COURSE OVERVIEW:

The operational efficiency of any pumping or compression system is fundamentally dependent on the reliability of the prime movers that drive it. This course provides a comprehensive exploration of the various types of drivers used in industrial applications, including electric motors, steam turbines, and internal combustion engines. Participants will examine the critical interface between the driver and the driven equipment, focusing on how power transmission and torque requirements dictate the selection and maintenance strategies for these essential industrial assets.

The scope of this training extends from the fundamental physics of energy conversion to the advanced diagnostic techniques required to sustain long-term performance. We will delve into the mechanical and electrical complexities of prime movers, exploring their internal components, lubrication requirements, and cooling systems. By understanding the specific stressors that prime movers face in continuous process environments, attendees will gain the perspective necessary to transition from reactive repairs to a structured, reliability-centered maintenance approach that minimizes unplanned downtime.

Coverage includes a detailed analysis of common failure modes, such as bearing degradation, insulation breakdown in motors, and thermal fatigue in turbines. The course emphasizes practical troubleshooting methodologies, enabling technicians and engineers to distinguish between issues originating in the prime mover versus those caused by the pump or compressor. Through this holistic view of the drivetrain, participants will be equipped to optimize energy consumption and extend the lifecycle of the entire machinery train.

COURSE OBJECTIVES:

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

• Identify the specific operational characteristics of different prime mover types used in industry.
• Analyze the torque-speed curves of drivers to ensure proper matching with driven equipment.
• Implement advanced maintenance schedules for high-voltage electric motors.
• Troubleshoot steam turbine governor issues and overspeed protection systems.
• Evaluate the impact of power quality on the longevity of electric prime movers.
• Perform detailed inspections of coupling systems and power transmission components.
• Diagnose internal combustion engine faults using exhaust gas and oil analysis.
• Apply vibration analysis techniques specifically tailored for rotating drivers.
• Execute precise alignment procedures between the prime mover and the pump or compressor.
• Assess the efficiency of drivers to identify opportunities for energy savings.
• Manage lubrication programs to prevent premature bearing and gear failure.
• Interpret thermal imaging data to detect hotspots in motor windings and turbine casings.
• Develop comprehensive contingency plans for prime mover failures in critical processes.
• Utilize diagnostic software and onboard monitoring systems for real-time troubleshooting.

TARGET AUDIENCE:

Mechanical Engineers, Maintenance Technicians, Plant Operators, Reliability Engineers, and Supervisors responsible for the upkeep of rotating machinery and power units in process plants.

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.