Air Compressors Operation and Maintenance Training 20th – 24th August 2024 (Weekdays)
- Description
- Reviews
This advanced course aims to enhance the knowledge and skills of experienced professionals in the operation, maintenance, and troubleshooting of various types of compressors. It covers theoretical concepts, practical applications, and best practices to ensure efficient and reliable compressor performance.
An industrial plant will have a variety of compressors, including axial, screw, reciprocating, and centrifugal compressors. Participants in this instructor-led training course see each of these compressor types while learning about the essential parts, functioning, maintenance, and troubleshooting of the compressor. The first courses cover subjects related to centrifugal compressors, including wet and dry sealing, balance, varieties of impellers, and how to remove the casing. The explanation of reciprocating compressors follows, covering a variety of subjects like cylinder clearance, clearance pockets, and valve maintenance. After that, screw compressors—both flooded and dry—are described. After that, axial compressor performance and component details are provided, along with anti-surge control. A major emphasis in the explanation of each compressor is maintenance.
Learning Objectives
By the end of this course, participants will be able to:
● Identify and Explain Different Types of Compressors
- Understand the principles of operation for centrifugal, reciprocating, rotary screw, and axial compressors.
- Differentiate between the applications and advantages of each compressor type.
● Understand Compressor Components and Their Functions
- Recognize and describe the function of key compressor components, including impellers, rotors, valves, pistons, cylinders, and seals.
- Comprehend the operational cycles and performance characteristics of different compressors
● Perform Installation and Commissioning of Compressors
- Follow proper procedures for site preparation, foundation requirements, and compressor alignment.
- Conduct pre-commissioning checks and start-up protocols to ensure safe and
efficient operation.
● Implement Effective Maintenance Strategies
- Develop and execute preventive maintenance schedules and inspections.
- Utilize predictive maintenance techniques such as vibration analysis, thermography, and oil analysis.
- Address corrective maintenance needs by troubleshooting and repairing common compressor issues.
● Diagnose and Troubleshoot Compressor Problems
- Identify symptoms and root causes of common compressor problems, including vibration, noise, temperature variations, and leaks.
- Apply advanced troubleshooting techniques and tools to resolve issues.
● Manage Lubrication and Cooling Systems
- Select appropriate lubricants and maintain lubrication systems.
- Understand and maintain cooling systems to ensure optimal compressor performance.
● Operate and Maintain Control Systems and Instrumentation
- Utilize manual, pneumatic, and electronic compressor control systems effectively
- Monitor and interpret data from pressure, temperature, flow, and level sensors.
● Adhere to Safety Practices and Industry Standards
- Recognize safety hazards and implement appropriate safety protocols.
- Use personal protective equipment (PPE) correctly.
- Comply with relevant industry standards and regulations (e.g., ASME, API).
● Optimize Compressor Energy Efficiency
- Analyze energy consumption patterns and implement efficiency improvement techniques.
- Manage compressor loads and select appropriate compressors for specific applications.
- Apply best practices to reduce energy costs and environmental impact
● Stay Updated with Advanced Topics and Technological Advancements
- Employ advanced troubleshooting techniques and tools.
- Stay informed about the latest advancements in compressor design and materials.
- Integrate Industry 4.0 and IoT technologies for smart maintenance and performance optimization.
● Apply Knowledge in Practical Scenarios
- Engage in hands-on training with compressor models and simulation tools
- Solve real-world problems through case studies and practical exercises.
- Visit operational compressor facilities (if applicable) to observe and learn from real-world applications.
● Be able to operate, maintain and troubleshoot all types of compressors
Who Should Attend?
This training course is recommended for the following personnel:
- Maintenance Engineers and Technicians
- Operations Managers
- Mechanical Engineers
- Plant Supervisors and Technicians
- Anyone involved in the operation and maintenance of industrial compressors
Course Outline
Day 1
Module 1: Introduction to Compressors
- Types of Compressors, Centrifugal, Reciprocating, Rotary
- Compressor Selection
- Casing Types
- Introduction to Seals and Bearings
- Introduction to Performance and Control
Module 2: Centrifugal Compressor Components
- Compressor Casing; Vertical and Horizontal Split
- Diaphragms
- Inducer and Diffuser
- Guide Vanes
- Compressor Rotor
- Centrifugal Compressor Stage
- Balance Piston/Drum
- Axial Thrust and Impeller Arrangements
Module 3: Centrifugal Compressor Seals
- Liquid Film Shaft Seals
- Dry Carbon Ring Shaft Seals
- Labyrinth Shaft Seals
- Dry Mechanical Shaft Seals
- Wet Seal System
- Dry Gas Sealing
Module 3: Reciprocating Compressors
- Overview of Components
- Performance; Influence of Component Design
- Valve Types, Components and Maintenance
- Liners and Cylinder Lubrication
- Thermodynamic Cycle of a Reciprocating Compressor
- Variable Clearance and Variable Volume Clearance Pockets
- Crankshaft and Bearings
- Connecting Rods
- Pistons and Cylinder Clearance
Day 2
Module 5: Multistage Compression
- Centrifugal Compressors
- Reciprocating Compressors
Module 6: Multistage Compression
- Types of Screw Compressor
- Rotor Design
- Components
- Dry and Flooded Screw Compressors
- Cooling
- Capacity Control
- Seals, Bearings and Casings
Module 7: Compressor Drivers
- Describe driver types and reciprocating compressor maintenance
- Describe compressor driver types and operations
- Describe valves and rod packing
- Describe lubrication principles and application.
Module 8: Axial Flow Compressor
- Overview and Components
- Performance and Thermodynamics
- Case
- Stator
- Rotor
- Inlet and Exit Guide Vanes (IGV’s and EGV’s)
Module 9: Nozzles and Piping
- Size and Position of Nozzles
- Reciprocating Compressor Piping
- Centrifugal Compressor Piping
- Best Practices for Compressor Piping
Day 3
Module 10: Compressor Operations
- Compressor Installation Checks
- Pre-Startup Checks
- Compressor Startup Sequences
- Compressor Operational Checks
- Compressor Shutdown Sequences
- Compressor Emergency Shutdown Sequences
- Function of Compressor De-superheating Valve
- Function of Oil Coolers
- Function of Compressor Oil Screens
Day 4
Module 11: Compressor Electrical, Instrumentation and Control Systems
- Compressor Motor Protection
- Compressor Enclosure Fan Start/Stop
- Compressor Lube/Seal Oil Pumps and permissives
- Temperature, Pressure, flow and Level Instrumentation and Compressor Control
- Coordinated Control and Protection
- Surge and Stall
- Anti-Surge Control
- Control and Load Sharing
- Fouling and Performance Monitoring
Day 5
Module 12: Monitoring and Troubleshooting
- Reciprocating Compressors
- Axial and Centrifugal Compressors
- Screw Compressors
- Monitoring Concepts
- Signal Processing and Frequency Analysis
- Vibration Signature Curve
- Vibration Measurement Locations and Design Limits
- Misalignment and Unbalance
- Rotor Rub, Clearance Problems
- Electrical Problems
- Reverse Rotation Check
- Bearing and Gear Damage
- Oil Whip
Module 13: Other Maintenance Considerations
- Compressor Protection and Safety System
- Compressor Condition Monitoring System
- Vibration Monitoring and Control Measurements
- Vibration Root Cause Analysis
- Bearing Failures and Lubricant Oil Analysis
- Mechanical Seal and Dry Seal Maintenance
- Preventive, Predictive and Corrective Maintenance: Scope & Procedure
- Inspection of Most Critical Parts
- Leak Control and Prevention
- Problem Detection and Diagnostics: Root Cause Analysis
- Troubleshooting Procedures in Normal and Abnormal Conditions
- Overhaul and Repair Options
Perks that come with our Trainings on Trainhub
- All participants get instant access to our Trainhub Software where they have access to more training materials, video and software related to the course
- All participants are graded and their competence in the course is matched before certificates are awarded
- All participants continue to retain access to the platform for 6 months or 12 months depending on the training
- All participants can print off their certificates right after the training having met all assessments assigned for the training on the software
- All participants get regular updates on this training over the coming years
- All participants join our community of professionals and can access the trainers and other professionals where they can share ideas and continue to grow their skills
