COURSE OVERVIEW:

Rotating equipment for process plants represents the "heart" of industrial operations, encompassing the pumps, compressors, turbines, and fans that move fluids and gases through the production cycle. Effective operation, control, and maintenance of these assets are essential for ensuring plant availability, product quality, and personnel safety. This course provides a comprehensive understanding of how these machines function within a larger process loop and the critical parameters that must be monitored to prevent catastrophic failure or inefficient energy consumption.

The scope of this course covers the mechanical design and hydraulic/pneumatic principles of various rotating machines. Participants will explore the performance curves of centrifugal and positive displacement units, learning how to interpret head-flow relationships and the impact of fluid properties on machine behavior. The coverage also includes modern control strategies, such as Variable Speed Drives (VSDs) and automated bypass systems, which allow for precise process modulation while protecting the equipment from surge, cavitation, or stonewalling.

In addition to operation and control, the course places a heavy emphasis on maintenance philosophies, ranging from basic preventive tasks to sophisticated predictive techniques. Attendees will learn to recognize the early warning signs of mechanical distress through vibration, temperature, and oil analysis. By integrating operational knowledge with maintenance best practices, participants will be able to optimize equipment performance, extend service life, and contribute to the overall reliability and profitability of the process facility.

COURSE OBJECTIVES:

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

1. Identify the various types of rotating equipment used in process plants.
2. Explain the fundamental operating principles of centrifugal and reciprocating pumps.
3. Interpret machinery performance curves and system head curves.
4. Manage equipment operations to avoid cavitation and internal recirculation.
5. Describe the internal components and function of centrifugal and axial compressors.
6. Implement effective startup and shutdown sequences for high-energy machinery.
7. Apply control strategies for flow, pressure, and surge protection.
8. Evaluate the role of mechanical seals and bearings in equipment reliability.
9. Conduct routine inspections and basic condition monitoring tasks.
10. Utilize vibration analysis and thermography to detect early-stage faults.
11. Develop maintenance schedules based on equipment criticality and risk.
12. Troubleshoot common operational problems such as surging and vibration.
13. Select appropriate lubrication types and methods for various rotating assets.
14. Ensure compliance with safety and environmental regulations during maintenance.

TARGET AUDIENCE:

This course is designed for Process Operators, Maintenance Technicians, Mechanical Engineers, Plant Supervisors, and Reliability Personnel working in oil, gas, chemical, and power industries.

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.