Industries prioritize achieving maximum efficiency, reliability, and durability of compressors, pumps, and bearings. However, these goals can only be accomplished by comprehending their characteristics, selection criteria, sizing calculations, sealing arrangements, common issues, repair techniques, and preventive and predictive maintenance practices. This training session is essential for individuals utilizing this equipment. It delves into the operation of compressors and pumps, offering guidelines and rules necessary for their effective application. The course covers the fundamental design, specification, and selection criteria, sizing calculations, and thoroughly addresses maintenance concerns, including vibration analysis and used oil analysis.

Course Objectives:

And you will be able to:

Size and select out of the various types of dynamic and positive displacement compressors and pumps using the performance characteristics and the selection criteria that you learn in the course
Carry out diagnostic testing and inspection of critical components with the knowledge of common failure modes of compressors and pumps by applying advanced fault detection techniques
Select bearings and lubrication, pump 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, pump operating cost and maximize their efficiency, reliability, and useful life
Gain a thorough understanding of compressor surge and surge prevention systems
Understand all the causes of failures in compressors and pumps
Determine all the design features that improve the efficiency and reliability of all compressors and pumps
Design different types of compressor and pumping systems
Gain a thorough understanding of the various types of sealing arrangements used in compressors and pumps

Who Should Attend?

Process engineers, design engineers, consulting engineers, plant engineers, project managers, piping engineers, maintenance managers, water treatment plant managers, facility managers and technicians and technologists
It will be of great interest to chemical process industries, oil and gas industries, manufacturing plants, power generation plants, defense establishment, and other industries and organizations that must use compressors and pumps

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, Avogrado’s law
Heat and work, property relationships, perfect gases, imperfect gases
Vapor pressure, partial pressures, critical conditions, gas mixtures, the mole
The volume percent of constituents, the molecular weight of a mixture, specific gravity and partial pressure, specific heats
Pseudo-critical conditions and compressibility, weight-basis items, compression cycles, compressor polytropic 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, the 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 valve.
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, packings
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, the theory of operation, compressor design
Materials of construction, accessories, cleaning and testing
Applications, automotive airbag 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
Selection of modern reverse-flow filter separators, conventional filter-separators, and self-cleaning coalescers, removal efficiencies, filter quality.
Selection of the most suitable gas filtration equipment, evaluation of the proposed filtration configuration, life-cycle-cost calculations, conclusions.
Coke fuel, Introduction, Properties and Usage, Other coking processes

Straight Lobe Compressors

Applications, operating characteristics, operating principle
Pulsating characteristics, noise characteristics, torque characteristics

Filters