Gas Turbine Failure Analysis


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Upcoming Course

Code Start Date End Date Location Cost Instructor Register
PST0189-201702  27 Nov 2017  29 Nov 2017  Kuala Lumpur, Malaysia  SGD 3595  Jim Oswald   Register
PST0189-201801  23 Apr 2018  25 Apr 2018  Kuala Lumpur, Malaysia  SGD 3595  Jim Oswald   Register
PST0189-201802  11 Jun 2018  13 Jun 2018  Bangkok, Thailand  SGD 3595  Jim Oswald   Register
PST0189-201803  19 Sep 2018  21 Sep 2018  Kuala Lumpur, Malaysia  SGD 3595  Jim Oswald   Register

Past Course

Code Start Date End Date Location Cost Instructor Register
        Aaron A. Zick, Ph.D. 
PST0189  10 Sep 2012  12 Sep 2012  Kuala Lumpur, Malaysia  SGD 4495  Jim Oswald 
PST0189-201401  25 Aug 2014  28 Aug 2014  Kuala Lumpur, Malaysia  SGD 3995  Jim Oswald 
PST0189-201501  27 Jul 2015  30 Jul 2015  Kuala Lumpur, Malaysia  SGD 4495  Jim Oswald 
PST0189-201701  24 Jul 2017  25 Jul 2017  Kuala Lumpur, Malaysia  SGD 2995  Jim Oswald 
Failure investigations are tough rigorous challenges form the best in engineering. This course will teach delegates the range of thinking and subjects, which need to be considered in driving to find the real root cause of a failure. The class will be based around some of the most difficult challenges faced by the professions in the industry and challenge the analytical and creative ability of the best students.
 
Jim Oswald has resolved many major gas turbine failures that can not be solved by many consultants before him. These cases will be presented on the course and there will be a lot of exercises to let the delegates have a deep understanding in solving major gas turbine failure.
 
Each attendee must bring a laptop computer with Microsoft operating system with Microsoft Excel and power point installed.
DAY 1
Delegates will be reminded in how a gas turbine works, learn how to think through failure sequences and learn how to avoid misleading failure information
• How a Gas Turbines works, flows, controls, combustors, noise.
• Group Task with Case Study – Delegates will identify gas turbine failure and chart sequence of events before and after failure. Discussion on need for creativity in failure investigation based on Trainer’s experience.
• The importance of careful recording and how to record.
• Case Study
• Misinformation and how it occures
• Group Task - How to improve recording data

 

DAY 2

 

Delegates will learn about formal failure methods, how and why metal fails when and how best to use specialist
expertise
• Fishbone, RCA, Ishikawa
• Group Task - Redo chart of DAY 1 using formal method. Discuss and Compare the benefits
• Using Specialist expertise in GT Failure investigations: mellurgy, noise, vibration, controls
• When and how to use them in validation and discovery of evidence
• How to break metal: fatigue, creep, fracture, vibration
• The differences, and why its vital to understanding failures
• Case Study
• Group Task - identify if fatigue or creep from reports / photos provided. Judge if high cycle or low cycle fatigue
 
Day 3
Delegates will learn about a common cause of failure (fatigue) and work through case study work using methods taught and thus how to avoid a repeat failure
• Case Study
• Thermal Fatigue - What is it, how does it arrive and how leads to cracking and failure.
• Case Study
• Group task - calculate if thermal fatigue likely from data supplied
• Pattern of failures and why patterns matter
• Group task - identify patterns from data supplied. What does the pattern tell you?
• Group task - Delegates will be presented with failure evidence (based on real and serious failures) and asked to explain the failure using methods learnt. They will work in teams of 3 or 4. Trainer will act as engine operator and OEM. They need investigate and identify root cause followed by presenting the results to senior management.
  • Identifying the true root cause of failures, consequences, sequences of failure and remedies
  • Understanding the interactions of components of gas turbine as a system including control systems and engine surge
  • Effectively organising and structuring an investigation plan
  • Experience first hand how fishbone analysis and Sequence of Events can help in investigations
  • Assessing fatigue failures and how it limits engine operational life
  • Assessing factors which limit reliable operation
  • Identifying the true root cause of failures, consequences, sequences of failure and remedies
  • Understanding, recognizing and preventing further repeat failures through pattern analysis
  • Strengthen understanding of gas turbine failures and operational limit concerns through thorough discussion with the trainer
The course is designed for professionals who want to know practical knowledge which will sharpen analytical skill in resolving major gas turbine failures.
  • Reliability Engineer
  • Rotating Mechanical Engineer
  • Maintenance Engineer
  • Electrical Engineer
  • Instrument Engineer

Aaron A. Zick, Ph.D.

Founder and President

Biography


President, Zick Technologies (Since 10/93).

Petroleum engineering consulting and software development, specializing in the area of reservoir fluid phase behavior modeling. References available on request. Key achievements:

-Developed numerous equation-of-state and black-oil fluid characterizations for various major oil companies and as a sub-contractor for Pera A/S.

-Recommended phase behavior experimentation and modeling guidelines for several major oil companies.

-Wrote PhazeComp, a new, state-of-the-art program from Zick Technologies for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Wrote Streamz, unique Petrostreamz A/S software for translating, manipulating, and managing vast quantities of fluid stream information.

-Designed and helped write Pipe-It, unique Petrostreamz A/S software for managing and manipulating petroleum resources, processes, and projects.

-Taught numerous industry courses on phase behavior, equations of state, reservoir fluid characterization, and miscible gas injection processes.

-Designed and helped implement a new set of equation-of-state routines for the in-house reservoir simulator of a major oil company.

-Advised the architects of a major commercial reservoir simulator on ways to significantly improve their equation-of-state routines.

 

Director of Research, Reservoir Simulation Research Corporation (6/91–10/93).

Responsible for the research and development of more efficient, accurate, and reliable techniques for modeling reservoir fluid phase behavior within MORE® (a fully-compositional, equation-of-state reservoir simulator). Also responsible for improving three-dimensional visualization of reservoir simulator output, and for occasional consulting work. Key achievements:

-Designed and implemented new equation-of-state solution algorithms for MORE®, improving both efficiency and robustness while using less memory.

-Developed a powerful and flexible interface between MORE® and TECPLOT™ (three-dimensional surface contouring software from AMTEC Engineering).

 

Senior Principal Research Engineer, ARCO Oil and Gas Company (9/83–5/91).

Developed expertise in reservoir fluid phase behavior, phase behavior modeling, compositional reservoir simulation, and relative permeability modeling.  Designed and analyzed PVT experiments. Created equation-of-state reservoir fluid characterizations. Developed ARCO’s phase behavior modeling software and relative permeability modeling software. Helped develop several of ARCO’s compositional and limited compositional reservoir simulators. Key achievements:

-Discovered the true, condensing/vaporizing mechanism of oil displace­ment by enriched hydrocarbon gases.

-Represented ARCO on the Prudhoe Bay co-owners’ Enhanced Oil Recovery Task Force for the Prudhoe Bay Miscible Gas Project.

-Designed and analyzed most of the PVT and slim-tube experiments for the Prudhoe Bay Miscible Gas Project.

-Created the equation-of-state reservoir fluid characterization adopted by the operating companies for the Prudhoe Bay Miscible Gas Project.

-Developed the miscibility pressure correlations used by the facility operators for the Prudhoe Bay Miscible Gas Project.

-Developed EOSPHASE, a then state-of-the-art program for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Developed SLIMTUBE, a special-purpose, equation-of-state simulator for slim-tube displacements.

-Developed new, compositionally-consistent, three-phase relative perme­ability models for ARCO’s compositional simulators and wrote data-fitting software for those models.

-Developed the phase behavior and relative permeability routines for a new, limited compositional reservoir simulator and assisted on other aspects of it.

-Continually added improvements to various in-house reservoir simulators.

-Regularly taught in-house courses on the phase behavior of miscible gas displacement processes.

 

IMPORTANT PUBLICATIONS

A. A. Zick, “A Combined Condensing/Vaporizing Mechanism in the Displacement of Oil by Enriched Gases,” presented at the 61st Annual Technical Conference and Exhibition of the Society of Petroleum Engineers, New Orleans, LA (October, 1986).

D. E. Tang and A. A. Zick, “A New Limited Compositional Reservoir Simulator,” presented at the 12th SPE Symposium on Reservoir Simulation, New Orleans, LA (March, 1993).