Petrotech Academy, Mahabubnagar
Major & Minor Overhauling of Rotating Equipments
Pumps, Compressors, Turbines & Other Rotating Equipments
A complete course for engineers and inspectors in Oil & Gas and Petrochemical plants: plan, execute, inspect, test and close out overhauls during shutdowns, turnarounds and routine maintenance, as per Saudi Aramco, SABIC, ADNOC and PDO standards and requirements.
18Detailed modules
4Client standard sets: Aramco, SABIC, ADNOC, PDO
Practical demonstrations & case studiesMethodology
Certificate of CompletionIncluded
Course overview
About this course
This course provides complete step-by-step knowledge and practical skills for planning, executing, inspecting and closing out minor and major overhauling of rotating equipments used in Oil & Gas and Petrochemical plants during shutdowns, turnarounds and routine maintenance.
Types of rotating equipment covered
- Centrifugal Pumps
- Positive Displacement, Vacuum, Gear and Screw Pumps
- Centrifugal Compressors
- Reciprocating Compressors
- Screw Compressors
- Steam Turbines
- Gas Turbines
- Gear Boxes
- Electric Motors
- Blowers / Fans
- Mixers / Agitators
- Expanders
Course outcomes
- Plan and prepare for shutdown / turnaround overhauls as per client standards
- Execute major and minor overhaul activities
- Inspect, test and evaluate rotating equipment condition
- Follow Saudi Aramco, SABIC, ADNOC and PDO standards and specifications
- Ensure safety, quality and reliability of equipment
- Document and close out overhaul activities effectively
Who should attend
- Maintenance Engineers & Supervisors
- QA/QC Engineers & Inspectors
- Reliability Engineers
- Mechanical Engineers
- Planning / Shutdown / Maintenance Planners
- Technicians & Craftsmen
Major overhaul vs minor overhaul
Know the scope, frequency and downtime of each type, then follow the same eleven-step workflow for either one.
| Activity | Minor overhaul | Major overhaul |
|---|---|---|
| Scope | Partial dismantling | Complete dismantling |
| Components | Wear parts, seals, bearings (if required) | All components |
| Inspection | Critical parts only | All parts, thorough cleaning and inspection |
| Repairs | Minor repairs, replacements | Major repairs, machining, replacement, re-balancing |
| Reassembly | With existing good parts | With new gaskets, seals, bearings |
| Testing | Functional test | Performance test and documentation |
| Downtime | Short | Long |
| Frequency | More frequent: 6–12 months or as per condition | Less frequent: 3–5 years or as per condition |
- 1Planning & Preparation
- 2Isolation & Depressurization
- 3Cleaning & Pre-Inspection
- 4Dismantling
- 5Inspection
- 6Evaluation & Repair / Replacement
- 7Reassembly
- 8Alignment & Balancing
- 9Pre-Commissioning Checks
- 10Testing & Commissioning
- 11Documentation & Handover
Detailed course content
Eighteen modules that follow an overhaul from strategy and safety to dismantling, inspection, equipment-specific work, alignment, testing and records.
Foundations: Equipment, Strategy, Planning, Safety and Pre-Overhaul
Introduction to Rotating Equipments
- Types, Functions & Applications
- Key Components
- Operating Principles
- Common Failure Modes
Maintenance Strategy & Overhaul Concepts
- Preventive vs Predictive vs Corrective Maintenance
- Shutdown vs Turnaround
- Minor vs Major Overhaul: Scope & Criteria
- RCM (Reliability Centered Maintenance)
- Life Cycle Costing
Shutdown & Turnaround Planning
- Scope Definition & Equipment List
- Workshop Planning
- Tools, Tackles & Special Tools
- Manpower Planning
- Spare Part Planning
- Permits, Risk Assessment (JSA) & Safety Plan
- Workpacks, ITPs, Checklists Preparation
Safety Requirements
- LOTO (Lock Out Tag Out)
- Working at Height
- Confined Space Entry
- Hot Work, Line Breaking
- Handling of Hazardous Materials
- HSE Requirements as per Client Standards
Pre-Overhaul Activities
- Equipment Isolation & Depressurization
- Drainage, Flushing & Cleaning
- Pre-Inspection & Condition Monitoring
- Documentation Review (History, Drawings, OEM Manuals)
- Tagging & Identification
Dismantling, Cleaning and Inspection
Dismantling Procedure
- Step-by-Step Dismantling
- Removal of Coupling, Guards, Piping, Auxiliaries
- Marking & Tagging of Parts
- Safe Handling of Components
- Storage & Preservation
Cleaning & Decontamination
- Mechanical Cleaning
- Chemical Cleaning
- Solvent Cleaning
- Passivation (for SS parts)
- Preservation
Inspection & Evaluation of Components
- Visual Inspection
- Dimensional Inspection
- NDT (PT, MT, UT, RT)
- Dye Penetrant for Cracks
- Hardness Testing
- PMI (Positive Material Identification)
- Acceptance Criteria as per Standards
Equipment-Specific Overhauling
Pumps Overhauling
- Types of Pumps
- Casing, Impeller, Wear Rings, Shafts
- Mechanical Seals, Packing
- Bearings & Bearing Housings
- Reassembly, Alignment & Testing
- Performance Test & Acceptance Criteria
Compressors Overhauling
- Reciprocating: Valves, Pistons, Rings, Cylinders, Rods, Crankshaft, Crossheads
- Centrifugal: Impellers, Diffusers, Seal Systems, Bearings, Thrust Bearing, Couplings
- Screw: Rotor Inspection, Bearings, Seals
- Reassembly, Alignment & Testing
Turbines Overhauling
- Steam Turbines: Rotor, Blades, Nozzles, Diaphragms
- Steam Turbines: Bearings, Seals, Governing System
- Gas Turbines: Rotor, Blades, Combustor, Bearings
- Gas Turbines: Gearbox, Seal Systems
- Reassembly, Alignment & Testing
Other Rotating Equipments
- Gearboxes
- Blowers & Fans
- Expanders
- Agitators & Mixers
- Electric Motors
Alignment, Assembly, Testing, Close-out and Case Studies
Alignment & Balancing
- Shaft Alignment (Soft Foot Check)
- Laser Alignment Procedure
- Dynamic Balancing
- Acceptance Criteria as per ISO 1940
- Documentation
Assembly & Reassembly
- Reassembly Best Practices
- Use of OEM Tools
- Torquing of Fasteners
- Seal Installation
- Bearing Installation
- Coupling Installation
Testing & Commissioning
- Pre-Start Checks
- Lube Oil System Checks
- Turning Gear Operation
- No Load Run Test
- Vibration, Temperature, Noise Monitoring
- Performance Test
- Final Acceptance Test (FAT)
Post Overhaul Activities
- Punch List Closure
- Cleaning & Housekeeping
- Restoration of Insulation & Painting
- Documentation & Dossiers
- Handing Over to Operations
Documentation & Records
- Overhaul Report
- Inspection Reports (NDT, Dimensional)
- Test Reports
- Alignment & Balancing Reports
- Material Certificates
- As-Built Drawings
- Lessons Learned
Case Studies & Best Practices
- Real Case Studies (Pumps, Compressors, Turbines)
- Common Issues & Solutions
- Lessons Learned
- Continuous Improvement
Equipment-wise overhauling content
The overhaul sequence for each machine family, with the inspection points and tests that matter for it.
Centrifugal Pumps (API 610)
- Description & Components
- Dismantling Sequence
- Inspection Points & Wear Limits
- Impeller, Casing, Wear Ring Inspection
- Mechanical Seal / Packing Replacement
- Shaft, Bearings, Sleeves Inspection
- Reassembly & Alignment
- Performance Test
Centrifugal Compressors (API 617)
- Overview & Components
- Dismantling Sequence
- Rotor, Impellers, Diffusers Inspection
- Seal & Labyrinth Inspection
- Bearings, Thrust Bearing Inspection
- Reassembly & Balancing
- Performance Test
Reciprocating Compressors (API 618)
- Components & Working Principle
- Dismantling Procedure
- Valves, Pistons, Rings Inspection
- Connecting Rod, Crankshaft Inspection
- Clearances & Wear Limits
- Reassembly & Adjustment
- Performance & Leak Test
Steam / Gas Turbines
- Overview & Components
- Rotor, Blades, Nozzles Inspection
- Bearings (Journal & Thrust) Inspection
- Seals & Diaphragms Inspection
- Reassembly, Alignment & Balancing
- Rolling & Functional Test
Other Rotating Equipments
- Motors: Bearing Replacement, Testing
- Blowers / Fans: Impeller, Bearing, Alignment
- Gear Boxes: Gear, Bearing, Oil Seal, Alignment
- Mixers / Agitators: Shaft, Impeller, Seal
Tools, inspection, assembly and records
Key tools & equipment
- Hydraulic Jacks, Pullers, Heaters
- Torque Wrenches
- Dial Indicators, Micrometers
- Alignment Tools (Laser / Dial)
- Balancing Machines
- NDT Equipment
- Lifting & Rigging Gear
- Bearing Heater, Vibration Analyzer
Inspection & NDT techniques
- Visual Testing (VT)
- Liquid Penetrant Testing (PT)
- Magnetic Particle Testing (MT)
- Ultrasonic Testing (UT)
- Radiographic Testing (RT)
- Eddy Current Testing (ET)
- Hardness Testing
- PMI Testing
- Vibration Analysis, Dimensional Inspection
Assembly best practices
- Cleanliness & Lubrication
- Correct Fit & Orientation
- Proper Torquing
- Avoid Over Tightening
- Protect Surfaces & Sealing Faces
- Maintain Alignment
Testing & acceptance criteria
- Dimensional Tolerance
- Rotor Run Out
- Shaft End Play
- Vibration Limits (as per API / ISO)
- Performance Parameters
- Leak Test Acceptance
Documents & records
- ITP / Check Sheets
- Torque Records
- Alignment Reports
- Balancing Reports
- NDT Reports
- Test Results
- Overhaul Completion Report
- Spare Parts Replacement Record
Safety reminders
- Follow PTW & LOTO
- Use Correct PPE
- Safe Lifting & Rigging
- Beware of Stored Energy
- Confined Space Precautions
Standards and documents covered by client
The same overhaul steps, applied under the requirements of each client.
Saudi Aramco
- SAEP-130, Rotating Equipment
- SAEP-131, Inspection Requirements
- SAEP-132, Vibration Monitoring
- SAES-P-010, Pumps
- SAES-P-020, Compressors
- SAES-T-010, Steam Turbines
- SAES-I-014, Balancing
- SA-ES-005, Predictive Maintenance
- Saudi Aramco Shutdown & Turnaround Handbook
- ITP as per SAEP
SABIC
- SABIC Engineering Standards (SES)
- SES-P-110, Pumps
- SES-C-110, Compressors
- SES-T-110, Steam Turbines
- SES-G-100, General Mechanical
- SES-I-020, Vibration Monitoring
- SABIC Maintenance Code (SMC)
- SABIC Turnaround Management Manual
- ITP & QCP as per SABIC requirements
ADNOC
- ADNOC Onshore Standards (AOS)
- AOS-1010, Mechanical Equipment
- AOS-1011, Pumps
- AOS-1012, Compressors
- AOS-1013, Turbines
- AOS-1040, Rotating Equipment Inspection
- AOS-1060, Vibration Monitoring
- ADNOC Maintenance Manual
- ADNOC Turnaround Manual
- ITP & QCP as per ADNOC requirements
PDO
- PDO Technical Standards (PDTOs)
- PDTO 01-01-010, Pumps
- PDTO 01-02-010, Compressors
- PDTO 01-03-010, Steam Turbines
- PDTO 05-10-050, Vibration Monitoring
- PDTO 05-20-020, Alignment & Balancing
- PDO Maintenance Management System (MMS)
- PDO Shutdown Handbook
- ITP as per PDO requirements
International and Indian standards you will work with
Overhaul work draws on API and ISO machinery standards, ASME repair references, Indian standards and statutory rules. The course teaches how to find the right requirement and apply it.
International standards
API, ISO, ASME, ASNT- API 610 / ISO 13709Centrifugal pumps for petroleum, petrochemical and natural gas industries
- API 617 / ISO 10439Axial and centrifugal compressors and expander-compressors
- API 618 / API 672Reciprocating compressors, packaged integrally geared air compressors
- API 611 / 612 / 616General and special purpose steam turbines, gas turbines
- API 613 / 614 / 671Gear units, lubrication and control-oil systems, couplings
- API 670 / 682 / 686Machinery protection, shaft sealing systems, machinery installation
- API RP 687Rotor repair
- ASME Section VIII / B31.3 / PCC-2Pressure parts, piping and repair of pressure equipment
- ISO 1940-1Rotor balance quality grades
- ISO 20816 / ISO 10816Evaluation of machine vibration
- ASNT SNT-TC-1A / ISO 9712Qualification and certification of NDT personnel
- ISO 9001Quality management systems
BIS: Indian Standards
Bureau of Indian Standards (IS codes)- IS 1520Horizontal centrifugal pumps for clear, cold, fresh water
- IS 1710Vertical turbine pumps for clear, cold, fresh water
- IS 5120Technical requirements for rotodynamic special purpose pumps
- IS 9137Acceptance tests for centrifugal, mixed flow and axial pumps
- IS 325Three-phase induction motors
- IS 12615Energy efficient induction motors
- IS 4722Rotating electrical machines
- IS 4691Degrees of protection of enclosures for rotating electrical machinery
- IS 2062Hot rolled structural steel for baseplates and supports
Indian statutory and industry
Regulations and safety bodies- Factories Act, 1948Statutory provisions for lifting machines, pressure plant and safe working
- OISD standardsOil Industry Safety Directorate guidelines, including work permit and shutdown safety
- BIS certification (ISI mark)Verification of certified products at material receiving
- Client and project specificationsAlways override and extend the general standards
The standard and edition that apply depend on the contract, client specification and OEM manual. Participants are trained to confirm the governing document before work starts.
What you receive and how it is taught
Course deliverables
- Comprehensive Training Manual (PDF)
- Checklists & Workpacks
- Overhaul Procedures (Step by Step)
- Inspection & Test Plans (ITP)
- Quality Control Plans (QCP)
- Overhaul Report Templates
- Alignment & Balancing Reports
- Case Studies & Best Practices
- Certificate of Completion
Benefits
- Industry best practices
- Standard based overhaul execution
- Reduced equipment failure
- Improved reliability and availability
- Better inspection & defect evaluation skills
- Effective documentation & reporting
- Compliance with international & client requirements
Learning methodology
- Classroom training / live lectures & presentations
- Practical demonstrations
- Case studies & examples
- Equipment videos & animations
- Checklists & templates
- Assessments & quizzes
Course content at a glance
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Plan, execute and close out rotating equipment overhauls
You will be able to plan, execute, inspect, test and close out major and minor overhauling of rotating equipments safely, efficiently and in compliance with industry standards.
Certificate of Completion included.