COURSE OVERVIEW:

The rotors of large turbines and compressors are among the most expensive and precision-engineered assets in an industrial facility. This course provides a specialized technical framework for the management of these components during their most vulnerable states: while in transit or long-term storage. Participants will examine the mechanical risks inherent in handling multi-ton rotors, where even a microscopic scratch on a journal surface or a slight deflection in the shaft can lead to catastrophic failure upon installation.

The curriculum focuses on the physics of rotor deformation, specifically the phenomenon of "permanent set" or bowing due to improper support. We will cover the engineering requirements for shipping containers, specialized cradles, and the use of vertical versus horizontal storage methods. Detailed instruction is provided on the selection of vapor-phase corrosion inhibitors (VPI) and long-term grease coatings that protect sensitive metallurgy from atmospheric degradation without damaging the precision balance of the rotating assembly.

Operational procedures for the "turn-over" of horizontal rotors and the management of nitrogen purging for storage containers are explored in depth. Attendees will learn how to document the chain of custody and preservation logs required for insurance and warranty compliance. By mastering these preservation techniques, maintenance teams can ensure that spare rotors remain in a "ready-to-run" condition, significantly reducing the downtime associated with emergency machinery repairs.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Identify the critical lifting points and center of gravity for various rotor designs.

2.  Select the appropriate rigging hardware for heavy rotating assemblies.

3.  Implement vertical storage techniques to eliminate shaft bowing.

4.  Calculate the required support points for rotors stored in horizontal cradles.

5.  Apply specialized corrosion inhibitors to journal and seal areas.

6.  Manage nitrogen-purged shipping and storage containers.

7.  Execute "rotor turning" schedules for horizontally stored shafts.

8.  Monitor and interpret humidity and pressure sensors in storage skids.

9.  Conduct pre-storage and post-transport dimensional inspections.

10.  Identify the signs of "brinelling" and vibration damage during transport.

11.  Develop a comprehensive preservation log and maintenance schedule.

12.  Audit the storage conditions of third-party warehouses.

13.  Prepare a rotor for immediate installation following long-term preservation.

TARGET AUDIENCE:

Reliability Engineers, Maintenance Managers, Rigging Supervisors, Warehouse Foremen, and Rotating Equipment Specialists involved in the upkeep of critical spares.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.