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Operation, Maintenance & Inspection of Rotating Machinery

15 days MTM/OMIRM
Level
Foundation
Audience
  • Engineers, supervisors and technical staff involved in rotating machinery maintenance and inspection.
Purpose
  • To provide a clear machinery understanding, including lubrication and troubleshooting, through vibration analysis and other techniques.
Learning Objectives
  • To explain how the machines and their components work.
  • To list the mechanical consequences of specific operating conditions.
  • To describe the failure modes of each component.
  • To participate in the machinery reliability improvement process.
Ways and means
  • Pumps, compressors and turbines manufacturing site visits.
  • Workshop and practical exercises.
  • Case studies based on industrial feedback.

Technology and operation of main rotating machines (pumps, compressors, turbines, electric motors) 5 days
  • Technology
  • Main parts of the machines: casing, rotor, bearing, coupling.
  • Ancillaries: flushing, heating and cooling, lubrication systems.
  • Maintenance: assembly and dismantling procedures, inspection, clearance, adjustment, roughness.
  • Operation and performance
  • Process aspects
  • Operational parameters; head, flow, rpm, efficiency
  • Characteristic curves. Regulation. Start-up, routine monitoring
  • Effect of internal wear.
  • Mechanical aspect
  • Stresses in machines. Influence on lifespan, on damage
  • Failure prevention; monitoring, repair quality.
  • Troubleshooting
  • Internal leakages. Unbalancing. Wear and ruptures.
  • Practical exercises (time included in above items)
  • Recording and plotting pressure of a centrifugal pump.
  • Plant visits: centrifugal pumps manufacturer; centrifugal compressors and steam turbines manufacturer.
Technology and maintenance 5 days
  • Lubrication
  • Purpose, different types of oil and grease. Practical aspect.
  • Bearings
  • Antifriction bearings: types, lifespan, mounting, applications, related problems.
  • Plain and pad bearings, thrust bearings: operation, maintenance, incidents.
  • Coupling and alignment
  • Different types of couplings, related problems.
  • Different methods of alignment, tolerances, practical aspects.
  • Sealing devices for pumps and compressors
  • Mechanical pump seals, types, operation, related problems.
  • Installation, geometrical checks.
  • Other seals for positive displacement pumps and reciprocating compressors.
  • Rotors and shafts
  • Balancing: eccentricity, tolerances. Assembling on shaft: effect on balancing.
  • Geometrical shaft controls.
  • Practical exercises
  • Bearing mounting and overhaul. Geometrical shaft control. Shaft alignment.
  • Mechanical seal mounting.
  • Plant visit: machine component manufacturer.
Forecasting breakdowns 5 days
  • Study of ruptures, wear and other failures
  • Typical damage to machines: onset of problems and causes of failures, influences of metallurgy and surface treatments.
  • Fatigue, wear and tear. Rupture face analysis.
  • Case studies: rupture and wear examinations of typical parts, analysis of some centrifugal pump breakdowns.
  • Use of vibration analysis
  • Different types of measurements and sensors.
  • Monitoring of turbomachines rotor behavior.
  • Spectrum analysis applied to pumps, fans.
  • Diagnosis.
  • Management of machinery reliability
  • Reliability centered maintenance.
  • Detection of Bad Actors.
  • Improving reliability through failure analysis and diagnosis.
  • Monitoring the maintenance activity performance.
  • Practical exercises
  • Measurement and analysis of vibrations.
  • Machinery component failures, analysis on examples.