Introduction

Pumps, compressors, and turbines are critical rotating equipment used across oil & gas, power generation, water treatment, and manufacturing sectors. Their efficient operation, regular maintenance, and prompt troubleshooting are essential to avoid costly downtime and ensure plant safety and reliability. This 12-day technical training program—developed by Global Horizon Training Center—equips engineers, technicians, and maintenance personnel with the comprehensive skills needed to operate, maintain, and troubleshoot a wide range of pumping, compression, and turbomachinery systems.

Objectives

By the end of this program, participants will be able to:

• Understand the principles of operation of pumps, compressors, and turbines.

• Identify key components and performance characteristics.

• Implement best practices in preventive and predictive maintenance.

• Diagnose common failures and apply troubleshooting techniques.

• Optimize equipment efficiency and reliability.

• Ensure compliance with safety, operational, and OEM standards.

Organizational Impact

• Improved reliability of rotating equipment

• Reduced unplanned downtime and maintenance costs

• Increased operator safety and maintenance efficiency

• Enhanced troubleshooting capacity of in-house teams

• Better energy utilization and performance optimization

Target Audience

• Mechanical and Maintenance Engineers

• Rotating Equipment Technicians

• Reliability and Asset Management Specialists

• Operation Supervisors and Plant Engineers

• Field Technicians and Utility Operators

Training Program Outline

Day 1: Fundamentals of Rotating Equipment

• Introduction to pumps, compressors, and turbines

• Mechanical energy transformation principles

• Classification and comparison

• Key performance indicators (flow, pressure, head, power)

Day 2: Pump Types and Operating Principles

• Centrifugal, positive displacement, gear, diaphragm, and screw pumps

• Pump curves and system curves

• Suction head, NPSH, cavitation prevention

• Application examples (water, chemical, oil)

Day 3: Pump Components and Maintenance

• Bearings, seals, impellers, volutes, shafts

• Alignment, lubrication, and cooling systems

• Mechanical seal maintenance and failure modes

• Preventive maintenance checklists

Day 4: Pump Troubleshooting and Failure Analysis

• Common pump problems: cavitation, vibration, overheating

• Root cause analysis techniques

• Fault isolation steps

• Case studies: pump breakdowns in oil & gas plants

Day 5: Compressors – Types and Applications

• Reciprocating, rotary screw, centrifugal compressors

• Air vs. gas compressors

• Single-stage and multi-stage designs

• Process applications and pressure ratios

Day 6: Compressor Components and Operation

• Valves, intercoolers, pistons, rotors, casings

• Control systems and instrumentation

• Compressor performance maps

• Safety valves and shutdown systems

Day 7: Compressor Maintenance and Troubleshooting

• Predictive indicators (temperature, pressure, vibration)

• Troubleshooting flow restrictions, leakage, lubrication issues

• Vibration analysis and condition monitoring

• Maintenance schedules and best practices

Day 8: Industrial Turbines – Principles and Design

• Steam turbines, gas turbines, and hydraulic turbines

• Energy conversion cycle and thermodynamic efficiency

• Blades, nozzles, rotors, casings

• Combined-cycle applications

Day 9: Turbine Operation and Performance Control

• Startup and shutdown procedures

• Load and speed control mechanisms

• Turbine control systems (governors, actuators)

• Efficiency improvement techniques

Day 10: Turbine Maintenance and Diagnostics

• Inspection intervals and recommended practices

• Hot section vs. cold section maintenance

• Fouling, erosion, thermal fatigue

• Monitoring critical parameters (vibration, temperature)

Day 11: Vibration, Alignment, and Balancing

• Vibration sources and measurement methods

• Shaft alignment techniques (laser, dial gauge)

• Rotor dynamic balancing principles

• ISO standards and field implementation

Day 12: Integrated Troubleshooting & Reliability Strategies

• Coordinated troubleshooting for pump/compressor/turbine systems

• Failure mode and effect analysis (FMEA)

• Reliability-centered maintenance (RCM)

• Developing site-specific O&M strategies