COURSE OVERVIEW:

A successful compressor overhaul requires meticulous planning, precision execution, and rigorous quality control to ensure the machine returns to service with high reliability. This course provides a comprehensive guide to the technical procedures involved in the major overhaul of centrifugal and reciprocating compressors. Participants will explore the step-by-step process of disassembly, component refurbishment, and precision reassembly while adhering to strict engineering tolerances.

The scope of this training focuses on the management of the overhaul environment, emphasizing cleanliness and the proper use of specialized tools. We will examine the critical measurements required during the overhaul, including "float" checks, clearance verifications, and alignment protocols. The course provides a detailed framework for developing Quality Control Plans (QCP) and Inspection and Test Plans (ITP) that align with manufacturer specifications and international standards.

Coverage includes the evaluation of component wear and the decision-making process for repair versus replacement of critical parts like impellers, shafts, and cylinders. Attendees will learn how to oversee contractor activities and verify that every stage of the overhaul meets the required quality benchmarks. By the end of this course, participants will be equipped to manage complex compressor turnarounds that result in extended machine life and optimized performance.

COURSE OBJECTIVES:

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

1. Develop a detailed project plan for a major compressor overhaul.
2. Define the resource and tooling requirements for a successful turnaround.
3. Execute the systematic disassembly and labeling of compressor components.
4. Perform precision measurements of all critical internal clearances.
5. Create a comprehensive Quality Control Plan (QCP) for the overhaul.
6. Verify the dynamic balance of rotors and reciprocating assemblies.
7. Manage the refurbishment of impellers, diaphragms, and cylinders.
8. Execute the correct installation of bearings and sealing systems.
9. Perform final alignment between the compressor and its driver.
10. Document all overhaul activities and measurements in a technical report.
11. Conduct post-overhaul mechanical run tests and performance checks.
12. Identify and mitigate risks during the reassembly process.
13. Supervise third-party vendors to ensure compliance with quality standards.

TARGET AUDIENCE:

Turnaround Managers, Maintenance Engineers, Mechanical Supervisors, Workshop Leads, and Quality Control Inspectors.

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.