Course Overview
This advanced technical training program is designed for engineers and maintenance professionals working with rotating mechanical equipment (pumps, compressors, turbines, motors, and gearboxes). The course provides hands-on methodologies for predictive/preventive maintenance, failure analysis, vibration diagnostics, and reliability improvement. Participants will learn industry best practices aligned with API, ANSI, and ISO standards to maximize equipment uptime and performance.
Course Objectives
By the end of this course, participants will be able to:
✔ Apply failure mode analysis (FMEA) to rotating machinery
✔ Conduct vibration analysis and interpret spectra (ISO 10816)
✔ Perform bearing and lubrication failure root cause analysis
✔ Implement reliability-centered maintenance (RCM) strategies
✔ Troubleshoot common issues in:
- Centrifugal & reciprocating compressors
- API 610/682 pumps and sealing systems
- Steam/gas turbines (API 612/616)
- Gearboxes and couplings (AGMA standards)
✔ Use condition monitoring tools (thermography, oil analysis, ultrasound)
Who Should Attend
- Rotating equipment engineers
• Mechanical reliability specialists
• Maintenance supervisors & technicians
• Condition monitoring analysts
• Plant operations engineers
• Lubrication engineers
• Asset integrity managers
Course Outlines
Module 1: Fundamentals of Rotating Equipment
→ Equipment classification: API/ANSI/ISO standards
→ Criticality ranking methodologies (RBI)
→ Performance curves and efficiency calculations
→ Material selection for wear/fatigue resistance
Module 2: Mechanical Failure Mechanisms
◉ Bearing failures (spalling, brinelling, fluting)
◉ Shaft alignment & balancing (ISO 1940)
◉ Lubrication-related failures (viscosity breakdown, contamination)
◉ Seal failure modes (mechanical, dry gas, labyrinth)
Module 3: Predictive Maintenance Technologies
→ Vibration analysis (FFT, time waveform, phase analysis)
→ Oil analysis (wear particle counting, ferrography)
→ Infrared thermography applications
→ Ultrasound detection for early fault identification
Module 4: Hands-on Troubleshooting Labs
✔ Case Study 1: High vibration in centrifugal pumps
✔ Case Study 2: Compressor surge detection & control
✔ Case Study 3: Gearbox tooth failure root cause
✔ Workshop: Laser alignment practical session
Module 5: Reliability Improvement Strategies
→ RCM (Reliability-Centered Maintenance) implementation
→ Spare parts optimization for critical equipment
→ Root Cause Failure Analysis (RCFA) methodologies
→ FMEA workshops for pump/compressor systems
Module 6: Emerging Technologies
◉ IIoT sensors for real-time monitoring
◉ AI-powered predictive maintenance
◉ Digital twin applications for rotating assets
◉ Blockchain in maintenance record-keeping