COURSE OVERVIEW:

In modern process plants, pumps and compressors are the most vital rotating assets, often working in tandem to maintain production flow and pressure. This integrated course provides a comprehensive technical analysis of both liquid-handling and gas-handling machinery, focusing on their distinct design philosophies and shared maintenance challenges. Participants will explore the mechanical complexities of centrifugal and positive displacement designs, gaining a holistic understanding of how these machines function within a complex industrial network.

The scope of this training bridge the gap between theoretical engineering and hands-on maintenance, covering everything from internal clearances and thermodynamics to advanced diagnostic techniques. We will examine the specific stressors that affect both pumps and compressors, such as thermal expansion, pressure pulsations, and rotor dynamics. The course emphasizes a unified approach to reliability, teaching participants how to implement cross-functional maintenance strategies that address the unique requirements of both types of machinery while optimizing overall plant uptime.

Coverage includes detailed troubleshooting modules that utilize vibration analysis, performance mapping, and root cause analysis to solve complex operational issues. Attendees will learn how to manage the lifecycle of these assets, from initial design review and installation to major overhauls and performance optimization. By the end of this course, participants will be equipped with an integrated skill set that allows them to oversee the health, safety, and efficiency of the entire rotating equipment fleet.

COURSE OBJECTIVES:

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

• Distinguish between the design requirements of pumps and gas compressors.
• Analyze the thermodynamic principles governing compressor performance.
• Evaluate the hydraulic characteristics and performance curves of centrifugal pumps.
• Implement integrated maintenance strategies for rotating equipment trains.
• Diagnose common failure modes in both liquid and gas handling machinery.
• Utilize advanced vibration analysis to identify rotor and bearing defects.
• Optimize the selection of mechanical seals and dry gas seals for various services.
• Execute precision alignment and balancing for high-speed machinery.
• Troubleshoot compressor surge and pump cavitation using field data.
• Manage the lubrication and cooling requirements of integrated machinery packages.
• Assess the impact of process changes on the reliability of pumps and compressors.
• Conduct Root Cause Failure Analysis (RCFA) for complex rotating asset failures.
• Develop comprehensive commissioning and startup procedures for machinery trains.
• Justify equipment upgrades based on performance and reliability audits.

TARGET AUDIENCE:

Senior Mechanical Engineers, Maintenance Managers, Rotating Equipment Specialists, Reliability Engineers, and Technical Supervisors responsible for diverse machinery fleets.

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.