Training on Rotating Equipment and Maintenance Logistics in Oil and Gas

Module 1: Rotating Equipment Overview and Criticality

• Types: centrifugal pumps, reciprocating compressors, centrifugal compressors, gas turbines, steam turbines, and engines.

• Equipment criticality assessment and impact on production.

• Key components: bearings, seals, impellers, rotors, stators, and casings.

• Case Study/Hands-on Exercise: Conduct a criticality assessment on rotating equipment in an offshore production facility, prioritizing spares and maintenance logistics.

Module 2: Spare Parts Management for Rotating Equipment

• Types of spares: rotable spares, consumables, and capital spares.

• OEM vs. non-OEM spares and interchangeability.

• Lead times, stocking strategies, and consignment inventory.

• Case Study/Hands-on Exercise: Develop a spare parts stocking strategy for a critical gas compressor, balancing lead time, cost, and downtime risk.

Module 3: Logistics for Rotating Equipment Maintenance

• Transporting heavy rotating equipment to/from repair centers.

• Specialized handling: lifting, skidding, and environmental protection.

• Coordination with OEMs and third-party repair shops.

• Case Study/Hands-on Exercise: Plan the logistics for sending a 10-ton pump for overhaul to an OEM repair center 1,000km away, including transport, crating, and customs.

Module 4: Vendor Coordination and Repair Management

• Long-term service agreements (LTSAs) with OEMs.

• Managing repair scope, quality, and schedule.

• Witness testing (FAT, SAT) and certification.

• Case Study/Hands-on Exercise: Negotiate an LTSA for gas turbine maintenance, including response times, spare parts availability, and repair cost caps.

Module 5: Turnaround (TAR) Logistics for Rotating Equipment

• Turnaround planning: critical path, outage duration, and resource loading.

• Marshalling of spare parts, tools, and contractor personnel.

• Coordinating multiple equipment overhauls in a single outage.

• Case Study/Hands-on Exercise: Develop a turnaround logistics plan for a refinery with 10 critical rotating equipment overhauls, including parts marshalling, contractor coordination, and schedule.