Rotating Equipment Maintenance & Troubleshooting

Course Introduction

This 5-day training program is designed to provide participants with in-depth knowledge and practical skills in the maintenance and troubleshooting of rotating equipment, including pumps, compressors, turbines, and motors. The course will cover the operation, failure modes, preventive maintenance, and diagnostic techniques required to keep rotating equipment running efficiently. Participants will learn best practices for maintaining and troubleshooting rotating machinery to reduce downtime, enhance reliability, and improve operational performance.

Objectives

By the end of this course, participants will be able to:

    Understand the fundamental principles and types of rotating equipment.

    Identify common failure modes in rotating machinery.

    Apply preventive maintenance strategies for different types of rotating equipment.

    Troubleshoot operational issues using systematic approaches.

    Perform vibration analysis and other diagnostic techniques to identify faults.

    Understand alignment, balancing, lubrication, and condition monitoring best practices.

    Ensure safety and compliance while working with rotating equipment.

Target Audience

•    Maintenance Engineers and Technicians
•     Mechanical Engineers
•     Plant Operators
•     Maintenance Supervisors and Managers
•     Reliability Engineers
•     Condition Monitoring Specialists

Daily Topics

Day 1: Introduction to Rotating Equipment and Operational Principles

    Course Overview and Objectives

        Introduction to the course structure and goals.

    What is Rotating Equipment?

        Types of rotating equipment: Pumps, compressors, motors, turbines, and fans.

        Key components of rotating machinery: Bearings, shafts, seals, and couplings.

    Operating Principles of Rotating Equipment

        Basic mechanical principles of rotation: Torque, speed, power, and efficiency.

        Understanding rotational dynamics and forces on rotating machinery.

        Load and speed characteristics of different types of rotating equipment.

    Key Failure Modes in Rotating Equipment

        Vibration, wear, lubrication failure, cavitation, overheating, misalignment, and imbalance.

        Effects of failure modes on machinery performance and efficiency.

Hands-on Activity: Overview of various rotating equipment and their components, followed by a visual inspection of sample equipment.

Day 2: Preventive Maintenance for Rotating Equipment

    Preventive Maintenance (PM) Principles

        Importance of routine maintenance to extend the life of rotating equipment.

        Developing a preventive maintenance plan for rotating machinery.

        Standard PM tasks for pumps, compressors, motors, and turbines.

    Lubrication Systems

        Types of lubricants: Oil, grease, and dry lubrication.

        Selecting the correct lubricant for different rotating equipment.

        Lubrication schedules, methods, and the role of condition monitoring in lubrication.

    Seals, Bearings, and Couplings

        Inspection and maintenance of seals and bearings.

        Identifying early signs of bearing wear and misalignment.

        Coupling types, inspection, and maintenance procedures.

    Vibration Monitoring and Balancing

        Importance of vibration monitoring in maintaining rotating equipment health.

        Techniques for vibration analysis: Single-point and multi-point vibration monitoring.

        Balancing techniques and balancing tolerances.

Hands-on Activity: Perform basic preventive maintenance tasks: Lubrication, bearing checks, and vibration monitoring.

Day 3: Troubleshooting and Fault Diagnosis in Rotating Equipment

    Troubleshooting Approach

        Systematic approach to troubleshooting rotating equipment.

        Analyzing symptoms and identifying potential failure modes.

        Using root cause analysis (RCA) to identify underlying issues.

    Common Troubleshooting Issues in Rotating Equipment

        Motor failure (overheating, electrical faults, poor alignment).

        Pump failure (cavitation, leakage, wear, and blocked impellers).

        Compressor issues (poor suction/discharge pressure, loss of capacity).

        Turbine failure (excessive vibrations, overheating).

    Fault Diagnosis Using Vibration Analysis

        Identifying and interpreting vibration patterns.

        Diagnosing imbalance, misalignment, bearing issues, and mechanical looseness.

        Using vibration analysis tools to monitor condition.

    Other Diagnostic Tools

        Thermography: Detecting hot spots in motors, bearings, and pumps.

        Ultrasonic testing: Detecting internal defects and leakage.

Hands-on Activity: Use vibration analysis tools to detect faults in rotating equipment, followed by interpreting results to identify specific issues.

Day 4: Condition Monitoring and Performance Optimization

    Condition Monitoring Techniques

        Understanding condition-based monitoring (CBM) for rotating machinery.

        Implementing sensors for real-time data collection: Vibration, temperature, pressure, and acoustic signals.

        Using advanced monitoring systems to track equipment health.

    Performance Optimization

        Techniques to improve the efficiency and performance of rotating equipment.

        Identifying performance degradation and corrective actions (e.g., addressing cavitation, optimizing load).

        Upgrading and retrofitting equipment for better energy efficiency.

    Alignment and Shaft Alignment Techniques

        Importance of proper alignment in reducing wear and failure.

        Methods for checking alignment (laser alignment, dial indicators).

        Practical alignment procedures for pumps, motors, and compressors.

Hands-on Activity: Perform alignment and condition monitoring activities on a rotating system.

Day 5: Advanced Troubleshooting, Safety, and Industry Best Practices

    Advanced Troubleshooting Techniques

        Analyzing complex failures using advanced diagnostic equipment (spectral analysis, acoustic emission).

        How to handle critical equipment failures and prioritize repairs.

    Safety Considerations in Rotating Equipment Maintenance

        Personal protective equipment (PPE) and safe working practices for rotating equipment.

        Lockout/tagout (LOTO) procedures and ensuring electrical safety during maintenance.

        Safe handling of high-speed rotating parts and pressure systems.

    Industry Standards and Best Practices

        Overview of international standards for rotating equipment maintenance (ISO 9001, ISO 14001, API standards).

        Best practices for implementing a reliability-centered maintenance (RCM) program.

        Continuous improvement and preventive measures to avoid recurrent failures.

Hands-on Activity: Review case studies of rotating equipment failures and discuss solutions using the techniques learned throughout the course.

Course Review and Certification:

    Final review of key concepts and principles covered in the course.

    Practical and theoretical assessment.

    Issuance of Rotating Equipment Maintenance & Troubleshooting Certification for successful participants.

For registration & more information please contact

NAYEL Training Centre 

Tel: +971 4 5587735 | Mob: +971 54 7962098 |WhatsApp: +971 54 7962098

Email:  [email protected]