COURSE OVERVIEW:

Air compressor overhauling is a critical technical skill required to maintain the reliability of plant air and instrument air systems. This course provides a hands-on, practical approach to the complete disassembly, inspection, and reassembly of reciprocating and screw air compressors. Understanding the mechanical tolerances and the sequence of overhaul activities is essential for ensuring that the equipment returns to service at peak efficiency and safety.

The scope of this training involves a detailed examination of internal components, including pistons, rings, valves, and rotors. Participants will learn how to measure critical clearances using precision instruments, identify signs of wear and fatigue, and perform necessary repairs or replacements. The coverage extends to the maintenance of auxiliary systems, such as oil pumps, coolers, and control valves, as well as the calibration of pressure and temperature safety devices.

Furthermore, the course addresses the technical standards for compressor testing and commissioning after an overhaul. It delves into the importance of proper lubrication during the break-in period and the use of vibration analysis to verify the quality of the overhaul. By focusing on practical workshop activities, the course ensures that technicians and engineers can execute compressor overhauls with precision, reducing the risk of premature failure and optimizing the life of the asset.

COURSE OBJECTIVES:

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

1. Execute a systematic disassembly of reciprocating and screw air compressors.
2. Inspect and evaluate the condition of compressor valves and unloaders.
3. Measure cylinder bore wear, piston clearances, and crankshaft run-out.
4. Identify failure modes in screw compressor rotors and bearings.
5. Perform precision honing and component cleaning according to standards.
6. Replace and seat piston rings and rider bands correctly.
7. Troubleshoot and repair compressor lubrication and cooling systems.
8. Utilize precision tools: Micrometers, dial indicators, and feeler gauges.
9. Implement quality control checks during the reassembly process.
10. Calibrate and test pressure relief valves and unloading mechanisms.
11. Execute a safe commissioning and "run-in" procedure post-overhaul.
12. Analyze the root causes of compressor overheating and oil carryover.
13. Develop a detailed overhaul report and documentation package.
14. Manage the inventory of compressor overhaul kits and gaskets.

TARGET AUDIENCE:

This course is intended for mechanical technicians, maintenance fitters, workshop supervisors, and junior engineers involved in the hands-on maintenance and repair of industrial air compressors.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.