COURSE OVERVIEW:

The Compressor Control and Operation (General) course provides a comprehensive foundation in the management of one of the most vital components in industrial process systems. Compressors, whether centrifugal, reciprocating, or screw-type, are essential for the transport of gases and the powering of pneumatic systems. This course explores the mechanical principles of gas compression alongside the automation strategies required to maintain stable operation. Participants will learn how to balance the demands of the process with the mechanical constraints of the machine to ensure long-term reliability and efficiency.

The scope of this training covers the entire operational envelope of various compressor types, with a focus on startup, steady-state control, and emergency shutdown procedures. Participants will examine the critical role of performance control such as suction throttling and variable speed controlling, meeting process demands. The curriculum provides a detailed look at the auxiliary systems that support compressor operation, including lubrication, cooling, and seal gas systems, and how these are monitored and interlocked within the control environment.

This coverage also emphasizes the fundamental safety and protection logic required to prevent catastrophic machine failure. Attendees will be introduced to the concepts of surge in centrifugal compressors and the risks of liquid carryover in reciprocating units. By understanding the diagnostic signals such as vibration, temperature, and pressure trends, participants will learn to identify early signs of mechanical distress. The program ensures that attendees can operate compressor sets safely while optimizing energy consumption and minimizing wear and tear.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Explain the operating principles of Centrifugal, Reciprocating, and Screw compressors.
• Execute safe compressor startup and shutdown sequences for different machine types.
• Monitor and interpret key performance indicators (KPIs) such as polytropic efficiency.
• Implement performance control strategies using speed, suction, and discharge throttling.
• Understand the basic principles of anti-surge protection for centrifugal machines.
• Manage compressor auxiliary systems, including Lube Oil and Seal Gas units.
• Interpret vibration and temperature data to assess machine health.
• Identify the causes and consequences of compressor surge and stonewall.
• Troubleshoot common operational problems and control loop oscillations.
• Optimize compressor energy consumption through efficient load management.
• Ensure machine safety through the testing of ESD interlocks and safety valves.
• Maintain comprehensive operational logs and performance reports.

TARGET AUDIENCE:

This course is designed for Plant Operators, Maintenance Technicians, Junior Engineers, and Supervisors who are responsible for the daily operation and basic control of compressor systems in industrial facilities.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.