Rotating Equipment
Why Attend
Course Objectives
Target Audience
Course Methodology
Why Attend
This course is designed to provide participants with a detailed and up to-date overview of Advanced Inspection & Performance Evaluation of Rotating Equipment. It covers the types, applications and significance of rotating equipment in industrial settings; the importance of safety in maintenance practices; the inspection techniques for rotating equipment and the role of lubricants in equipment performance; the techniques and tools for vibration analysis and thermal imaging to identify potential issues; the ultrasonic testing methods for detecting internal flaws; the tools used for precise measurement in maintenance; and the patterns of wear and how to address them.
The advanced course on inspecting and evaluating the performance of rotating equipment would equip participants with the expertise needed to tackle complex challenges in the field, empowering them to optimize equipment performance, minimize downtime, and enhance operational efficiency in industrial settings.
The advanced course on inspecting and evaluating the performance of rotating equipment would equip participants with the expertise needed to tackle complex challenges in the field, empowering them to optimize equipment performance, minimize downtime, and enhance operational efficiency in industrial settings.
Course Objectives
Upon the successful completion of this course, each participant will be able to:-
- Apply and gain an advanced knowledge on inspection and performance evaluation of rotating equipment.
- Discuss the types, applications and significance of rotating equipment in oil & gas industrial settings
- Carryout inspection techniques for rotating equipment.
- Explain the potential problems of inappropriate inspection and evaluation of performance on the various types of Rotating Equipment at own site.
- Determine the tools used for precise measurement in maintenance and describe the patterns of wear and how to address them
- Make adjustments, as required, to Rotating Equipment settings, with advice from SME or Manufacturer, based upon analysis of condition monitoring results.
- Evaluate and enhance equipment efficiency and discuss the principles and implementation of RCM
- Apply the techniques and tools for vibration analysis and thermal imaging to identify potential issues
- Explain what should be done if the results of condition monitoring are unacceptable.
- Explain the need for condition monitoring records registration.
- Explain the risks and hazards when working around rotating equipment.
- Perform the correct evaluations when performing routine inspection.
- Coach others on applying and implementing elements of KOC Inspect & Evaluate Performance of Rotating Equipment Rules and Standards.
- Explain the permit to work requirements & the standards and procedures for this work.
- Analyze and interpret the results of condition monitoring as part of plant integrity.
- Assess the technical competence of others in implementing KOC Inspect & Evaluate Performance of Rotating Equipment Rules and Standards and related KOC
- Perform the correct evaluations when performing routine inspection.
Target Audience
This course provides an overview of all significant aspects and considerations of advanced inspection and performance evaluation of rotating equipment including turbine maintenance for mechanical engineers, maintenance engineers, plant managers and supervisors, reliability engineers, process engineers, maintenance planners, maintenance and reliability managers, field service engineers, energy industry professionals, pump and compressor specialists and those who are involved in the operation, maintenance, and inspection of rotating machinery.
Course Methodology
All our Courses are including Hands-on Practical Sessions using equipment, Stateof-the-Art Simulators, Drawings, Case Studies, Videos and Exercises. The courses include the following training methodologies as a percentage of the total tuition hours:-
- 30% Lectures
- 20% Practical Workshops & Work Presentations
- 30% Hands-on Practical Exercises & Case Studies
- 20% Group discussion & team work
Course Outline
Day - 1
07:30 – 07:45
Registration & Coffee
07:45 – 08:15
Welcome & Introduction
Discuss Objectives & Outline
08:15 – 09:45
Introduction for Rotating Equipment in our oil and gas industry.
Activity – learn video & necessary animation, graphics
09:45 – 10:00
Break
10:00 – 12:00
Advanced Inspection Techniques & condition monitoring & its tools and correct evaluation for rotating equipment
Activity – workshop (critical rotating equipment monitoring system), Practical application, learning video
12:00 – 12:15
Break
12:15 – 14:15
Potential problems and failures of various types of Rotating Equipment at own site due to inappropriate inspection and evaluation of performance through practical exercises and case study.
(Safety hazards, equipment Failure, reduced Operational efficiency, increased maintenance costs, environmental impact, loss of Reputation, loss of asset integrity)
Activity –- 3D animation, learning videos & workshop (pump cavitation) & compressor surge
14:15–14:30
Course Conclusion
Registration & Coffee
07:45 – 08:15
Welcome & Introduction
Discuss Objectives & Outline
08:15 – 09:45
Introduction for Rotating Equipment in our oil and gas industry.
- Compressors. (Theory of operation, calcifications, construction, codes and, STD).
- Pump (Theory of operation, calcifications, construction, codes and, STD).
- Steam turbine. (Theory of operation, calcifications, construction codes and, STD).
- Gas turbines. (Theory of operation, calcifications, construction codes and, STD).
- Blower & fans. (Theory of operation, calcifications, construction codes and, STD).
Activity – learn video & necessary animation, graphics
09:45 – 10:00
Break
10:00 – 12:00
Advanced Inspection Techniques & condition monitoring & its tools and correct evaluation for rotating equipment
- Vibration Analysis
- Thermography (Infrared Imaging)
- Oil Analysis
- Ultrasound Testing
- Magnetic Particle Inspection (MPI) and Dye Penetrant Testing (DPT)
- Remote Monitoring Systems
- Acoustic Emission Testing
- X-ray and Eddy Current Testing
- Laser Alignment Systems
- Condition Monitoring Software
Activity – workshop (critical rotating equipment monitoring system), Practical application, learning video
12:00 – 12:15
Break
12:15 – 14:15
Potential problems and failures of various types of Rotating Equipment at own site due to inappropriate inspection and evaluation of performance through practical exercises and case study.
(Safety hazards, equipment Failure, reduced Operational efficiency, increased maintenance costs, environmental impact, loss of Reputation, loss of asset integrity)
- Machine vibration (Causes, failure consequence, remedy action). Advanced techniques of vibration condition monitoring & protection system. Adjustments as required according to MFR.
- Bearing failure (Causes, failure consequence, remedy action). Advanced techniques of bearing condition monitoring & protection system. Adjustments as required according to MFR.
- Pump cavitation (Causes, failure consequence, remedy action). Advanced techniques of pump operation condition monitoring & protection system. Adjustments as required according to MFR.
- Compressor surge (causes, failure consequence, remedy action). Advanced techniques of compressor operation condition monitoring & protection system. Adjustments as required according to MFR.
Activity –- 3D animation, learning videos & workshop (pump cavitation) & compressor surge
14:15–14:30
Course Conclusion
Day - 2
07:30 – 07:45
Registration & Coffee
07:45 – 08:15
Recap of Day 1
08:15 – 09:45
Activity –- 3D animation, learning videos & workshop (coupling & machine alignment)
09:45 – 10:00
Break
10:00 – 12:00
The Major activities and required actions procedures if the results of condition monitoring unacceptable.
12:00 – 12:15
Break
12:15 – 14:15
Condition monitoring records registration
The Role of Records Registration in Condition Monitoring
14:15 – 14:30
Course Conclusion
Registration & Coffee
07:45 – 08:15
Recap of Day 1
08:15 – 09:45
- Pump sealing system failure (Causes, failures consequence, remedy action). Advanced techniques of sealing parameters condition monitoring & protection system. Adjustments as required according to MFR.
- Compressor dry seal failure. (Causes, failures consequence, remedy action). Advanced techniques of dry seal operation condition monitoring & protection system. Adjustments as required according to MFR.
- Lubricating system failure. (Causes, failures consequence, remedy action). Advanced techniques of lube oil system condition monitoring & protection system.
- Machine misalignment. (causes, failures consequence, remedy action). Advanced techniques of shaft alignment condition monitoring & protection system. Adjustments as required according to MFR.
Activity –- 3D animation, learning videos & workshop (coupling & machine alignment)
09:45 – 10:00
Break
10:00 – 12:00
The Major activities and required actions procedures if the results of condition monitoring unacceptable.
- Immediate Action
- Root Cause Analysis.
- Maintenance or Repair.
- Optimization.
- Continuous Monitoring
- Training and Education.
- Documentation and Reporting.
12:00 – 12:15
Break
12:15 – 14:15
Condition monitoring records registration
The Role of Records Registration in Condition Monitoring
- Definition of Records Registration, Importance of documenting condition monitoring data
- How records registration enhances equipment maintenance and reliability
- Improved equipment reliability and uptime, Early detection of potential failures
- Cost savings through predictive maintenance, Compliance with regulatory requirements
- Data collection methods and tools, Data storage and management systems
- Documentation standards and best practices
- Real-world examples of successful condition monitoring programs
- How proper records registration contributed to maintenance efficiency and cost savings.
- Accessing the Database, Identifying Equipment, Reviewing Existing Records
- Updating Records, Accuracy Check, Saving Changes, Verification
- Documentation, Notification, Regular Maintenance
14:15 – 14:30
Course Conclusion
Day - 3
07:30 – 07:45
Registration & Coffee
07:45 – 08:15
Recap of Day 2
08:15 – 09:45
Work permit requirements, standards & procedures.
09:45 – 10:00
Break
10:00 – 12:00
Risks and hazards for working around rotating equipment:
12:00 – 12:15
Break
12:15 – 14:15
Major Faults Identified by Vibration Analysis
Activity –- Final Workshop: Practical Assessment
14:15 – 14:30
Course Conclusion
Registration & Coffee
07:45 – 08:15
Recap of Day 2
08:15 – 09:45
Work permit requirements, standards & procedures.
- Importance of Permits to Work
- Permit to Work System Overview
- Risk Assessment and Hazard Identification
- Isolation Procedures
- Training and Competency Requirements
- Communication and Coordination
- Emergency Procedures
- Documentation and Record-Keeping
- Review and Continuous Improvement.
09:45 – 10:00
Break
10:00 – 12:00
Risks and hazards for working around rotating equipment:
- Entanglement, Contact Injuries, Pinch Points, Flying Debris, Noise, Vibration
- Electrical Hazards, Chemical Hazards, Overheating, Lack of Guarding
- Maintenance Hazards.
- Training and Education, Personal Protective Equipment (PPE), Machine Guarding
- Lockout/Tag out Procedures, Regular Maintenance and Inspections
- Warning Signs and Labels, Safe Work Practices, Emergency Response Plan
- Risk Assessments, Continuous Improvement.
12:00 – 12:15
Break
12:15 – 14:15
Major Faults Identified by Vibration Analysis
- Machine imbalance
- Machine misalignment
- Resonance
- Bent shafts
- Blade pass disturbances
- Recirculation and cavitation
- Motor faults
- Bearing failures
- Mechanical looseness
- Critical machine speeds
Activity –- Final Workshop: Practical Assessment
14:15 – 14:30
Course Conclusion