Rotating Engineer Graduate Certification

ROTENG-EN-P

Who should attend?

  • To provide an operational competency in rotating machinery (pumps, compressors, turbines of all types) engineering, operation, and maintenance. This course will provide an IFP Training Graduate Certification according to the IFP Training procedures.
Public :
  • Engineers or technicians interested in rotating machinery competency personal development.

Level : Foundation

Course Content

  • Module 1: STATIC EQUIPMENT, SAFETY AT WORKPLACE

      • Piping and fittings: standards, types, materials. Gasketing procedures. Practical work in workshop: gasketing procedure on test benches. Heat exchangers: working principle, basic constructions, applications with rotating machinery circuits. Safety at work: occupational safety. Risk analysis during rotating equipment maintenance works. Prevention: work permit types and validity; purpose and use, job safety analysis, responsibilities.
  • Module 2: PUMPS (engineering, operation, technology)

      • Pumps types. Selection. Bidding. Fluid flow: friction losses; system curve, operating point; parallel and serial arrangements. Centrifugal and positive displacement pumps: standards, constructions; performances vs design and operating conditions; affinity laws. Operation, major troubles. Installation, commissioning. Applications with dynamic simulator (centrifugal pumps) and test benches.
  • Module 3: PUMPS (maintenance)

      • Bearings and mechanical seals assembly/disassembly. Couplings and alignment: coupling types, alignment methods and tools. Rotors: dynamic balancing, shaft assembly, run-out check. Pump assembly/disassembly: key checks and steps - Pump overhaul schedule. Practical work in the workshop: completion of different antifriction bearings assemblies, alignment operation of a centrifugal pump and driver shaft, completion of geometrical checks, pump assembly.
  • Module 4: ON THE JOB TRAINING 1

      • OJT: Application of the previous module(s) content to an actual equipment. (Proposed by the tutor or the instructor). Group or individual work, depending on OJT conditions. Topic: maintenance or design activity on a given equipment. The trainees will be requested to prepare a written report and a 20 minutes presentation about “Pumps”: safety (work permit, risk analysis, safeguards…), process role of the selected pump, technical topics (maintenance activities, calculations), results analysis (accuracy, acceptance criteria…). The trainee will present its work to other trainees and lecturer during the next module.
  • Module 5: RECIPROCATING COMPRESSORS (engineering, operation, technology)

      • Gas compression: thermodynamical compression laws and models; single and multistage compression; compression work and power; machine protection against liquid slugs. Compressor types. Selection. Bidding. Reciprocating compressors: types, standards, construction and technology; Compression cycle vs operating conditions. Operation, major troubles. Installation, commissioning. Applications with dynamic simulator.
  • Module 6: RECIPROCATING COMPRESSORS (maintenance)

      • Mechanical and compression parts assembly and disassembly: crankshaft, crosshead, piston, valves and cylinders. Key checks and steps. Crankshaft, cylinder, crosshead and piston alignment methods. Maintenance of main auxiliary circuits. Overhaul scheduling. Practical work in the workshop: maintenance & inspection activities on a complete machine or on basic elements.
  • Module 7: ON THE JOB TRAINING 2

      • OJT: Application of the previous module(s) content to an actual equipment. (Proposed by the tutor or the instructor). Group or individual work, depending on OJT conditions. Topic: maintenance or design activity on a given equipment. The trainees will be requested to prepare a written report and a 20 minutes presentation about “Reciprocating compressor”: safety (work permit, risk analysis, safeguards…), process role of the selected compressor, technical topics (maintenance activities, calculations), results analysis (accuracy, acceptance criteria…). The trainee will present its work to other trainees and lecturer during the next module.
  • Module 8: CENTRIFUGAL & AXIAL COMPRESSORS (engineering, operation, technology)

      • Centrifugal and axial compressors: types, standards, construction and technology; bidding. Compression mechanism through a compression stage; performances curves vs operating conditions and rotor design; affinity laws. Operation, major troubles. Installation, commissioning. Applications with dynamic simulator.
  • Module 9: CENTRIFUGAL & AXIAL COMPRESSORS (maintenance)

      • Compressor overhaul: planning and scheduling, key checks and steps. Bearings, seals, labyrinths, diaphragms: main checks, assembly/disassembly typical procedures. Rotor checks, dynamic balancing. Auxiliary systems: main checks, typical procedures. Machine alignment and installation: key points and procedures. Practical work in the workshop: maintenance & inspection activities on a complete machine or on basic elements.
  • Module 10: ON THE JOB TRAINING 3

      • OJT: Application of the previous module(s) content to an actual equipment. (Proposed by the tutor or the instructor). Group or individual work, depending on OJT conditions. Topic: maintenance or design activity on a given equipment. The trainees will be requested to prepare a written report and a 20 minutes presentation about “Centrifugal compressor”: safety (work permit, risk analysis, safeguards…), process role of the selected compressor, technical topics (maintenance activities, calculations), results analysis (accuracy, acceptance criteria…). The trainee will present its work to other trainees and lecturer during the next module.
  • Module 11: STEAM & GAS TURBINES, EXPANDERS (engineering, operation, technology)

      • Steam turbines, gas turbines, expanders: types, standards, construction and technology. selection, bidding; thermodynamical cycles, expansion mechanism through a stage; performances vs operating conditions, rotor design; turbine control, overspeed device, emissions to atmosphere control and fumes treatment; operation, major troubles; installation, commissioning.
  • Module 12: STEAM & GAS TURBINES, TURBOEXPANDERS (maintenance)

      • Turbine overhaul: planning and scheduling, key checks and steps. Bearings, seals, labyrinths, diaphragms: main checks, assembly/disassembly typical procedures. Rotor checks, dynamic balancing. Auxiliary systems: main checks, typical procedures. Machine alignment and installation: key points and procedures. Practical work in the workshop: maintenance & inspection activities on a complete machine or on basic elements.
  • Module 13: ON THE JOB TRAINING 4

      • OJT: Application of the previous module(s) content to an actual equipment. (Proposed by the tutor or the instructor) Group or individual work, depending on OJT conditions. Topic: maintenance or design activity on a given equipment. The trainees will be requested to prepare a written report and a 20 minutes presentation about “Turbines/expanders”: safety (work permit, risk analysis, safeguards…), process role of the selected machine, technical topics (maintenance activities, calculations), results analysis (accuracy, acceptance criteria…). The trainee will present its work to other trainees and lecturer during the next module.
  • Module 14: ROTATING EQUIPMENT (monitoring, predictive maintenance, troubleshooting, failure analysis)

      • Troubleshooting and predictive maintenance: performance follow-up and trouble analysis; oil analysis, vibration and sound analysis, temperature analysis, electrical feed current analysis. typical rotating machinery monitoring schemes. Case studies.
      • Failure analysis: root cause analysis, Ishikawa diagrams; typical reports. Case studies.
      • Rupture analysis: rupture types, wear types; broken parts analysis. Case studies: rupture and wear analysis of typical machine components
  • Module 15: ON THE JOB TRAINING 5

      • OJT: Application of the previous module(s) content to an actual equipment. (Proposed by the tutor or the instructor) Group or individual work, depending on OJT conditions. Topic: maintenance or design activity on a given equipment. The trainees will be requested to prepare a written report and a 20 minutes presentation about “rotating equipment troubleshooting”: safety (work permit, risk analysis, safeguards…), process role of the selected machine, technical topics (measurements, maintenance activities, calculations), results analysis (accuracy, acceptance criteria…). The trainee will present its work to other trainees and lecturer during the next module.
  • Module 16: FINAL ASSESSMENT

      • Last OJT presentation to the classroom. Written and or practical test about all the training content, according to the IFP Training Certification procedure.

Learning Objectives

  • Upon completion of the course, participants will be able to:
  • select a rotating machine according to process requirements,
  • perform the implementation of a rotating machine in a plant, from bidding to site commissioning,
  • explain how a rotating machine is constructed and designed,
  • explain how to operate a rotating machine,
  • perform troubleshooting and failure analysis of a rotating machine,
  • perform the key tasks during a rotating machine overhaul,
  • schedule and plan a rotating machine overhaul,
  • participate to a rotating machine reliability improvement plan.

Ways & Means

  • The training is split into thematic modules and “On the Job Training” (OJT) periods: OJT periods consist in various rotating machinery projects, to be achieved on site; each project will be assessed orally during the next thematic module, on the basis of a written project report.
  • Practical training session in workshops.
  • Interactive course, with experienced instructors.
  • Practical case studies coming from IFP Training industrial experience.
  • Use of rotating machinery test benches and dynamic simulators.
  • Continuous trainees assessment.
  • Intermediate and final practical tests to evaluate trainees according to IFP Training Certification procedure.

Certification

  • An international recognition of your competencies.
  • A Graduate Certificate is delivered.
  • An expertise confirmed in Rotating Engineer Graduate .
  • Ready-to-use skills.