Rotating Equipment Technician / Engineer Training


Giant Indo's Veritas Pvt Ltd

Rotating Equipment (5 days)


Level


Foundation

Audience


Engineers, supervisors and technicians involved in rotating machinery operation, maintenance or engineering.

Purpose


To deepen knowledge about the performance, technology and operation of rotating machinery.

Learning Objectives

  • To recognize the different types of rotating machinery and their main applications.

  • To explain operating principles and key performances of this equipment.

  • To describe the technology of the rotating machinery and the main operating constraints.

Ways and means

  • Use of cutaway drawings, pictures or videos of installed equipment.

  • Study of actual cases based on industrial situations.

Pumps (1.5 days)


  • Different types of pumps, applications in the process industry.

  • Operating principle and technology of positive displacement pumps.

  • Performance curves of a centrifugal pump: head, efficiency, absorbed power, NPSH.

  • Technology of centrifugal pumps, different architectures.

  • Mechanical seals: different arrangements, related ancillary systems.

  • Operating limits: cavitation, hammer shock, priming issues, case of 2 pumps running together.

  • Start-up and operation monitoring: specific case of hot pumps, LPG pumps, vacuum pumps.

  • Troubleshooting and common failures.

Reciprocating and rotary positive displacement compressors (1 day)


Giant Indo's Veritas Pvt Ltd
  • Different types of positive displacement compressors.

  • Reciprocating compressor architecture: number of stages, cylinders, overall layout, typical applications.

  • Technology of main components and ancillaries.

  • Influence of process conditions on compressor performance: suction or discharge pressure, suction temperature, gas composition.

  • Flow control, specific safety devices. Start-up philosophy. Troubleshooting.

Centrifugal compressors (1 day)


  • Description of a multi-stage centrifugal compressor.

  • Technology of main components and ancillaries.

  • Pressure increase process for a compressor stage. Performance curves, influence of suction conditions and gas composition.

  • Operating window: low and high speed limits, stonewall, surge, typical anti surge protection systems.

  • Flow control: throttling valve, speed variation, inlet guide vanes. Specific precautions for start-up. Troubleshooting.

Steam turbines (0.75 day)


  • Description of a steam turbine, different families, standard applications.

  • Operating principle, classification and technology: number of stages, exhaust conditions, expansion process through the machine.

  • Operation: start-up and performance monitoring. Speed control, safety devices.

Gas turbines (0.75 day)


Giant Indo's Veritas Pvt Ltd
  • Gas turbine design and performance, main types, industrial and aero derivative engines, pressure and temperature profiles through the machine.

  • Influence of environmental conditions: temperature, elevation. Impact of suction and exhaust friction losses on turbine performance. De-rating from ISO conditions.

Centrifugal Compressors (5 days)


Giant Indo's Veritas Pvt Ltd

Level


Proficiency

Audience


Operation and technical department staff involved in the running and maintenance of centrifugal compressors.

Purpose


To provide a broader understanding of the technology, performance and operation of centrifugal compressors.

Learning Objectives

  • To describe the technology of centrifugal compressors.

  • To select adequate operating conditions.

  • To explain the main operating problems.

  • To be involved in a troubleshooting process.

Ways and means

  • Case studies based on industrial feedback.

  • Various illustrations of actual systems.

  • Use of a dynamic simulator.

Technology (1.25 days)


  • Different types of centrifugal compressors.

  • Component parts and architecture of a centrifugal compressor.

  • Technology of the essential components: stator, rotor, bearings, thrust bearing, seals.

  • Vibrations, critical speed, dynamic balancing.

  • Auxiliary equipment: lubrication system, buffer gas, balancing line, etc.

  • Safety devices: axial displacement, vibrations, bearing and thrust bearing temperatures, oil pressure, etc.

Performance (1.75 days)


Giant Indo's Veritas Pvt Ltd
  • Changes in gas velocity and pressure in a centrifugal compressor.

  • Mass and volume flow rate as a function of pressure, temperature and the nature of the gas.

  • Discharge temperature, power absorbed as a function of the nature of the gas and the operating conditions.

  • Compressor performance: influence of process parameters, impeller velocity and geometry.

  • Characteristic curves of the circuit and the compressor. Influence of the operating conditions: intake pressure and temperature, nature of the gas, rotation speed.

Operation (0.5 day)

  • Flow rate regulation. Adaptation to service conditions.

  • Surge and antisurge devices. Conventional control.

  • Start-up and shutdown.

  • Monitoring the compressor and auxiliary equipment under normal operating conditions.

  • Troubleshooting.

Centrifugal Pumps & Positive Displacement Pumps (5 days)


Level


Proficiency

Audience


Engineers and technical staff involved in centrifugal and positive displacement pump operation, maintenance or engineering.

Purpose


To provide better understanding of centrifugal and positive displacement pumps technology and operating principle.

Learning Objectives

  • To describe the behavior and the operation of pumps.

  • To analyze the technical solutions applied in their units.

  • To establish a diagnosis of incidents and participate in troubleshooting meetings.

  • To identify essential elements in pump selection.

Ways and means

  • Actual examples from the refining, petrochemical and chemical industry.

  • Active participation is encouraged through case studies.

Hydrodynamics applied to a pumping system (2 days)


Giant Indo's Veritas Pvt Ltd
  • Pump performance

  • Flow in a pump, velocities triangle, internal flow and energy losses.

  • Theoretical and practical head: characteristic curve.

  • Other characteristics: efficiency, power, NPSH required.

  • Changes in characteristics vs. rotation, viscosity, impeller shape, cavitation.

  • Pipe system

  • Liquid flows in pipes: friction losses.

  • System curve, resistance of flow and throttling control.

  • Operating point: normal and maximum capacities, change in fluid characteristics and incidence on operating conditions.

  • Case study: study of a reflux line and its pump.

Centrifugal pump technology and selection (2 days)


Giant Indo's Veritas Pvt Ltd
  • Centrifugal pump

  • Construction and technology: API and ISO specifications.

  • Internal forces and mechanical criteria: balancing, wear ring clearances.

  • Specific numbers, impeller and pump shape, suction conditions.

  • Mechanical seal

  • Selection according to API 682 standard, materials, type.

  • Friction face heating.

  • Safety and environment: typical arrangements (single, dual, dry seal).

  • Specific solutions: canned motor pump, magnetic drive pump.

  • Installation

  • Suction and discharge pipe design.

  • NPSH available; base plate and grouting.

  • Ancillary lines and equipment.

  • Coupling and driven machines.

  • Safety and environment.

Positive displacement pump technology and performance (0.5 day)

Giant Indo's Veritas Pvt Ltd
  • Technology

  • Different types of pumps: rotary and reciprocating pumps.

  • Operating principle and utilization of the different types of pumps.

  • Performance

  • Influence of clearance, internal leaks, nature of product on flow rate and pressure.

  • Flow rate control.

  • Installation guidelines: position of tanks, line diameters, metering drums, pulsation dampeners, pressure valves.

Pump operation (0.5 day)

  • Preparation: filling, draining; spare pumps: heating, ancillaries.

  • Start-up / Shutdown: priming, remote/local controls, hammer shock, risks for process and pump.

  • Survey: parameters (vibration levels, noises, bearing housing temperature, motor intensity, pressures); process incidences (discharge pressure, viscosity, specific gravity, capacity); hazards.

  • Parallel and series operations: risks, dysfunction.

  • Reliability: types and source of damage (wear, ruptures, cavitation, leakages); improvement methods.

  • Safety conditions.

  • Centrifugal pump operations and case study on simulator.

Ethylene Compression & Hyper compressors (4 days)


Level


Proficiency

Audience


Engineers and technical staff (operation, maintenance and/or engineering) interested or involved in ethylene compression.

Purpose


To provide a comprehensive understanding of ethylene compression pertaining to compressors technology, operation and efficiency.

Learning Objectives

  • To learn about the technology and operation of ethylene compressors.

  • To understand the basic design in relation to ethylene compression operating conditions.

  • To monitor and optimize the performance of compressors.

  • To identify most common failure modes and corrective measures.

Ways and means

  • Study of actual cases based on industrial situations.

  • Various illustrations of actual systems.

  • Display of components of compressors.

Ethylene behavior during compression (1 day)


  • Ideal gas equation and implementation; isentropic compression; mass and volume capacity. Supercritical gas behavior.

  • Practical compression laws: discharge temperature, power of compression.

  • Pressure-Enthalpy diagram for Ethylene: for primary compressors and hypercompressors.

  • Main limitations: risks of condensation, overheating, decomposition, grease deposits.

  • Case studies: ethylene compression from 1 to 3000 bar.

Primary compressors behavior and operation (1 day)


  • Indicator diagram for ideal and actual cases.

  • Influence of process temperatures and pressures.

  • Dead volume: impact on the intake of the machine.

  • Capacity control: different methods.

  • Power, efficiency.

  • Behavior of multistage reciprocating compressors.

  • Typical troubleshooting.

  • Operation: start-up and shut-down difficulties.

  • Cases studies: industrial ethylene compression, troubleshooting.

Hypercompressors behavior and operation (1 day)


Giant Indo's Veritas Pvt Ltd
  • Compression ratio limitation due to axial loads on the crankshaft.

  • Interstage pressure control, risk of rods overbendings or plunger/seals breaks.

  • Discharge temperature limitation due to decomposition and oligomer deposits.

  • Lubrication operation and survey: crankshaft, oil seal and cooling. Criticity of the oil type.

  • Machine safety – PROGNOST™ type monitoring: axial vibrations, rod drop, oil temperatures and pressures, process temperatures and pressures.

  • Typical defaults, solutions and diagnosis.

  • Cases studies: various cases of troubleshooting.

Technology of primary compressors (0.5 day)

  • Main components: frame, cylinders, piston, piston rings, piston rod, crankhead, crankshaft, distance pieces, valves, rod seals.

  • Auxiliaries: pulsation dampeners, crankshaft, seals and cylinder lubrication systems, cooling systems, safety devices.

  • Capacity control technology: main components (unloaders, clearance pockets).

  • Application: various compressor parts demonstrations.

Technology of hypercompressors (0.5 day)

  • Main differences with classical reciprocating compressors.

  • Hypercompressor description: valves, cylinders, seals.

  • Auxiliaries:

  • construction and survey

  • crankshaft lubrication

  • rod seal lubrication

  • oil seal and cooling

  • drains