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Objectives

• The course covers how these machines work on process, mechanical aspects, wear, lubrication and troubleshooting by vibration analysis and other techniques.
• The course provides participants with knowledge for inspecting and monitoring compressors, and details how to make fault detections and diagnoses. Emphasis is placed upon the importance of a combined condition monitoring and strip-down inspection approach to maintenance.
• Extensive use is made of case study material to underline the key aspects of the course and to give the delegates exposure to current best practice.
• Be knowledgeable about the type of compressors and systems .
• Be aware of system design considerations in compressed air generation and distribution .
• Be able to comprehend the principle components, basic operation, and safety considerations associated with air compressors and compressed air systems.
• Use P&ID, wiring, schematic, and installation detail drawings to install, calibrate, and verify proper operation of instruments  .
• Explain methods for reducing electrical hazards including intrinsically safe installation .
• Describe the trend toward using field bus systems and personal computers in process control .
• Understand the relevance of ISO 9000 standards to maintenance practices and procedures .

The Delegates

This course is intended for engineers, supervisory SNR Foremen Mechanical Maintenance and technical staff involved in the maintenance and inspection of Process Gas compressors.

The Contents

• Maintenance Concepts & Control.
• Overview of Gas Compressors :
• Types of Off Gas Compressors.
• Cost of ownership.
• Maintenance Theories and Strategies:
• Breakdown, Preventive & Proactive Strategies.
• Detection, Analysis, Correction & Verification, RCA .
• Centrifugal Compressors Operation :
• Compressors material selecting and testing.
• Installation & Commissioning.
• Compressors start-up and testing.
• Pressure, Head, Flow & Compressor Curves.
• Minimum flow protection.
• Compressor capacity control.
• Centrifugal Compressor Maintenance :
• Centrifugal Compressor Maintenance.
• Mechanical seals.
• Couplings and Alignment.
• Causes of failure.
• Compressors Maintenance Philosophy.
• Maintenance & Troubleshooting.
• Duty/Standby change-over philosophy.
• Centrifugal and Axial Compressors Construction:
• Compressor installation.
• Lube and Seal oil systems.
• Compressor shaft seals – Mechanical & Dry Gas Seals.
• Tilt-Pad Bearings.
• Compressor commissioning & Control :
• Compressor start-up and testing.
• Compressor performance.
• Compressor capacity control & anti-surge protection.
• Compressor Maintenance :
• Effect of fouling.
• Overhaul Philosophy.
• Operation and Maintenance of Cryogenic Expanders.
• Reciprocating Compressors & Gas Turbines Reciprocating Compressors :
• Types of Reciprocating compressors.
• Valves and unloaders.
• Piston and rings.
• Piston packings.
• Capacity control.
• Overhaul philosophy.
• Effect of Gas Quality on operation.
• Electric Motor Drives :
• Types of Electric Motor.
• Start-up and testing.
• Operating profile.
• AC supply systems.
• Component parts.
• Repair of components.
• Troubleshooting & Fault Diagnosis :
• Condition monitoring, vibration, thermography, oil analysis, ultrasound.
• Performance monitoring.
• Lubrication – Hydrodynamic (Fluid Film) & Elastohydrodynamic (Rolling Element).
• Bearing types & selection.
• Failure Analysis :
• Overview of API RP 571.
• Fatigue and fracture.
• Corrosion & Material loss mechanisms.
• Trouble Shooting & Predictive Maintenance.
• Vibration Analysis :
• Vibration concepts
• On-line/Off-line monitoring.
• Frequency analysis.
• Enveloping/Demodulation.
• 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.
• 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.
• Tooth wear/load.
• Misalignment/Eccentricity of gears.
• Significance of gear sidebands.
• Diagnosis Mechanical looseness problems.
• FFT vibration symptoms.
• Diagnosis Belt problems :
• Detecting worn or damaged belts/pulleys.
• Misaligned or eccentric pulleys.
• Diagnosing Bearing Problems (Fluid Film & Rotating Element) :
• Mounting & Removal, Fits & Tolerances.
• Life of Bearings, Failure Modes – Diagnosis & Repair .
• Stages of defects.
• Examples of Failed Bearings, How bearings fail.
• Inspection & Monitoring.
• Course summary.

 Notes:

• Great Discount for companies and governmental Organizations .
• All programs are held in five star hotels .
• All lecturers have sufficient knowledge and experience to implement the programs at an optimal level .
• Large package of services is offered to the participants .

The Discount

10% in case of Three P. (or more)