Rotating equipment such as compressors, turbines, and pumps are vital components in oil refineries and large petrochemical plants, playing a central role in the overall operation. These pieces of equipment, which involve intricate control systems, are susceptible to wear, degradation, and aging over time, leading to failures, breakdowns, and operational downtime. Each type of equipment serves a specific function within the refinery, and their failure can have varying degrees of impact, with risks that can affect safety, the environment, production, and maintenance costs.
This hands-on and engaging Energy training course on Refinery Critical Equipment Operation for Compressors, Turbines, and Pumps will delve into the operation and maintenance of these critical components. It will focus on conducting a quantitative analysis of faults and defects, ranking them based on their impact on safety, environmental concerns, and production losses. Participants will explore the most effective maintenance management strategies that prioritize high-impact tasks, minimizing unexpected breakdowns and recurring failures, and ultimately extending the lifespan of the components and the entire system.
Key topics covered in this Refinery Critical Equipment Operation for Compressors, Turbines and Pumps training course include:
- The technical specifications of compressors, turbines, and pumps for their specific applications
- Creating and using criticality indices and ranking components based on their importance
- Addressing practical challenges to ensure reliable operation of rotating equipment
- Conducting root cause analysis for issues related to vibration and dynamic balancing
- Developing strategies for effective monitoring, maintenance, and troubleshooting of equipment
By the conclusion of this Refinery Critical Equipment Operation for Compressors, Turbines and Pumps training course, you will be able to:
- Understand the technical specifications of compressors, turbines, and pumps.
- Implement best practices for efficient operation while reducing maintenance expenses.
- Analyze the results from testing and inspection of vital components.
- Examine failure patterns in critical components.
- Utilize diagnostic and monitoring technologies to optimize performance.
This Energy training course will be conducted along the workshop principles with formal lectures, case studies and interactive work examples. Relevant and real-life case studies will be provided to illustrate the application of each tool in an operation and troubleshooting situation. Learning topics will be re-enforced with practical exercises. There will be plenty of opportunities for discussions and sharing experiences during class workshops.
Upon completing this training course, participants will have the ability to effectively evaluate the operation and maintenance practices within their organization. They will be equipped to identify areas for potential improvements. This training will provide the necessary technical knowledge and skills that will be valuable in their professional roles.
The insights gained from this training course will enhance the understanding of compressors, turbines, and pumps under complex operational conditions. Participants will be equipped to establish a proactive maintenance approach, enabling improved inspection, monitoring, and control. This will help prevent unexpected equipment failures while optimizing the availability and reliability of rotating equipment.
This Energy training course is suitable to a wide range of professionals but will greatly benefit:
- Mechanical and Process Engineers
- Plant Engineers responsible for operations, maintenance and troubleshooting
- Project Leaders
- Maintenance and Instrumentation Professionals
- Technologists and Facility Operators
Day One: Equipment Criticality Analysis
- Rotating Equipment in Refineries: Criticality Aspect
- Quantitative Analysis of Equipment Faults
- Input Data Preparation
- Tools and Techniques
- Risk Assessment and Determination of Equipment Criticality
- Equipment Criticality Index
- Reliability of Critical Equipment and Mean Time Between Failures (MTBF)
- Application of Criticality Analysis on Maintenance Program
Day Two: Compressors
- Overview of Positive Displacement Compressors
- Reciprocating Compressor Design Elements: Valves, Pistons, Bearings, Seals
- Effect of Gas Composition and Suction Conditions on Performance
- Wet Gas Compressors in FCC Operations
- Centrifugal Compressors Design and Configuration
- Performance Curves: Choke Conditions, Surge and Anti-Surge Protection
- Flow Control Techniques and Start-Up Procedures: Low- and High-speed Limits
- Auxiliary Systems: Lubrication and Cooling
Day Three: Turbines
- Steam Turbine Construction Elements
- Technical Characteristics of Blades and Nozzles
- Control Systems and Safety Devices
- Technical Characteristics of Gas Turbines
- Combustion Monitoring, Ignition and Flaming System, Fuel Control
- Start-Up System, Over-speed Control Protection and Calibration
- Rotor Dynamics and Balancing
- Associated Equipment and Systems: Lubrication, Bearings and Seals
Day Four: Pumps
- Centrifugal Pumps Design Overview
- Impellers, Shafts and Bearings
- Importance of Mechanical Seals
- Characteristic Curves
- NPSH and Cavitation Prevention
- Design of Suction Configuration and Flow Control
- Positive Displacement Pumps: Reciprocating and Rotary
- Problems with Pumping Difficult Liquids
Day Five: Maintenance and Overhaul Management
- Maintenance and Overhaul of Rotating Equipment
- Preventive Maintenance for Critical Machines
- Predictive Maintenance Based on Inspection and NDT
- FMEA and Root Cause Analysis (RCA)
- On-Line and Off-Line Condition Monitoring
- Reliability-Centered Maintenance
- Computerized Maintenance Manageme