Course Overview

Maximum Efficiency, Reliability, and longevity of Compressors, Pumps, Fans, Bearings, Motors, and Variable-Speed Drives are of great concern to Many Industries. These objectives can only be achieved by understanding the Characteristic, Selection Criteria. Sizing Calculations, Sealing Arrangements, Common Problems and Repair Techniques, Preventive and Predictive Maintenance of this equipment. This course is a MUST for anyone who is involved in the Selection. Calculations, Sizing, Applications, or Maintenance of Compressors, Pumps. Bearings, Motors or Variable-Speed Drives.This intensive course is designed to provide a comprehensive understanding of the various types of compressors, pumps. Bearings, motors, and variable-speed drives. Participants will be able to specify, select, size, commission and maintain these equipment for their applications. Further, participants will learn how to achieve reduced capital, operating and maintenance cost along with increase in efficiency. Condition Monitoring (CM) has a unique benefit in that conditions that would shorten Normal Lifespan can be ad-dressed before they develop into a Major Failure. Condition Monitoring Techniques are normally used on Rotating Equipment and other Machinery (Pumps, Compressors, Electric Motors. and internal Combustion Engines), while periodic inspection using non-destructive testing techniques and Fit for Service (FF5) evaluation are used for stationary plant equipment such as Steam Boilers, Piping and Heat Exchangers.

Course Objectives

Attendees will gain an understanding of:

• Explain the Concepts and Principles of Equipment Care and Condition Monitoring and Monitor and Care for Process Equipment
• Identify common causes of rotating equipment failures to ensure successful troubleshooting
• Apply troubleshooting procedures that lead to the determination of root causes of failures
• Investigate troubleshooting tools and select the most appropriate ones for the situation in hand
• Implement best practice maintenance on the common causes of failures like shaft alignment, rotor balancing, performance testing, and others
• Design and plan a failure prevention program that reduces the number of failures of the most critical equipment to reduce maintenance cost and increase equipment reliability
• Have in-depth knowledge of Equipment Selection, Proper Operation Activities. Fault Diagnosis and Troubleshooting through Presentation of actual Case Studies

Who Should Attend?This course is intended for Maintenance Engineers and Technician, Rotating Engineers and Technicians. Also, Operation Engineers and Operators.

Course Contents

Module (01): Introduction and Common Basics

• Introduction to Rotating Equipment
• Classification of Rotating Equipment
• Performance Parameters
• Different of Applications
• Common Problems of Rotating Machines
• Accessories of Rotating Machines
• Auxiliary Systems

Module (02): Lubrication & Bearings

• Types of Bearings and their Applications
• Lubricants function. Properties and Types
• Bearings Failure and Common Problems
• Troubleshooting of Lubrication Systems
• Case Studies and Discussion

Module (03): Rotating Equipment Failure

• Failure Definition
• Failure Modes identification
• Categories of failure Causes
• Physical
• Human
• Latent (Hidden)
• Failure Effects
• Failure Cascading
• Chronic Vs. Sporadic Problems
• exercises (Applications)

Module (04): Condition Monitoring for Pumps

• Centrifugal Pumps
• Reciprocating Pumps
• Rotary Pumps
• Controlling Leaks
• Cavitation Phenomena

 Module (05): Condition Monitoring for Compressors

• Centrifugal Compressors
• Reciprocating Compressors
• Rotary Compressors
• Excess Heat Problem
• Unwanted Moisture
• Compressor Surge Phenomena

Module (06): Contrition Monitoring for Motors

• Overheating
• Frequency (Fixed/Variable)
• Lubrication System
• Overcurrent

Module (07): Rotating Equipment Support System

• Lubrication System
• Alignment & Balancing
• Vibration Monitoring & Analysis
• Mechanical Seals
• Cooling System
• Warm Up System

Module (08): Condition Monitoring for Attachments

• Hammering
• Leakage
• Corrostn
• vibration
• Sealing Problems
• operation Problems

Module (09): Equipment Care Management

• Standard Operation Procedures (SOP)
• Safe Standard isolation Procedures (SSIP)
• Plan Preventive Maintenance Work
• Execute Preventive Maintenance Tasks
• Manage Predictive /Proactive Maintenance
• Work with Reliability Improvements
• Supervise Maintenance Staff
• Coordinate with CM/PM Tasks
• Historical Date for Equipment using CMMS
• Managing & Leading always Operators

Module (10): Enhancing Plant Reliability System

• Reliability as Maintenance Strategy
• Basic System Analysis • Stand by Equipment/System/ Unit
• Life Cycle Cost (LCC) Analysis
• How we can Contribute with Reliability Improvement?