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Engineering, Oil and Gas

Compressor Technology




Introduction:

This program provides a comprehensive understanding of the various types of reciprocating, rotary, and dynamic compressors. This includes trunk piston, sliding crosshead piston, diaphragm, rotary screw, straight lobe, sliding vane, liquid ring, centrifugal, and axial compressors. Bearings are also covered thoroughly. The characteristics, selection criteria, sizing calculations, sealing arrangements, common problems, repair techniques, as well as the preventive and predictive maintenance of these compressors, are covered in detail.

This program is a must for those who use this equipment. It covers how compressors and bearings operate and provides the guidelines and rules that must be followed for their successful application

Targeted Groups:

  • Operation and Maintenance Operators
  • Supervisors & Technicians
  • Facility Engineers
  • Utility Engineers
  • Anyone requiring a working level knowledge of rotating equipment & compressors
  • Technical Professionals dealing with condition monitoring, reliability and integrity analysis

Course Objectives:

At the end of this course the participants will be able to:

  • Maximize the efficiency, reliability, and longevity of all types of compressors and bearings
  • Size and select out of the various types of dynamic and positive displacement compressors using the performance characteristics and the selection criteria that you learn in the program
  • Carry out diagnostic testing and inspection of critical components with the knowledge of common failure modes of compressors and bearings by applying advanced fault detection techniques
  • Select bearings and lubrication, compressor sealing arrangements, meet commissioning requirements, conduct vibration and used oil analyses, troubleshoot, provide predictive and preventive maintenance, enhance reliability, and reduce cost
  • Determine the maintenance required to minimize compressor downtime and operating cost and maximize its efficiency, reliability, and useful life
  • Gain a thorough understanding of compressor surge and surge prevention systems
  • Understand all the causes of failures in compressors
  • Determine all the design features that improve the efficiency and reliability of all compressors
  • Design different types of compressor systems
  • Gain a thorough understanding of the various types of sealing arrangements used in compressors

Targeted Competencies:

  • Basic Design
  • Specification
  • Selection Criteria
  • Sizing Calculations
  • Sealing Arrangements
  • Common Operational Problems
  • All Diagnostics, Troubleshooting, and Maintenance Required for this Equipment Including Vibration Analysis, and Used Oil Analysis

Course Content:

Unit 1: Gas Laws, Compressor Types and Applications:

  • Perfect and Imperfect Gases
  • Compressor Polytropic Efficiency and Power Requirements
  • Compressor Volumetric Flow Rate and Volumetric Efficiency
  • Rotary and Reciprocating Compressors
  • Dynamic Compressors (Centrifugal and Axial)
  • Compressor Performance Measurement
  • Receivers, Compressor Control, and Compressor Unloading Systems
  • Preventive Maintenance and Housekeeping

Unit 2: Positive Displacement Compressors:

  • Performance of Positive Displacement Compressors
  • Reciprocating Compressors
  • Reciprocating Compressors Troubleshooting and Maintenance
  • Diaphragm Compressors
  • Rotary Screw Compressors and Filter Separators
  • Straight Lobe Compressors
  • Recent Developments in Liquid/Gas Separation Technology

Unit 3: Dynamic Compressors:

  • Dynamic Compressor Technology
  • Centrifugal and Axial Compressors
  • Simplifies Equations for Determining the Performance of Dynamic Compressors
  • Centrifugal Compressors – Components, Performance Characteristics, Balancing, Surge Prevention Systems and Testing
  • Choking, and Anti-Choking Systems
  • Compressor Auxiliaries, Off-Design Performance, Stall, and Surge

Unit 4: Dynamic Compressors Performance, Compressor Seals, and Compressor System Calculations:

  • Dynamic Compressors Performance
  • Surge Limit, Stonewall, Prevention of Surge, Anti-Surge Control Systems
  • Compressor Seal Systems
  • Gas Seals, Liquid Seals, Liquid Bushing Seals, Contact Seals, Restricted Bushing Seals, Seal Liquid leakage System
  • Dry Seals, Advanced Sealing Mechanisms, and Magnetic Bearings
  • Compressor System Calculations
  • Sizing of Compressor System Components, Sizing of Gas Receiver
  • Design and Selection of Different Compressor Systems for the Oil and Gas industry, and the Power Generation Industry

Unit 5: Bearings, Lubrication, Vibration Analysis, and Predictive Maintenance:

  • Bearings, Types of Bearings, Thrust Bearings
  • Lubrication, Viscosity of Lubricants, Non-Newtonian Fluids, and Greases
  • Used Oil Analysis
  • Vibration Analysis and Predictive Maintenance
  • Vibration Causes, Resonant Frequency, Vibration in Predictive Maintenance, Diagnostics
  • Intelligent (Smart Transmitters)
  • Advantages of Intelligent Instrumentation
  • Control Valve Selection, Cavitation, and Noise
  • Actuators, Positioners, and Accessories
  • Diagnostic Testing