Compressor Control and Protection Training Course

Course Overview:

The course enhances the skills and knowledge of the participants through providing information about the construction of the reciprocating compressor and also troubleshooting them.

The participants are also taught to do regular wear and tear of the compressor. After the completion of the course the participants will be able to make proper performance evaluation of the compressor and do maintenance work. Furthermore, the participants are taught the design and construction of multi-cylinder piston compressor as well as the methods in which multi-cylindrical piston compressor works. 

The rotor dynamic feature of the LZ metallurgy and any operational or physical limitations are also touched on. Apart from these, auxiliary systems, overhauling, vibration, swings and corrections in multi-cylindrical compressors are also addressed.

Course Objectives:

The course provides an in-depth study of reciprocating compressors technology, performance, operation, and maintenance. Participants will be able to solve operation and mechanical problems. Participants will practice a complete compressor overhauling and parts inspection at the workshop and report the compressor condition.

Who Should Attend?

Engineers and Technicians' operation, mechanical, reliability, electrical, and instrument working on operation and maintenance and compressors are the ones to attend this course.

Course Outlines:

Over view:

• Consideration in Compressors Selection

• Discharge pressure required.
• Capacity required.
• Power supply characteristics.
• Availability and cost of cooling water.
• Space required for the compressor.
• Compressor weight.
• Type and size of the foundation required.
• Type of control required.
• Maintenance costs.
• Budget

• Compression methods and calculation
• Positive-Displacement And Rot dynamic Compressors advantage and disadvantage
• Introduction To Aerodynamics and positive displacement compressors

• Definition Of Compressor
• Comparison between positive displacement and Rot dynamic compressors
• Types Of  positive displacement Compressors

1.     Reciprocating compressor

2.     Labyrinth compressor

3.     Diaphragm compressor

4.     Screw compressor

5.     Lobe compressor

6.     Slide vane compressor

• Types of turbo compressors

1.     Centrifugal compressor

2.     Axial flow compressor

• Video moves the centrifugal compressor
• General
• Different types of machine for the compression of gas
• Piston compressors
• Design applications of reciprocating compressors with one or more stages
• Types of construction
• Machines with and without crossheads
• Compression cycle of reciprocating compressors and basic calculations
• The Ideal cycle of piston compressor
• Real cycle departure from ideal cycle
• Volumetric efficiency
• Example of calculation
• Capacity
• Power
• Compression in several stages
• Allowable pressure and temperature
• Allowable speed
• Rod loading
• Main Parts and Construction
• Frame and crankshaft assembly
• Crosshead
• Connecting rod
• Bearing and bushes
• Cylinders and clearance volume
• Pistons rings and rider rings
• Stuffing boxes
• Valves
• Capacity control
• Auxiliary Systems
• Frame and cylinder lubrication
• Cooling system
• Accessories
• Compressor control system
• The piping system and gas filters
• Coolers and cooling system
• Suction and discharge sunders
• Reduction gears, flywheel and coupling
• Compressor Performance

• Ideal gas compression, power
• P-V diagram
• Actual operating conditions, valves behavior
• Characteristic curves
• Efficiency

• Compressor Operation

• Start-up and loading system
• Capacity control

• Maintenance

• Disassembly and assembly procedures
• Crankshaft and bearings inspection \ replacement and assembly
• Web deflection checks and adjustment
• Inspection repair and installation of cylinders
• Disassembly and assembly of piston and piston rods
• Adjusting end clearances of pistons
• Inspection and replacement of piston and rider rings
• Packing components inspection and assembly
• Oil scraper rings replacement
• Valves disassembly, inspection, and assembly
• Frame lubricating system
• Cylinder lubricating system

•  Pressure Pulsation in Compressor and Piping

• Vibration Monitoring and Control
• Failures Analysis and Troubleshooting
• Pressure Pulsation in Compressor and Piping
• Specification and Selection