PROGRAM DETAILS

Program Overview

This course will focus on the working principle and classifications of compressors, the components of each type, the application of each of them in the plant. The course will focus on the compressors operation and operational problems, and the required maintenance. This course offers a firm understanding of the selection, troubleshooting and fault diagnoses of compressors and its supporting systems.

 Course Objectives

Upon successful completion of this course the participant should be able to:

• Define the working principle of the compressors, the application, and the compressor classification.
• Define the working principle of each type of compressors, and the components of each.
• Describe the operational problems that could happen in compressor (positive displacement and roto-dynamic compressors) during operation.
• Identify the causes of the defects.
• List the possible corrective actions concerning the defect.
• Describe the required maintenance for each type.
• Describe the checks and inspections performed during compressor overhauling.
• Get to know methods for troubleshooting.

 Who should attend?

This course is intended for Maintenance and Operation Engineers, Maintenance and Operation Supervisors, Operation Supervisors and Senior Technicians. The course will also benefit anyone who expects to become involved in any stage in project applications.

 Course Outlines

 Day 1

 The function of compressors in the plant.

• Classification of compressors: Dynamic and positive displacement compressors.
• Classification of dynamic compressors and the working principle of each type.
• Centrifugal compressor components and their functions.
• Axial flow compressor components and their function.
• Surge and surge control systems.
• Flow control in case of axial flow and centrifugal compressors
• Compressor prime-movers.
• Operation and maintenance problems of centrifugal compressors.
• Operation and maintenance problems of axial flow compressors.

Day 2

Positive displacement compressors: How it works? Classification.

• The reciprocating compressor
• Principle of operation and the compressor component
• Multi-stage compressors
• Compressor operation and maintenance

Screw compressors

• Principle of operation and the compressor components
• Compressor operation and maintenance
• The compressor selection for specific application, the required information to order new compressor for certain application

Day 2

Centrifugal Compressors Operation

• Compressors material selecting and testing
• Compressors start-up and testing
• Minimum flow protection
• Compressor capacity control

Centrifugal Compressor Maintenance

• Mechanical seals
• Couplings and Alignment
• Causes of failure
• Maintenance & Troubleshooting
• Effect of fouling
• Overhaul Philosophy

Reciprocating Compressors

• Types of Reciprocating compressors
• Valves and unloaders
• Fixtures
• Piston and rings
• Piston rod packing
• Capacity control
• Overhaul of reciprocating compressors
• Effect of Gas Quality on operation

Day 3

Maintenance Concepts & Control

• Maintenance Theories and Strategies
• Breakdown, Preventive & Proactive Strategies
• Detection, Analysis, Correction & Verification, RCA

Troubleshooting & Fault Diagnosis

• General Issues and Problem Diagnosis
• Condition monitoring, vibration, thermo-graphy, oil analysis, ultrasound
• Performance monitoring
• Bearing types & selection

Day 4

 Failure Analysis

• Fatigue and fracture
• Corrosion & Material loss mechanisms
• Trouble Shooting & Predictive Maintenance

Vibration Analysis

• Vibration concepts
• On-line/Off-line monitoring
• Frequency analysis
• Enveloping/Demodulation

Specific Fault Diagnosis

• Diagnosis of Rotating Unbalance
• What is rotating unbalance? Causes
• Types of Unbalanced = Single plane, Couple & Dynamic
• Diagnosis of unbalance
• Eccentricity of rotating components
• Forces associated with unbalance
• Types of balancing & balancing machines
• Recommend vibration and balance tolerance

Day 5

Diagnosing Misalignment

• Different types misalignment = Parallel (offset), Angular, Combined
• Diagnosis and Repair
• Alignment techniques

Diagnosis of Gear problems

 Different types of Gears

 Gear Mesh Frequencies

 Misalignment/Eccentricity of gears

 Diagnosis Mechanical looseness problems

Diagnosing Bearing Problems (Fluid Film & Rotating Element)

 Life of Bearings, Failure Modes – Diagnosis & Repair

 Examples of Failed Bearings, How bearings fail

 Inspection & Monitoring

 Case studies