Maintenance & Operation of Rotating Machinery

Foundation Course

Summary:

This course is essential for anyone who is involved in the selection, applications
or maintenance of rotating equipment because it covers the various types of
rotating equipment including Centrifugal Pumps, Positive Displacement
Pumps, Compressor Components, Reciprocated Compressors and steam
Turbines. The course provides an understanding of how this equipment
operates, introduces participants to the latest preventive and predictive
maintenance techniques, and provides guidelines and rules that ensure the
successful operation of this equipment to increase reliability of the equipment
and reduce operation and maintenance costs.

Who Should Attend?

This course is designed for valuable for Junior Mechanical Engineers, Junior
Operation Engineers, Maintenance Engineers and Operators and Maintenance
Mechanics.

Duration

Certification
The course will be certified based on PETROGISTIX request
 Agenda

Module 1: MATERIAL - PIPING - VALVES (maintenance basics)

• Materials and Piping standards: pipes, nominal diameter; thickness, Piping
classes. Piping accessories: different types of valves, check valves, relief valves,
line support, filters, flanges and gaskets.
• Risks related to equipment opening, isolation, blinding work, circuit lockout and
tagging procedure.

Module 2: ROTATING EQUIPMENT - Pumps

• Pumps: different types of pumps. Technology of centrifugal pumps and positive
displacement pumps. Mechanical seals, Start-up and operation monitoring,
Centrifugal force
• Fundamentals of a centrifugal pumps, Various kinds of impellers, Single stage
pump, multi-stage pumps, Bearings, Packed glands and mechanical seals,
Operation of centrifugal pumps, Trouble shooting
• Positive Displacement Pumps Pump types, Reciprocating pumps, Piston-
plunger, Diaphragm, Rotary pumps, Pumps main components, Troubleshooting
Module 3: RECIPROCATING COMPRESSORS (maintenance)
• Valves, cylinders, pistons: assembly, alignment, rings and bands assembly, rod
drop control.
• Rod packing seals, rods: stuffing box parts control and assembly, rod
geometrical control, crosshead junction, clearance adjustment.
• Crankcase, crank shaft and cranks: crankshaft bearings control, stress
measurement, bearings alignment. Assembly of cranks and crosshead, typical
clearances, tightening torque. Auxiliary systems: maintenance of main
lubrication circuit.

Module 4: CENTRIFUGAL COMPRESSORS

• Compressor parts overhaul: impellers and rotor, diaphragm, counter casing and
casing, mechanical seals. Checks.
• Common turbomachinery parts assembly and maintenance
• Case studies: centrifugal compressor troubleshooting; assembly/disassembly
procedures studies.
Module 5: ROTATING EQUIPMENT (condition monitoring & troubleshooting)

• Troubleshooting analysis.
• Monitoring results analysis: vibrations levels, lubrication and seal circuit
parameters, abnormal values, oil quality.
• Component failures: seal leakages, bearing damages, rotor sags, impeller
cracks, misalignment. Hydraulic phenomena: cavitation, un-priming, volute
effect, surge.
• Machine monitoring devices: process operating parameters (monitoring and
analysis of the machine process data and logs). Monitoring tools dedicated to
the machine type: vibration monitoring, PV card indicator, rod drop, bearings
temperature.
• Failure analysis and inspection tools.

Module 6: DIESEL ENGINE Operation and Maintenance

• Principles of operation of diesel engines

• Function and operation of the major components:
o Main Components of Diesel Engines
o Lubrication and Cooling Systems
o Supercharging and Turbochargers
o Air Supply and Exhaust Systems
o Starting System
• Modern Injection systems and Engine Management System
• Diesel Engines Operation and Troubleshooting
o Pre-checks for Operation
o Normal Operation Observation and Monitoring
o Shutdown Procedures
o Abnormal Operating Conditions
o Common Problems for Diesel Engines
o Diesel Knock
o Troubleshooting Matrix
• The best maintenance practice of diesel engine