The program assumes familiarity with troubleshooting and maintenance of rotating equipment. It adopts the approach to understanding the failure of all types of pumps and compressors. From a component-by-component perspective, the program investigates the root causes of failure, and relates these to operating conditions and process parameters. Installation, lubrication and wear related failure mechanisms are identified and a detailed understanding of the troubleshooting and diagnostic methods needed to detect and identify these is developed. The program provides participants with the knowledge needed to be effective in the inspection, monitoring and diagnostics of pumps and compressors, with emphasis placed upon the importance of a combined condition monitoring and strip-down inspection approach to maintenance. The main objective of this course is to enhance skills of plant personnel to increase productivity. This program aims to provide delegates with a comprehensive understanding of how to use a combined predictive and preventive maintenance approach to achieve maximum reliability and greatest understanding of any deterioration that may occur. This course focuses on the essentials to add to the skills of those who are responsible for plant equipment to reduce breakdowns and get more operation hour.

Plant and process engineers, operators, supervisors and team leaders and managers in maintenance engineering and production.  It is suitable for those who expects to become involved at any stage in project application and applicable maintenance technologies. The seminar will also benefit anyone who wishes to update themselves on pump and compressor technology, judge the suitability of different types of rotating equipments  for their needs, and learn how to operate and maintain them for the benefit of their organizations

TECHNOLOGY OF PUMPS

•         Parts of the machine: casing, rotor, bearing, coupling.
•         Auxiliaries: heating, cooling, lubrication.

• Maintenance:strip-down,assembly,inspection,clearance,                               

•         Summary of Thermodynamic Concepts involving Entropy. .  

OPERATION & PERFORMANCE

•         Process aspects
•         Operating parameters; head, flow, rpm, efficiency.
•         Characteristic curves.
•         Effect of wear.
•         Mechanical issues.
•        Pumps maintenance

Compressors

1. Overview
   1. Compression Methods
   2. Positive-Displacement And Rotodynamic compressors

• Reciprocating compressors technology and maintenance

1. Different types of machine for the compression of gas
2. Piston compressors
3. Design applications of reciprocating compressors with one or more stages
4. Types of construction
5. Machines with and without crossheads

3. Compression cycle of reciprocating compressors and basic calculations

1. Ideal cycle of piston compressor
2. Real cycle departure from ideal cycle
3. Volumetric efficiency
4. Example of calculation
5. Capacity
6. Power
7. Compression in several stages
8. Allowable pressure and temperature
9. Allowable speed
10.  Rod loading

4. Main Parts and Construction

1. Frame and crankshaft assembly
2. Crosshead
3. Connecting rod
4. Bearing and bushes
5. Cylinders and clearance volume
6. Pistons rings and rider rings
7. Stuffing boxes
8. Valves

5..Maintenance

1. Disassembly and assembly procedures
2. Crankshaft and bearings inspection \ replacement and assembly
3. Web deflection checks and adjustment
4. Inspection repair and installation of cylinders
5. Disassembly and assembly of piston and piston rods
6. Adjusting end clearances of pistons
7. Inspection and replacement of piston and rider rings
8. Packing components inspection and assembly
9. Oil scraper rings replacement
10. Valves disassembly, inspection and assembly
11. Frame lubricating system
12. Cylinder lubricating system

6.Failures Analysis and Troubleshooting

Centrifugal Compressors Technology And Maintenanc

1.Aerodynamic Components

1. Axial Compressors
2. Centrifugal Compressors
3. Interstage Seals
4. Balance Piston Seal
5. Impeller Thrust
6. Efficiency Improvement

2.Compressor Characteristics

1. Centrifugal Compressors
2. Slope
3. Stonewall
4. Surge
5. Off-Design Operation
6. Adjustable Vanes

3.Systems And Techniques Of  Protection

4.Technology Of Maintenance

1. Disassembly And Assembly Procedures
2. Inspection, Repair And Installation Of Labyrinth
3. Dry Seal Replacement
4. Tribology And Lubrication Of Bearings

5.Troubleshooting

1. Field Problems (Case Studies)
2. Troubleshooting Guide
3. Bearing Inadequate Lubrication Failure

Gas turbine

Fundamental Thermodynamics:

            -           Reversible cycles with ideal gases

            -           Actual gas turbine cycle

            -           Combustion air compressor performance characteristics

            -           Combustion processes

            -           Gas turbine performance calculation

            -           Comparison of basic specifications

Gas Turbine Components:

            -           Axial-flow compressor

            -           Radial-inflow turbines

            -           Combustors, construction types

            -           Igniters

            -           Fuel nozzles

            -           Hot path components

            -           Firing concept and emission control

Gas Turbine Operation and Maintenance:

            -           Operating philosophies

            -           Analytical on-line condition monitoring

            -           Modern bores copy

            -           Selecting maintenance approaches

            -           Maintenance planning

            -           Spare parts and special tools

            -           Inspection, overhaul and repair

            -           Maintenance control and documentation

            -           Evaluation

            -           Gas turbine maintenance effectiveness

            -           Establishing and tracking performance indices

Steam Turbines:

• Operating Principles, Impulse Turbines, Reaction Turbines
• Turbine Components:
• Turbine Rotors, Blading, Diaphragms, Nozzles, Steam Chests, Glands and Gland Systems, Bearings           
• Balancing, Rotor Dynamics, Governing Systems, Lube Oil Management
• Overview of Selection and Sizing of Steam Turbines for Reliability:
• Thermodynamics, Steam (Water) Rates, Condensing and Backpressure Turbines, Single and Multistage Types, Process Considerations –   
• Operation and Maintenance of Steam Turbines:
• Operation and Maintenance of Steam Turbines (Continued):
• Steam Turbine Washing, Steam Turbine Inspection, Maintenance, Overhaul and Repair

LUBRICATION AND BEARING PROBLEMS

• Purpose, different types of oil and grease.
• Anti-friction bearings: types, lifetime, mounting, applications,          related problems.
•  Plain and pad bearings, thrust bearings: operation, maintenance, incidents.

COUPLINGS & MISALIGNMENT

•         Different types of couplings, related problems
•         Different methods of alignment.

SEALS

•  Mechanical pump seals, types, operation, related problems.
• Other seals for positive displacement pumps and reciprocating compressors.
•  Pump Sales: Affinity laws. Pump software. Suction lift. Viscosity. Re-rate/retrofit. Head-rise.  Radial/horizontal split case

 VIBRATION MONITORING

o       What to monitor and where.

• Measurement devices
• Overall and spectral measurements.
• Vibration limits
• Introduction to spectrum analysis.

• Mass Unbalance
• Eccentric Rotors
• Bent Shaft
• Misalignment
• Practical case study
• Mechanical Looseness
• Tracking Of Rolling Element Bearings Failure Stage Using Vibration Signature Analysis
• Journal Bearings Failure
• Gear Problem Detection
• Practical case study
• Electrical Problem Detection
• Belt Drive Problem
• Resonance Problem
• Hydraulic And Aerodynamic Forces Problem
• Rubbing
• Practical case study

Alignment Methods & Application

1- Introduction

• What's Alignment?
• The alignment Process
• Pre-shutdown preparation
• Prior to Misalignment Measurement
• Base preparation
• Coupling Run out
• Soft Foot
• Piping Strain

2- Alignment Calculation

3- Rim and Face Shaft Alignment

4- Double Radial Method.

5- Reverse/Cross Dial Alignment Method.

6-Shaft to Coupling Spool Method .

Planned Maintenance Concepts

• Overview
• Why do I need a strategy?
• Reactive Maintenance
• Preventive Maintenance
• Predictive Maintenance
• Proactive Maintenance

Predictive Maintenance Technology

1 Introduction

2 Benefits of predictive maintenance

3 Predictive maintenance techniques

3.1 Vibration monitoring

3.2 Thermography

3.3 Tribology

3.4 Process parameters

3.5 Visual inspection

3.6 Ultrasonic monitoring

3.7 Other techniques

RECTUS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration