Name: Rotating Equipment - Start-up, Operation, Maintenance and Troubleshooting
Price: 4500.00 EUR
Availability: InStock

Pumps, compressors, fans and turbines are the heart of process plants, utilities and water systems, and their failures cause lost production, safety incidents and high repair costs. Repeat failures are common: seals that fail within months, bearings damaged by contamination or misalignment, pumps run at low flow or with insufficient suction head, and compressors surging during start-up. Too often, the response is to replace parts rather than to find and remove the root cause.

This programme follows the life of a machine in service. It starts with how the main types of rotating equipment work and fail, then covers installation and commissioning, safe start-up and operation, preventive and condition-based maintenance, and a structured troubleshooting and root cause analysis method. Throughout, the focus is on the checks, readings and decisions that operators and maintenance staff make every day.

Built on recognised practice. The programme references widely used industry standards and practices, including API 610 for centrifugal pumps, API 617 and API 618 for centrifugal and reciprocating compressors, API 682 for pump shaft sealing systems, API 686 for machinery installation, ISO 20816 for the evaluation of machine vibration, ISO 21940 for rotor balancing, and reliability-centred maintenance principles. Manufacturer instructions remain the primary reference for each machine.

Decisions this programme improves. Whether a machine is ready to start; how to respond to rising vibration or temperature; when to run to failure, maintain on time or maintain on condition; which spares and seal plans to hold; how to investigate a repeat failure; and when equipment is being operated outside its safe or efficient range.

How it is delivered. Twenty hours across five sessions, built around one running case: a pumping and compression station with repeat seal and bearing failures. Participants review installation records, plan a start-up sequence, interpret vibration and process data, select maintenance strategies and complete a root cause analysis. Exercises use equipment data sheets, performance curves and sample vibration spectra.

In-house option. For organisations, the programme can be tailored to your own equipment types, operating procedures, maintenance system and failure history, and delivered for operations and maintenance teams together.

Who Should Attend

Mechanical and rotating equipment engineers: those responsible for machinery performance and reliability

Maintenance supervisors and planners: those who plan and supervise machinery maintenance

Operations engineers and supervisors: those who start up, operate and monitor rotating equipment

Reliability and condition monitoring staff: vibration analysts and reliability engineers

Senior technicians: mechanical technicians moving into supervisory or diagnostic roles

Objectives

Explain the operating principles, components and typical failure modes of pumps, compressors, fans and turbines

Read and use performance curves, including best efficiency point, NPSH and surge limits

Check installation quality, including foundations, grouting, piping strain and alignment

Prepare and carry out safe pre-start checks, start-up and shutdown sequences

Monitor operating parameters and recognise early signs of abnormal operation

Select and maintain lubrication, bearings and mechanical seal systems

Apply preventive, predictive and condition-based maintenance strategies to rotating equipment

Interpret basic vibration, temperature and oil analysis data to diagnose common problems

Use a structured troubleshooting method and root cause analysis to eliminate repeat failures

Recommend improvements that raise equipment reliability, availability and energy efficiency

Course Outline

How Rotating Equipment Works and Fails

Centrifugal and positive displacement pumps
Centrifugal, axial, screw and reciprocating compressors
Fans, blowers, steam and gas turbines and drivers
Performance curves, operating envelope and best efficiency point
NPSH, cavitation, recirculation and surge
Common failure modes and their mechanisms

Installation, Commissioning and Start-Up

Foundations, baseplates and grouting
Piping strain, supports and flushing
Shaft alignment methods: dial indicator and laser
Pre-commissioning checks and run-in tests
Start-up and shutdown sequences for pumps and compressors
Permits, isolation and safe work practices around machinery

Operating for Reliability and Efficiency

Operating parameters to monitor and their limits
Running at reduced flow, parallel and series operation
Anti-surge and capacity control
Lubrication principles, oil selection and contamination control
Bearings: types, fits, temperatures and failure signs
Mechanical seals, seal support plans and dry gas seals
Energy efficiency: variable speed drives and right-sizing

Maintenance Strategies and Condition Monitoring

Corrective, preventive, predictive and condition-based maintenance
Reliability-centred maintenance principles for rotating equipment
Vibration monitoring and ISO 20816 evaluation zones
Balancing principles and ISO 21940
Oil analysis, thermography and ultrasound
Online monitoring systems and the role of analytics
Spare parts, overhaul planning and workshop quality

Troubleshooting and Root Cause Analysis

A structured troubleshooting method: symptoms, data and hypotheses
Diagnosing common problems: imbalance, misalignment, looseness, bearing and seal damage
Pump and compressor process-related problems
Root cause analysis tools: five whys, fishbone and fault tree
Failure reporting and learning from repeat failures
Key reliability indicators: MTBF, availability and bad actor lists
Action plan: improving rotating equipment reliability at your site

Competencies

Rotating equipment operating principles and failure modes

Performance curve interpretation

Installation quality and shaft alignment

Start-up and shutdown procedures

Lubrication, bearing and mechanical seal management

Condition monitoring and vibration evaluation

Maintenance strategy selection

Troubleshooting and root cause analysis

Reliability and energy efficiency improvement

Dubai

Elite Academy can deliver its complete portfolio of professional training programs in Dubai. With a global business, aviation and services hub with excellent international accessibility, the destination suits both scheduled learning and tailored arrangements for organizations or individual professionals. As an Elite Academy training destination, Dubai provides access to our full portfolio rather than a city-specific set of specializations. The city is a global business, aviation and services hub with excellent international accessibility, creating a suitable environment for organizations developing their teams and for professionals attending independently. Upcoming scheduled courses are listed on this page, while any other Elite Academy program can also be requested for delivery in Dubai, subject to scheduling and delivery requirements. Explore the schedule or browse our training areas to find the right option.

Rotating Equipment - Start-up, Operation, Maintenance and Troubleshooting