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ENERGY

Customized Training

Power Generation

 

50 Hertz Gas Turbine Familiarization

DESCRIPTION: Overview of 50 Hz engine and rotor technology for power generation applications. Topics include:

  • Overview of 50 Hz engine turbine technology
  • Review of rotor design
  • Review of rotor incoming inspection
  • Review of tooling list and tooling
  • Review of Class 2 inspection criteria and disassembly
  • Review of serrated type couplings and reassembly
  • Final machining and balancing requirements

TARGET AUDIENCE: Seasoned professionals in the field with strong understanding of rotor technology, commercial leads in rotor repair business, NDE experts & mechanical engineers

60 Hertz Gas Turbine Familiarization

DESCRIPTION: Overview of a gas turbine for power generation applications. Topics include:

  • Introduction to 60 Hz Gas Turbines
  • Turbine Engine Overview
  • Inlet Casing
  • Compressor Casing
  • Combustor
  • Turbine Cylinder
  • Exhaust Cylinder & Manifold
  • Compressor-Turbine Rotor
  • Generator-Exciter-Starting Package
  • Electrical Systems
  • Auxiliary Systems
  • Control Systems
  • Simple Cycle Configuration
  • Combined Cycle Configuration
  • Power Plant Performance
  • Operation
  • Manufacturing

TARGET AUDIENCE: Seasoned professionals in the field with strong understanding of rotor technology, commercial leads in rotor repair business, NDE experts & mechanical engineers

Contractor safety & quality

DESCRIPTION: An instructor-lead program to teach and reinforce nuclear safety culture and use of event-free tools such as three way-communication, questioning attitude, conservative decision making, procedural use and adherence and other proven practices and approaches used throughout the nuclear industry. Emphasis will be placed on compliance with local plant policies and the avoidance of unplanned events. This is an interactive course designed to quickly acclimatize and orient contractor staff to the practices important to the nuclear facility. Courses can be specifically developed and delivered for each plant environment. Topics include:

  • Plant work program objectives.
  • Site radiation zones, buildings and areas.
  • Organization of a nuclear shutdown.
  • Nuclear work planning processes and methodologies.
  • Operational nuclear safety.
  • Practices to ensure reliable and safe operations.

  • Event scene preservation.
  • Quality Assurance procedures specific to the nuclear plant.
  • Risk management overview.
  • Qualification and assessment of contractors.
  • Performance management process for contractors..

TARGET AUDIENCE: All potential contractors and consultants planning to perform work within a nuclear operating environment.

Craft perspective

DESCRIPTION: Effective nuclear teams consist of multiple work groups, management, supervisory and administrative staff. Often delays and barriers encountered by field workers are not well understood by all team members. This program provides the craft perspective on getting work done in the nuclear facility. Lead by instructors with extensive field and work management experience, the learning objective is to closely improve understanding between each element of the team and align engineering and planning staff with the reality of “How it Works” in the field. The course has classroom and field components where tasks will be discussed and followed from planning through to close-out. Courses can be specifically developed and delivered for each plant environment. Topics include:

  • Operation Experience overview.
  • Understanding the various work groups on the team.
  • Field work processes.
  • Facility reporting requirements.
  • A day in the life of a craft worker.
  • Administrative processes.

  • Plant walk-through.
  • Task life cycle tour.
  • Improving communication between work groups.
  • Removing barriers.
  • Planning and developing work packages for success..

TARGET AUDIENCE: All management, supervisory and planning staff interested in gaining a better perspective on how field work is performed in a nuclear facility.

Effective Management in Unionized Environments

DESCRIPTION: This course is designed to compliment management’s relationship with their employees. Having an edge can make all the difference in todays global market.  Topics include:

  • Effective Management Overview
  • Working relationships: Understanding One’s Role
  • Effective change & flexibility
  • Teamwork: perceptions, honesty & sincerity
  • Decision making
  • Middle Management Leadership
  • Senior Management
  • Advantages of change
  • Ownership & motivation
  • Workshops, review & discussion

TARGET AUDIENCE: This course is designed for all employees (both management & union)

Efficient process engineering

DESCRIPTION: In a highly process-driven industry, such as nuclear power generation, process weakness and failure can accounts for significant cost and schedule losses. Users of these processes often feel frustrated and helpless in their efforts to get work done. The resulting loss of moral can greatly reduce an organization’s effectiveness and can lead to unsafe work-arounds and unplanned events. This course raises awareness of the importance of robust, efficient processes and teaches methods to build and administer effective, easy to use processes. Topics include:

  • Process failure operational experience.
  • Knowledge vs. Process Operation.
  • Procedural use and adherence.
  • Understanding the process user’s world.

  • Process design fundamentals.
  • Process communication and roll-out.
  • Process change.
  • Enforcing process use.
  • Process efficiency tracking and reporting.

TARGET AUDIENCE: All staff developing and administering processes in a highly process driven industry.

Event free operation

DESCRIPTION: Building on the concepts discussed in the Nuclear Culture course, this program provides practical tools and techniques that are currently in use at highly rated nuclear power plants around the world. Various task scenarios are discussed and participants will have the opportunity to practice the use of the tools and techniques with simulated plant equipment and conditions. A package of handy tips and tools, can be customized, ready for use for each facility. Topics include:

  • Industry Operational Experience (OPEX).
  • Conservative decision making.
  • Event-free tools.
  • Examples of improvements in safety and production due to Event Free Tools (EFTs).

  • Practical workshop.
  • Foreign material exclusion tools and materials.
  • Discipline in the use of EFTs.
  • Metrics and reporting.

TARGET AUDIENCE: Regular staff and contractors involved in nuclear planning and execution

Failure Mode & Effects Analysis (FMEA)

DESCRIPTION: The FMEA is a design tool used to systematically analyze postulated component failures and identify the resultant effects on system operations. This course provides step-by-step instruction of the FMEA process focussing both on Design FMEAs (DFMEAs) and Process FMEAs (PFMEAs). Topics include:

  • Introduction to FMEA
  • FMEA Process Overview
  • FMEA Development Technology
  • Language of the FMEA
  • Quantitative & Qualitative Techniques
  • Design & Process FMEAs
  • Other FMEA Types
  • Team & Team Mechanics of FMEA
  • Roles & Responsibilities of FMEA Team
  • Voice of the Customer (VOC)
  • FMEA & Robustness
  • Typical Tools Used in FMEA
  • Workshops: Application of an FMEA

TARGET AUDIENCE: Anyone trying to identify and reduce risk: design and/or process managers and engineers, or personnel in the fields of manufacturing, quality assurance, reliability research, development, and safety engineering.  Employees completing this training will be able to effectively participate on an FMEA team and can make immediate contributions to quality and productivity improvement efforts.

Foreign Material Exclusion (FME)

DESCRIPTION: FME is a program that helps prevent damage to equipment during a maintenance of critical equipment . This course will train employees to create their own FME procedures and help drive behaviors that support event free work campaigns. Xellerix can provide consulting services to help set up an FME program. Topics include:

  • Introduction to FME
  • Industry OPEX
  • Plant systems vulnerability
  • Critical elements of an FME plan
  • Developing an FME plan
  • FME tools and materials
  • Accountability in event reporting
  • FME metrics
  • Outage FME
  • Performance management tools

TARGET AUDIENCE: Primarily for workers and line management but is catered to all employees of a company. Regular staff and contractors involved in planning and execution of plant outage projects

Hot Gas Path Components & Repair

DESCRIPTION: Overview of service and repair to turbine hot gas path components. Topics include:

  • Design features & engine frame differences of
    • blades
    • vanes
    • combustor baskets
    • transitions
  • Repair Technologies
  • Refurbishment Technologies
  • Procedures
  • Research, Document Review & Preparation

TARGET AUDIENCE: Seasoned professionals in the field with strong understanding of rotor technology, commercial leads in rotor repair business, NDE experts & mechanical engineers

Nuclear culture

DESCRIPTION: The overwhelming priority in a nuclear facility is safe, event-free operation. This is often seen as being at odds with the idea of production, as it is viewed in other industries, and workers in the nuclear environment must understand and embrace the concept of conservative decision making and verification prior to executing critical steps. This is an interactive course that discusses some of the major unplanned events in nuclear industry history and how these could have been avoided with the use of current industry best practices. Event Free Operation is a natural extension to this program. Topics include:

  • Industry operating experience (OPEX)
  • Overview of behavior at highly rated nuclear facilities.
  • Understanding the priorities.
  • Linking the reduction of unplanned events to successful operation.

  • Importance of processes and procedures.
  • Knowledge curve.
  • Improving “wrench time” without sacrificing safety.
  • Performance management in nuclear.

TARGET AUDIENCE: All staff and contractors involved in the nuclear industry

Nuclear outage management

DESCRIPTION: Planned and forced shut-downs at nuclear facilities are usually managed differently from normal operation. Often short-term, temporary workers are introduced and routine practices are replaced by outage practices with different objectives. The likelihood of unplanned events can increase and steps must be taken to mitigate the risk. This program provides an overview of best practices used successfully in the international nuclear industry and is lead by instructors experienced in all aspects of nuclear plant outages. Courses can be specifically developed and delivered for each plant environment. Topics include:

  • Outage anatomy.
  • Understanding the work scope and schedule.
  • Critical path and schedule optimization.
  • Team building and alignment.
  • Work-face hand-offs.
  • Transitioning from operation to shutdown and back.

  • Outage team structure.
  • Outage reporting requirements.
  • Quality assurance.
  • Outage organization.
  • Risk management.

TARGET AUDIENCE: Regular staff and contractors involved in nuclear planning and execution.

Risk mitigation

DESCRIPTION: This program details the essential elements of a robust Risk Management Process. Specific plant scenarios and used to develop the framework for a Risk Management Plan for regular operation and plant outages. Example of industry best practices and  using the right level of risk management  for each application is discussed. Topics include: 

  • Industry OPEX.
  • Understanding risk.
  • The pros and cons of Risk Management.
  • Determining the right level of risk management effort for each occasion.
  • Normal operation and outage risk.

  • Critical elements of a Risk Management Plan.
  • Risk plan development scenarios.
  • Available industry tools to manage risk.
  • Accountability in managing risk.
  • Risk metrics and reporting.
  • Performance management tools.

TARGET AUDIENCE: Regular staff and contractors involved in nuclear planning and execution.

Turbine Rotor Service

DESCRIPTION: Overview of Class 2, 2A, 2B & 3 gas Turbine Service & Life Time Extension. Topics include:

  • Incoming Inspection
  • Destack Inspection
  • Repair process for single item components
  • Restack and allowable tolerances
  • Assembly & Refurbishment Processes
  • Field Issues
  • Fleet History
  • Long Lead Items

TARGET AUDIENCE: Seasoned professionals in the field with strong understanding of rotor technology, commercial leads in rotor repair business, NDE experts & mechanical engineers