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.
Public :
Machinery technicians from refineries and petrochemical plants.
Level :Skilled
Prerequisite :
Provide evidence of a professional experience of at least 1 month related to the concerned field.
Course Content
Module 1: MATERIAL - PIPING - VALVES (maintenance basics, safety during works)
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Duration : 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)
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Duration : 5 Days
Pumps: different types of pumps. Technology of centrifugal pumps and 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 and 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)
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Duration : 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
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Duration : 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)
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Duration : 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.
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.
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 and 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 and destructive tests after rupture. Solutions to avoid failure: design parameters, stress limitations, operatingconditions, 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
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Duration : 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 classroom.
Written test about all the training contents according to the IFP Training Certification procedure.
Learning Objectives
Attendees will be able to implement the following skills:
Analyze work instructions and prepare an intervention taking into account the environment,
Carry out the dismantling and detailed expertise of the rotating machine,
Diagnose a malfunction by identifying failures,
Assemble and adjust a rotating machine,
Draw up simple mechanical drawings,
Communicate simple technical information and advice orally,
Fill in the various maintenance documents and make an intervention report.
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 and final practical tests to evaluate trainee according to IFP Training Certification procedure.
Learning assessment
Knowledge assessment according IFP Training Certification specific standards.
Certification
An international recognition of your competencies.
A is delivered Vocational Certificate.
An expertise confirmed in Rotating Equipment Technicians .
Ready-to-use skills.
More
Additional information :This course is composed of 8 modules of 5 days each. It includes all the evaluations related to the IFP Training Certification. In case of a local training, the customer will supply all the material and equipment needed for the course, including workshop and tools.
Coordinator :IFP Training trainer (permanent or contracted) having a good expertise and/or experience of the related topics, trained to adult teaching methods, and whose competencies are kept up-to-date.
To French entities : IFP Training is referenced to DataDock ; you may contact your OPCO about potential funding.
Please contact our disabled persons referent to check the accessibility of this training program : referent.handicap@ifptraining.com
IFPT Account
