Rotating Equipment Reliability & Optimization (Condition Monitoring & Best Practices) This course provides participants with practical knowledge and hands-on skills for operating, maintaining, and troubleshooting industrial gas engines. It covers engine principles, fuel systems, ignition, cooling, lubrication, electrical systems, control systems, safety, and preventive maintenance.

Practical Session:

• Engine component identification
• Engine layout demonstration

Practical Session:

• Fuel system inspection
• Ignition system demonstration
• Lubrication & coolant check

Practical Session:

• Starting, running, and stopping the gas engine
• Control panel operation demonstration

Practical Session:

• Fault simulation & troubleshooting exercises
• Preventive maintenance practice
• By the end of this course, participants will be able to:
• Understand the principles of gas engine operation
• Identify engine components and systems
• Perform safe start-up, shutdown, and operation procedures
• Conduct routine inspection and preventive maintenance
• Diagnose and troubleshoot mechanical, fuel, and ignition system faults
• Optimize engine efficiency and reliability
• Apply safety protocols and environmental best practices
• Day 1 – Diesel Engine Fundamentals
• Day 1 – Gas Engine Fundamentals
• Module 1: Introduction to Gas Engines
• Applications in industry
• Types of gas engines (spark ignition, dual-fuel, lean burn)
• Engine layout and configuration
• Comparison with diesel engines
• Module 2: Engine Components
• Cylinders, pistons, crankshaft, camshaft
• Valves and timing mechanisms
• Ignition systems (spark plugs, coils)
• Fuel system components
• Module 3: Engine Operation Principles
• Otto and dual-fuel cycles
• Combustion process & air-fuel ratio
• Power & torque characteristics
• Day 2 – Fuel Systems & Ignition
• Module 4: Fuel Supply & Gas Handling
• Types of fuel gases (natural gas, biogas, LPG)
• Fuel supply systems and regulators
• Safety devices and flame supervision
• Gas leak detection
• Module 5: Ignition System
• Spark plugs & coils
• Ignition timing
• Sensors for knock detection
• Ignition safety interlocks
• Module 6: Lubrication & Cooling Systems
• Lubricants and viscosity selection
• Oil pumps & filters
• Cooling system types (water, air)
• Temperature monitoring
• Day 3 – Electrical Systems & Controls
• Module 7: Engine Electrical Systems
• Battery & starting systems
• Alternator & charging circuits
• Sensors & indicators (temperature, pressure, speed)
• Control panels overview
• Module 8: Control Systems
• Engine governors & speed control
• Remote monitoring & automation
• Safety interlocks & shutdown systems
• Module 9: Engine Start-up & Shutdown
• Pre-start inspection
• Operational checks
• Load connection & synchronization (if applicable)
• Safe shutdown procedures
• Day 4 – Troubleshooting & Maintenance
• Module 10: Mechanical Faults
• Cylinder wear & scoring
• Valve issues
• Excessive vibration & noise
• Overheating
• Module 11: Fuel & Ignition Faults
• Poor combustion
• Spark plug failure
• Gas supply interruptions
• Misfiring & knocking
• Module 12: Preventive & Predictive Maintenance
• Daily, weekly, and monthly checklists
• Lubrication and filter maintenance
• Cooling system maintenance
• Record-keeping and logs
• Day 5 – Safety, Case Studies & Workshop
• Module 13: Safety & Environmental Practices
• PPE requirements
• Gas handling & leak prevention
• Hot-work safety
• Emission monitoring & compliance
• Module 14: Case Studies
• Industrial engine failures
• Root cause analysis
• Lessons learned & corrective actions
• Module 15: Capstone Practical
• Full inspection & preventive maintenance
• Troubleshooting simulated faults
• Engine operation under load demonstration
• Knowledge evaluation & team discussion
• Module 16: Course Review & Wrap-Up
• Q&A session
• Assessment & certification