COURSE OVERVIEW:

The sudden failure of a compression system can lead to significant production losses and safety risks. This course provides a high-level technical framework for conducting systematic failure analysis and inspections on centrifugal, reciprocating, and screw compressors. Participants will learn how to transition from simply replacing broken parts to performing deep-dive forensic investigations that identify the true root causes of mechanical and aerodynamic distress.

The scope of this training includes advanced inspection techniques such as borescope imaging, non-destructive testing (NDT) of impellers, and the analysis of wear patterns on valves and seals. We will examine the physics of common failure modes, including fatigue, erosion, liquid slugging, and rotor-stator rubs. The course emphasizes the importance of "reading" the components to distinguish between failures caused by poor maintenance, operational errors, or design limitations.

Coverage extends to the development of sophisticated troubleshooting trees designed to resolve chronic issues such as high vibration, oil contamination, and efficiency degradation. Attendees will learn how to integrate process data with mechanical evidence to reconstruct failure events. By the end of this course, participants will be equipped with the analytical skills necessary to implement corrective actions that prevent recurrence and enhance the overall reliability of the plant's compression assets.

COURSE OBJECTIVES:

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

1. Implement a structured Root Cause Failure Analysis (RCFA) methodology for compressors.
2. Identify the characteristic signatures of fatigue and stress corrosion cracking.
3. Conduct detailed visual inspections of compressor internals and housings.
4. Utilize borescope technology to assess the condition of internal stages.
5. Analyze the failure modes of reciprocating compressor valves and unloaders.
6. Diagnose the causes of dry gas seal and mechanical seal failures.
7. Interpret vibration and temperature data to reconstruct a failure sequence.
8. Evaluate the impact of liquid carryover and solids ingestion on impellers.
9. Distinguish between various types of bearing damage, including fluting and wiping.
10. Specify appropriate NDT methods for inspecting high-speed rotors.
11. Troubleshoot chronic lubrication system issues and oil degradation.
12. Develop comprehensive inspection reports with evidence-based recommendations.
13. Apply the lessons learned from failures to update preventive maintenance tasks.

TARGET AUDIENCE:

Senior Maintenance Engineers, Reliability Specialists, Rotating Equipment Inspectors, and Machinery Supervisors.

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.