COURSE OVERVIEW:

Turbine vibration and alignment are the most critical indicators of mechanical health in high-speed rotating machinery, where even microscopic deviations can lead to catastrophic structural failure. This course provides an advanced technical exploration of rotor dynamics and the precision engineering required to maintain turbine stability under varying thermal and operational loads. Participants will examine the complex relationship between shaft centerline position, bearing oil film stiffness, and the resultant vibration signatures that define the machine's reliability.

The scope of this training focuses on the deployment of sophisticated condition monitoring technologies, specifically the use of proximity probes, accelerometers, and dual-channel phase analysis. We will investigate the diagnostic power of orbit plots, Bode plots, and polar plots to identify specific malfunctions such as oil whirl, whip, and rotor rubs. The curriculum covers the high-stakes process of hot and cold alignment, emphasizing the calculation of thermal growth offsets to ensure the turbine train achieves perfect colinearity at its stabilized operating temperature.

Coverage also includes the integration of automated monitoring systems with plant-wide asset management platforms to enable real-time health assessments. By focusing on the interpretation of spectral data and the application of ISO standards for vibration limits, the course empowers engineers to predict failures long before they occur. Through this rigorous study, attendants will gain the expertise necessary to troubleshoot complex vibration issues, oversee precision alignment activities, and manage a world-class turbine condition monitoring program.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Identify the fundamental causes of vibration in steam and gas turbine assemblies.
2. Configure and calibrate proximity probes and transducers for accurate data acquisition.
3. Interpret orbit plots and time-base waveforms to diagnose specific rotor faults.
4. Distinguish between synchronous and non-synchronous vibration components.
5. Perform precision shaft alignment using laser and dial indicator methodologies.
6. Calculate thermal expansion offsets for turbine-to-generator and turbine-to-compressor trains.
7. Utilize Bode and Nyquist plots to identify critical speeds and resonance peaks.
8. Diagnose fluid-film bearing instabilities such as oil whirl and oil whip.
9. Implement a comprehensive condition monitoring route for a fleet of turbines.
10. Evaluate the impact of coupling unbalance and eccentricity on overall vibration.
11. Apply ISO 10816 and API 670 standards for vibration alarm and trip settings.
12. Conduct field balancing operations to reduce residual unbalance in turbine rotors.
13. Formulate detailed condition assessment reports with data-driven maintenance advice.

TARGET AUDIENCE:

This course is designed for Rotating Equipment Engineers, Vibration Specialists, Reliability Engineers, Maintenance Supervisors, and Senior Condition Monitoring Technicians.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.