COURSE OVERVIEW:

The reliable operation of industrial compressors is dependent on the ability to detect developing faults before they lead to catastrophic failure. This course provides an advanced technical framework for the condition monitoring and performance diagnostics of centrifugal, reciprocating, and axial compressors. Participants will learn how to integrate mechanical vibration data with thermodynamic performance parameters to create a holistic view of machine health.

The scope of this training includes the application of various monitoring technologies, such as proximity probes, accelerometers, and high-speed pressure transducers. We will examine the use of performance aero-thermal analysis to detect internal issues like fouling, erosion, or seal leakage that vibration analysis alone might miss. The course emphasizes the transition from reactive maintenance to a predictive, high-reliability strategy for critical compression assets.

Coverage extends to the interpretation of complex diagnostic plots, including orbits, spectra, and performance maps. Attendees will learn how to use digital twins and automated diagnostic software to identify the root causes of efficiency loss and mechanical distress. By the end of this course, participants will have the expertise to implement a world-class condition monitoring program that optimizes maintenance intervals and safeguards plant production.

COURSE OBJECTIVES:

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

1. Explain the principles of a predictive maintenance strategy for compressors.
2. Identify the appropriate sensors for monitoring different compressor types.
3. Interpret vibration orbits and spectra to diagnose rotor dynamic faults.
4. Conduct an aero-thermal performance analysis to detect internal fouling.
5. Utilize P-V diagram analysis for reciprocating compressor diagnostics.
6. Identify the early warning signs of surge and aerodynamic instability.
7. Monitor the condition of dry gas seals and lubrication systems.
8. Distinguish between mechanical imbalance, misalignment, and looseness.
9. Calculate isentropic and polytropic efficiency from field data.
10. Use trend analysis to predict the remaining useful life of components.
11. Implement an effective oil analysis program for compressor frames.
12. Integrate condition monitoring data into a centralized reliability platform.
13. Develop a diagnostic report with clear corrective action recommendations.

TARGET AUDIENCE:

Reliability Engineers, Condition Monitoring Technicians, Rotating Equipment Engineers, and Maintenance Managers.

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.