipment needed for turbomachine field analysis, data collection and system performance measurements.

Performance Optimization Study Methodology, Analysis and Reporting:
A format for analyzing and presenting the results of a turbomachine study will be discussed.

Case Studies:
This module will focus on optimization and trouble-shooting case studies for a wide range of turbomachine applications.

Commissioning:
Principles of installation, pre-start-up checks and inspections, start-up procedures and final site data collection will be presented. Forms will be provided concerning the site measurements taken along with acceptance criteria. A brief review will be taken of the procedures to follow when a recommissioning of equipment is undertaken.

Performance Enhancements and Upgrades:
It is common that system requirements change after the original turbomachines are installed to the extent that they may be inadequate. An obvious but expensive solution is to simply install new equipment. However, it is very likely that existing equipment can be altered to allow the new conditions to be met. This session will examine the techniques to achieve reduced or increased performance and a wider operating range to match swing requirements. The range of options will be presented with special emphasis on inexpensive measures or tweaking techniques to boost output.

Economics of Turbomachine Operation:
While the initial capital costs can be readily identified, much less can be known about the true or hidden costs of turbomachine operation. This session will provide rules of thumb for installation, maintenance and energy operating costs. Special emphasis will be placed on methods for determining the load-duty cycle of turbomachines.

Maintenance:
Turbomachines have widely varying maintenance requirements depending on the type, design and application of the equipment. General maintenance philosophy and specific measures will be presented. Checklists and other forms will be provided.

Control:
Turbomachine control follows system requirements and can be achieved in several ways. Each control technique (dampers, valves, recirculation, variable speed, etc) has an appropriate application. The "Control" module will focus on general control strategies and philosophy, specific hardware types and the positive and negative features of each type.

Laboratory Principles:
Turbomachine manufacturers have long recognized the benefits of a well equipped test laboratory. This training session will examine laboratory principles from a number of perspectives, ie. establishing laboratory criteria, different laboratory designs, types of laboratory equipment and set-ups, costs, limitations and procedures.

Certified Ratings Program:
The principles of establishing a turbomachine ratings program incorporating manufacturer's standard for performance and noise will be the focus of this module. Different programs will be defined. Operating a program will be discussed in terms of getting started, maintaining the program, costs, benefits and drawbacks.

Quality Control/Quality Assurance:
With tighter quality control criteria, QC/QA procedures have been vaulted into a prominent consideration for both turbomachine buyers and vendors. This training module will provide details on practical approaches to the following: source inspection, vendor qualifications, material certification, welding inspection, design verification, mechanical run tests, balancing, guarantees/penalties, etc. This module is normally tailored to suit audience requirements and applicable standards.

Specification Development:
An important step in the purchasing of new equipment is the issuance of an appropriate bid specification. The development of this document will be reviewed with emphasis placed on ensuring that necessary features are requested without "over specifying".

Finite Element Analysis:
Finite Element Analysis (FEA) is a sophisticated design and trouble-shooting method for many turbomachine engineering issues. This module will examine the role of FEA in design, design verification and problem solving and how the use of FEA can be optimized for determination of natural frequencies, stress and fatigue life.
Modal Analysis:
Modal analysis is a technique for establishing the movement of equipment under dynamic conditions. This is useful in determining causes of high vibration and arriving at appropriate structural modifications to minimize vibrations. The use of spectrum analysis equipment will be taught in conjunction with data interpretation to facilitate practical solutions to problems.

System Effect Factors:
Turbomachines frequently fail to meet field system requirements even though laboratory results indicate design performance can be reached satisfactorily. In many cases the problem is with faulty inlet and outlet connections and design. This seminar will show how to properly allow for and mitigate these so called System Effect Factors (SEF's).

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