Maximum efficiency, reliability, and longevity of compressors and turbines are critical considerations for numerous industries. Achieving these objectives requires a comprehensive understanding of their characteristics, selection criteria, sizing calculations, sealing arrangements, common problems, repair techniques, as well as preventive and predictive maintenance practices. This program is highly recommended for professionals utilizing these equipment types. It provides insights into the operation of compressors and turbines and offers guidelines and rules for their successful application.

Course Objectives:

To provide a comprehensive understanding of the various types of compressors, turbines, and bearings so participants can specify, select, size, commission and maintain compressors and turbines for their applications
To achieve reduced capital, operating and maintenance costs along with increase in efficiency
Upon participating in this programme, delegates will be able to:
Carry out diagnostic testing and inspection of critical components with the knowledge of common failure modes of compressors and turbines by applying advanced fault detection techniques
Select bearings and lubrication, turbine and 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 and downtime, turbine operating cost and maximize their efficiency, reliability, and useful life
Gain a thorough understanding of compressor surge and surge prevention systems
Understand the major causes of failures in compressors and turbines
Determine the design features that improve the efficiency and reliability of all compressors and turbines
Operate and maintain different types of compressor and turbines systems

Who Should Attend?

Engineers with little previous knowledge of compressors and who are involved in the design, control, operation or commissioning of process plants.
Chemical, mechanical, instrumentation and process engineers
Process plant operation and supervisory staff
Design engineers wanting to learn about the operation and control of compressors as part of a process plant
Engineers interested in using dynamic simulation model to learn more about the control and operation of compressors

Course Outlines:

Gas Laws and Compression Principles

Introduction, symbols, compressor operation, first law of thermodynamics, second law of thermodynamics
Ideal or perfect gas laws, Boyle’s law, Charles’ law, Amonton’s law, Dalton’s law, Amagat’s law, Avogadro’s law
Heat and work, property relationships, perfect gases, imperfect gases.
Vapor pressure, partial pressures, critical conditions, gas mixtures, the mole
Volume percent of constituents, molecular weight of a mixture, specific gravity and partial pressure, specific heats.
Pseudo-critical conditions and compressibility, weight-basis items, compression cycles, compressor polytrophic efficiency.
Compressor power requirement, compressibility correction, multiple staging
Compressor volumetric flow rate, cylinder clearance and volumetric efficiency, cylinder clearance and compression efficiency, Appendix A

Compressor Types and Applications

Introduction, positive displacement compressors
Rotary compressors, rotary lobe compressors, rotary vane compressors, rotary screw compressors, rotary liquid ring compressors
Reciprocating compressors
Dynamic compressors, centrifugal compressors, the principle of operation of centrifugal compressors, centrifugal single-stage (low ratio) compressors, centrifugal single stage integral gear compressors, centrifugal multi-stage horizontally split compressors, centrifugal multi-stage with side loads compressors, centrifugal multi-stage (barrel) compressors, centrifugal multi-stage integral gear compressors
Axial flow compressors, axial horizontally-split compressors

Compressors

Compressor types: positive displacement (reciprocating and rotary), and dynamic (centrifugal and rotary), compressor operation, gas laws
Compressor performance measurement, inlet conditions, compressor performance, energy available for recovery.
Positive displacement compressors, reciprocating compressors, trunk piston compressors, sliding crosshead piston compressors, diaphragm compressors, bellows compressors
Rotary compressors, rotary screw compressor, lobe type air compressor, sliding vane compressors, liquid ring compressors
Dynamic compressors, centrifugal compressors, axial compressors
Air receivers, compressor control, compressor unloading system
Intercoolers and aftercoolers, filters and air intake screens
Preventive maintenance and housekeeping

Performance of Positive Displacement Compressors

Compressor performance, positive displacement compressors
Reciprocating compressor rating, reciprocating compressor sizing
Capacity control, clearance pockets, compressor performance
Reciprocating compressors, compressor valves
Reciprocating compressor leakage, screw compressor leakage

Reciprocating Compressors

Introduction, crankshaft design, bearings and lubrication systems
Connecting rods, crossheads, frames and cylinders, compressor cooling
Pistons, piston and rider rings, valves, piston rods, packing
Cylinder lubrication, distance pieces

Reciprocating Air Compressors Troubleshooting and Maintenance

Introduction, location, foundation, air filters and suction lines
Air-receiver location and capacity, starting a new compressor
Lubrication, non-lubricated cylinders, valves, piston rings
Intercoolers and aftercoolers, cleaning, packing

Diaphragm Compressors

Introduction, theory of operation, compressor design
Materials of construction, accessories, cleaning and testing
Applications, automotive air bag filling, petrochemical industries
Limitations, installation and maintenance
Diaphragm compressor specification

Rotary Screw Compressors and Filter Separators

Twin-screw machines, compressor operation, applications of rotary screw compressors
Dry and liquid injected compressors, operating principles, flow calculation
Power calculation, temperature rise, capacity control, mechanical construction
Industry experience, maintenance history, performance summary
Oil-flooded single-screw compressors

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