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Rotating Equipment Technicians Certification

Rotating Equipment Technicians Certification

40 days
MTM/TECMT-E
Sessions
This course is not scheduled.
Who should attend?

Audience

    • Machinery technicians from refineries and petrochemical plants.

Level

  • Foundation
  • Improve rotating equipment technicians performance in safety, quality and work efficiency. This course will provide an IFP Training Certification according to the IFP Training procedures.
Learning Objectives
  • Upon completion of the course, participants will be able to:
  • perform monitoring, checks and repairs of rotating equipment in workshop and on the field,
  • write maintenance procedures for rotating equipment,
  • achieve an alignment and recognize vibration standard signatures,
  • prevent mechanical failures and participate in the machinery reliability improvement process.
Course Content

Module 1: MATERIAL - PIPING - VALVES (maintenance basics, safety during works)

5 days

  • Materials and norms. Piping standards: pipes, nominal diameter; thickness, resistance to internal pressure, standards related to pressure equipment. Piping classes. Maintenance.
  • Piping accessories: different types of valves, check valves, relief valves, steam traps, line support, filters, flanges and gaskets.
  • Occupational safety, work prevention. Identification and analysis of hazards during maintenance and construction works.
  • Risks related to equipment opening, isolation, blinding work, circuit lockout and tagging procedure.
  • Work at height, high pressure cleaning, chemical cleaning. Lifting risks.
  • Prevention: work permit types and validity; purpose & use, job safety analysis, responsibilities.

Module 2: ROTATING EQUIPMENT (technology)

5 days

  • Pumps: different types of pumps. Technology of centrifugal pumps & positive displacement pumps. Mechanical seals: different layouts, related ancillary systems. Start-up and operation monitoring: specific case of hot pumps, LPG pumps, vacuum pumps. Troubleshooting.
  • Reciprocating and rotary positive displacement compressors: different types of positive displacement compressors. Reciprocating compressor architecture: number of stages, cylinders. Ancillaries. Safety devices. Troubleshooting.
  • Centrifugal compressors: technology of main components and ancillaries; operating window & troubleshooting.
  • Steam turbines: different families and standard applications. Classification and technology. Operation: start-up and performance monitoring. Speed control, safety devices.

Module 3: PUMPS (maintenance)

5 days

  • Bearings, lubrication, sealing, coupling and alignment: different types of technical and maintenance procedures.
  • Rotors and shafts: balancing, shaft assembly, run-out check.
  • 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

5 days

  • OJT:
  • Application of the previous module(s) content to the actual plant.
  • According to a subject submitted by the lecturer, the trainees will be requested to prepare a written report and 20 minutes presentation about “Pumps”: safety (work permit, risk analysis, safeguards), process role of the selected pumps, maintenance procedures (tools and check-list), results analysis (accuracy, acceptance criteria), each team has to identify the priorities for an assigned machinery subject submitted by the lecturer.
  • The trainee will present its work to other trainees and lecturer during other modules.

Module 5: RECIPROCATING COMPRESSORS (maintenance)

5 days

  • Valves, cylinders, pistons: assembly, alignment, rings and bands assembly, rod drop control.
  • Rod packing seals, rods: stuffing box parts control and assembly, rod geometrical control, crosshead junction, clearance adjustment.
  • Crankcase, crank shaft and cranks: crankshaft bearings control, stress measurement, bearings alignment. Assembly of cranks and crosshead, typical clearances, tightening torque. Auxiliary systems: maintenance of main lubrication circuit.
  • Practical work in the workshop: if available, maintenance & inspection activities on a complete machine or on basic elements.

Module 6: CENTRIFUGAL COMPRESSORS & STEAM TURBINES (maintenance)

5 days

  • Compressor parts overhaul: impellers and rotor, diaphragm, counter casing and casing, mechanical seals. Checks.
  • Steam turbine parts overhaul: blade replacement and cleaning, turbine labyrinth seals, mechanical over speed system tuning, routine maintenance. Use of specific tools.
  • Common turbomachinery parts assembly and maintenance: labyrinth sealing systems, tilt pad bearings, tilt pad thrust bearings, related rotating equipment, couplings and alignment, rotor dimensional checks and rotor balancing according to API specifications.
  • Case studies: centrifugal compressor and steam turbine troubleshooting; assembly/disassembly procedures studies.
  • Practical work in the workshop if available.

Module 7: ROTATING EQUIPMENT (condition monitoring & troubleshooting)

5 days

  • Troubleshooting analysis. Monitoring results analysis: vibrations levels, lubrication and seal circuit parameters, abnormal values, oil quality.
  • Component failures: seal leakages, bearing damages, rotor sags, impeller cracks, misalignment. Hydraulic phenomena: cavitation, unpriming, volute effect, surge. Applications & exercises.
  • Machine monitoring devices: process operating parameters (monitoring and analysis of the machine process data and logs). Monitoring tools dedicated to the machine type: vibration monitoring, PV card indicator, rod drop, bearings temperature. Failure analysis and inspection tools.
  • Material analysis: non destructive tests & destructive tests after rupture. Solutions to avoid failure: design parameters, stress limitations, operating conditions, online monitoring.
  • Case studies: rupture and wear examinations of typical machine components (bearings, mechanical seals, rotors, crankshaft).

Module 8: ON THE JOB TRAINING 2 & FINAL TEST

5 days

  • OJT (3 days):
  • Application of the previous module(s) content to the actual plant. The subject is submitted by the lecturer.
  • At the end of the OJT period, the trainees will be requested to prepare a written report and a 20 minutes presentation about “Compressors/steam turbines maintenance”: process role of the selected machinery, selected maintenance specification review, safety (work permit, risk analysis, safeguards), detailed maintenance procedures (checks and overhaul), results analysis (accuracy, acceptance criteria).
  • Final test (2 days):
  • Presentation of OJTs to the class room.
  • Written test about all the training contents according to the IFP Training Certification procedure.
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Ways & Means
  • Training split into thematic modules and “On The Job Training” (OJT). To give participants the opportunity to better assimilate the content of the previous course module, and apply the studied subjects to the facilities.
  • Workshop practice.
  • Exercises on site.
  • Intermediate & final practical tests to evaluate trainee according to IFP Training certification procedure.
Certification
  • An international recognition of your competencies.
  • A Vocational Certificate is obtained.
  • An expertise confirmed in Rotating Equipment Technicians Certification.
  • Ready-to-use skills.