Monday July 24, 2017 |
Kuala Lumpur, Malaysia
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.
Monday July 24, 2017 |
Kuala Lumpur, Malaysia
Module 1 - Identifying root cause of failure.
Group task: Testing the delegates critical thinking skills through role play by explaining and solving a failure example provided by the tutors failure example:
• Identifying what happened before the failure
• What consequence was there of the failure
• What was the sequence of failure
• What was root cause and how can we remedy?
This teaches delegates to think carefully through the failure from start to finish and appreciate that understanding sequence and consequences is vital to identifying true root cause, and this is vital if repeat failures are to be avoided.
Module 2 - Controls and engine surge
Control system: How it protects the engine, explained and discussed Failures often involve understanding the interactions of components of the gas turbine as a system system. The controls are the central place where protection is enabled. Delegates will learn the importance of controls and how that impacts on protection of the wider engine system.
Group task: Compressor surge - calculate compressor limits
• How compressors work and interact with combustors and turbine nozzles
• How engine surge can occur and how controls protect against this
• Impact of turbine entry temperature and Inlet Guide Vanes on engine surge control during start acceleration and operation
This module teaches the delegates to consider the engine as a system.
Module 3 - Failure investigation methods
Organising and structuring an investigation to plan a thorough root cause analysis investigation:
Importance and methods of communications
Formal failure investigation methods
• How to create a fishbone analysis
- Identifying possible failure causes (sub-categories of people, process, equipment)
- Failure effects and how this helps plan the investigation
• Sequence of Events analysis
- How to create a sequence of events diagram
- Differences between incidents, event, forcing function, qualifiers and assumptions
Group task: Produce fishbone and Sequence of Events diagrams of role play example.
Discuss strengths and weaknesses of each approach and how to apply them in practice.
Module 4 - Important factors which limit reliable operation
Engine Thermodynamic Performance
Group task: Calculate turbine entry temperature and turbine blade temperature.
Creep life – Group exercise - calculate turbine creep life using turbine blade temperature
Calculate turbine blade creep life reduction for an increase in turbine temperature of 20C
Discussion of importance of controls system in protecting engine.
Module 5 - Fatigue failures
Fatigue life – Low cycle and high cycle fatigue explained.
What is fatigue, where can it occur in a gas turbine?
Why is fatigue life important and how it limits engine operational life.
• Low cycle fatigue examples
• High cycle fatigue examples
Group task: Calculate number cycles to failure for presented example
Discuss and learn methods by which gas turbine fatigue life can be improved.
Module 1 - Types of metal fracture that could lead to gas turbine failure
Recognising Metallurgy fracture surfaces to correctly identify and explain cause of component failure
• Inter-granular cracks
• Ductile fracture
• Brittle fracture
• Fatigue fracture
Module 2 - Thermal fatigue
• Examples of thermal fatigue failure in gas turbines
• What is it? How does it break metal
- Thermal fatigue examples of combustors and transition components
- How thermal barrier coating helps reduce thermal fatigue
Group task: Example calculation of fatigue life on gas turbine transition piece
• How can you reduce thermal fatigue in gas turbines
- Influence of start sequence on thermal fatigue
- Importance of number of starts on thermal fatigue
Module 3 - Importance of failure patterns in root cause analysis
Looking for patterns in repeating failures
• Why pattern analysis is important in understanding root cause of failure and prevention of further repeat failures
• Examples of pattern analysis in real life gas turbine failure case studies
• Using creative thinking to test and explore possible failure patterns
• Methods to identify patterns
Group task: Role-play simulations of real life gas turbine failures identify failure patterns from real life gas turbine failures presented
Module 4 - Summarising learning form course
• Summaries and review causes of gas turbine failure – controls / temperature / fatigue
• Review importance of component interaction of whole system behavior and how controls protects engine
• Summarise metallurgical failure types and how they help identify root causes
• Review how delegate will report failure investigation better to management in the future
Group tasks: Update Sequence of Events diagram to include lessons learnt from course
Module 5 - Students can raise gas turbine failures and operational limit concerns they are familiar with for discussion with group / trainer