COURSE OVERVIEW:

The transport and processing of industrial gases rely heavily on the efficient operation of both centrifugal and reciprocating compressors. This course offers a deep technical analysis of these two distinct technologies, exploring their aerodynamic and thermodynamic principles. Participants will examine how the continuous flow characteristics of centrifugal machines contrast with the intermittent, positive-displacement nature of reciprocating units.

The scope of this training includes a detailed look at the mechanical design of each compressor type, focusing on components such as impellers, diaphragms, pistons, and valves. We will analyze the performance maps of centrifugal compressors, including surge and stonewall limits, as well as the pressure-volume (P-V) diagrams associated with reciprocating machines. The course highlights the specific operational challenges related to gas composition changes and varying suction conditions.

Coverage extends to advanced troubleshooting techniques for both machine types, including vibration analysis and pulsation control. Attendees will learn how to diagnose common failure modes such as valve leakage in reciprocating units and aerodynamic instability in centrifugal units. By the end of this course, participants will possess the analytical tools required to optimize the performance and reliability of complex gas compression trains.

COURSE OBJECTIVES:

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

1. Explain the fundamental differences between dynamic and positive displacement compression.
2. Interpret centrifugal compressor performance maps and surge lines.
3. Analyze reciprocating compressor P-V diagrams to evaluate valve health.
4. Execute safe startup and shutdown procedures for multi-stage gas compressors.
5. Identify the critical mechanical components of centrifugal and reciprocating units.
6. Understand the role of intercoolers and separators in gas quality management.
7. Manage lubrication and seal oil systems for high-pressure gas service.
8. Implement effective anti-surge control strategies for centrifugal machines.
9. Troubleshoot pulsation and vibration issues in reciprocating piping.
10. Calculate compressor efficiency and power requirements based on field data.
11. Recognize the early warning signs of bearing and piston ring failure.
12. Define maintenance protocols for compressor valves and unloading systems.
13. Execute root cause failure analysis on compressor components.

TARGET AUDIENCE:

Mechanical Engineers, Compressor Operators, Maintenance Specialists, and Reliability Engineers in the Oil and Gas or Petrochemical sectors.

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.