Maintenance and Operation of Rotating Equipment

Introduction

This intensive training course will introduce delegates to elements of rotating equipment as encountered in the oil and gas industry.  Various types of gas compressors, pumps and turbines will be discussed and the importance of their vital design elements such as bearings, seals, filters, safety controls, and others, will be explained in detail.

The focus of this training course will be on the start-up and operation of these machines and their optimal maintenance, diagnostics, and troubleshooting techniques. The training will also highlight the guidelines for efficient and safe operation, by indicating the important elements of safety control systems.

This training course will feature:

• Principles of compressor, pump and turbine start-up and operation
• Best practices for maintenance and repair
• Measurement and control of the performance of these machines
• Inspection and diagnosing the root cause of problems
• Troubleshooting techniques for operational problems of pumps, compressors, and turbines
• This course covers equipment driven directly by gas turbines or indirectly through gas turbine-driven generator sets.
• Machines deteriorate as they get older so we can expect a certain amount of performance falloff and general deterioration of the machine.  If we understand the failure mechanisms that are in place we can identify which parameters best indicate the deterioration of the machine. 
• Failure analysis, Troubleshooting and Predictive & Planned Maintenance techniques, including vibration analysis, are discussed in the course with a view to optimizing the maintenance engineering effort while maximizing production
• This course covers root cause analysis “RCA”, Mode of failure for gas turbine, inspection for blades, buckets, nozzle, bearings, repair method, oil analysis and relation with vibration analysis.

Objectives

By the end of this training course, participants will be able to:

• Understand the operation of various types of compressors, pumps, and turbines
• Operate compressors pumps and turbines close to their design efficiency
• Monitor compressor, pump and turbine reliability, and availability
• Combine a range of operation and cost-effectiveness
• Select the best operation and maintenance strategy
• Troubleshoot compressor, pump and turbine problems

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations.

Who Should Attend?

This course is directed towards Supervisors, Team Leaders and Managers in Maintenance, Engineering and Production.  The course will also benefit anyone who wishes to update themselves on Predictive Maintenance Technologies and Failure Analysis techniques, as well as those who have to judge the suitability of these technologies for their needs, and learn how to implement them for the benefit of their organizations.

Course Outline

Day 1: Pumps and Compressors

• The basic principles of rotor dynamic and positive displacement pumps and compressors and the effects of:
• Cavitations
•  Compressibility
• Viscosity variation
• Humidity
•  Losses in fluid systems and interaction between machines and systems.
•  Introduction to the basic design principles of pumps and compressors, involving shafts, bearings and seal systems.
• A discussion of the regulation of pumps and compressors.
• The correct selection and application of pumps and compressors.

Day 2: Understanding Failures

• Machine Failure Analysis
• Wear and tribology
• Fatigue mechanisms
• Plain, tilt-pad and anti-friction bearing and seal failures

 Avoiding Failures

• Analysis and identification of failures
•  FMEA and FMECA to identify failure modes and criticality analysis
• Troubleshooting techniques
• Statistical analysis of failures
•  Reliability, availability, and maintainability

Day 3: Understanding Planned Maintenance

• Planned Maintenance Concepts
• Introduction
• Maintenance Strategies
• Planned Maintenance – background and history
• Planned Maintenance Technologies – an overview
•  CMMS – an overview
• Potential Failure Analysis –
• Deciding which technologies to apply to avoid failures

Day 4: Using Predictive Maintenance

• Vibration Analysis
•  Introduction to Vibration Analysis
•  Frequency Analysis and the Fast Fourier Transform
• Vibration Transducers
• Basic Failure Mechanisms with examples
• Vibration Standards and Alarm Levels
• Vibration Diagnostics
• Amplitude Demodulation – aka Enveloping, SSE, HFD, Peak-Vue
•  Vibration on Rolling Element Bearings
•  Resonance – identification & cure
• Other Predictive Maintenance Techniques
• Infrared Thermography
• Thermographic applications
• Passive Ultrasonics - contact and non-contact
• Ultrasonic Applications
•  Tribology – oil analysis

Day 5: Control Mechanisms

• Managing Planned Maintenance
• Performance and Efficiency Monitoring
• Managing the Planned Maintenance effort
• Cost Analysis
• Reporting Techniques
• Integrating Predictive Maintenance into the Maintenance Plan