COURSE OVERVIEW:

The purpose of this course is to provide a comprehensive understanding of the systems responsible for providing clean, dry, and compressed air to industrial facilities. In most automated plants, instrument air is the lifeblood of the control system, powering pneumatic actuators, valves, and sensitive controllers that require a constant and contaminant-free supply. This program focuses on the technical operation of compressor packages and the critical importance of air quality in preventing process failures.

The scope of this training encompasses the mechanical and thermodynamic principles of various compressor types, including reciprocating, rotary screw, and centrifugal units. Participants will explore the entire air treatment chain, specifically focusing on the operation of after-coolers, moisture separators, and desiccant or refrigerant dryers. The curriculum is designed to address the stringent requirements for "Instrument Quality" air, ensuring that participants can manage the dew point and filtration levels necessary to protect downstream equipment.

Coverage includes the practical aspects of routine maintenance, troubleshooting common pressure fluctuations, and optimizing the energy efficiency of the compressor house. Attendees will learn how to monitor system health through vibration analysis and temperature trends, manage air receiver safety inspections, and implement effective leak detection programs. By focusing on both the generation and the purification of compressed air, the course ensures that participants can maintain a reliable utility system that supports uninterrupted plant operations.

COURSE OBJECTIVES:

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

• Analyze the difference between Utility Air and Instrument Air requirements.
• Identify the operating principles of Screw and Centrifugal compressors.
• Execute startup and shutdown procedures for modern compressor packages.
• Manage the regeneration cycles of Desiccant Air Dryers.
• Monitor and maintain oil-water separators and condensate drains.
• Calculate the impact of pressure drops on pneumatic tool performance.
• Troubleshoot high discharge temperatures and vibration alarms.
• Inspect and test pressure relief valves on air receiver tanks.
• Implement a leak detection and repair (LDAR) program for air headers.
• Evaluate the efficiency of compressor loading and unloading cycles.
• Replace air intake filters and oil separators according to PM schedules.
• Ensure compliance with ISO 8573-1 compressed air quality standards.

TARGET AUDIENCE:

This course is intended for Mechanical Technicians, Plant Operators, Maintenance Supervisors, and Utility Engineers responsible for compressed air infrastructure.

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.