COURSE OVERVIEW:

The Control and Operation of Centrifugal Gas Compressors course is an intensive technical program focused on the sophisticated management of high-speed rotating assets. Centrifugal compressors are critical to the oil, gas, and petrochemical sectors, where their stable operation is essential for maintaining production throughput. This course examines the complex aerodynamic behaviors of gas compression, providing participants with the expertise needed to manage performance variables while protecting the machine from the destructive forces of surge and mechanical stress.

The scope of this training focuses on the intersection of mechanical engineering and advanced control logic. Participants will explore the development of compressor maps and the calculation of polytropic head and efficiency. The curriculum provides a deep dive into the engineering of anti-surge control systems, explaining how to define safety margins that allow for flexible operation without risking catastrophic "surge" events. Attendees will also learn the nuances of performance control, including variable speed, suction throttling, and the management of load sharing in parallel compressor trains.

This coverage also details the critical auxiliary and safety systems that ensure the machine's longevity. The course addresses the operation of dry gas seals, lubrication systems, and the integration of vibration monitoring into the overall control strategy. By focusing on real-time diagnostic techniques and the interpretation of machine trends, the program prepares participants to identify early warning signs of fouling, wear, or process instability. This comprehensive approach ensures that compressor sets are operated at peak efficiency while maintaining the highest safety integrity.

COURSE OBJECTIVES:

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

• Analyze the aerodynamic principles and performance curves of centrifugal compressors.
• Execute safe startup, loading, and shutdown procedures for multi-stage machines.
• Map the Surge Limit Line (SLL) and configure the Surge Control Line (SCL).
• Implement high-speed anti-surge control logic to prevent mechanical damage.
• Manage performance control using suction throttling, guide vanes, and speed control.
• Optimize load-sharing strategies for parallel and series compressor configurations.
• Interpret vibration, axial displacement, and temperature data for machine health.
• Manage Dry Gas Seal (DGS) systems and interpret leakage and buffer gas signals.
• Troubleshoot controller instability and recycle valve hunting issues.
• Calculate compressor power, polytropic head, and efficiency in real-time.
• Analyze the impact of gas molecular weight and temperature changes on the surge margin.
• Ensure safety compliance through the validation of ESD and machine protection interlocks.

TARGET AUDIENCE:

This course is intended for Control Systems Engineers, Rotating Equipment Specialists, Plant Operations Managers, and Senior Maintenance Personnel responsible for the reliability and performance of gas compression systems.

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.