COURSE OVERVIEW:

Screw gas compressors and dry gas seal applications represent a critical combination of technologies used extensively in the oil, gas, and petrochemical industries for gas gathering, vapor recovery, and process compression. Screw compressors are favored for their ability to handle varying gas compositions and high compression ratios in a single stage, while dry gas seals provide a reliable, oil-free sealing solution for the compressor shafts. This course provides a deep technical understanding of the mechanical design, operational characteristics, and maintenance requirements of these complex systems.

The scope of this course covers the twin-screw and single-screw geometries, focusing on the "meshing" process and the role of oil injection for cooling, sealing, and lubrication. Participants will explore the compressor's internal control mechanisms, such as slide valves for capacity modulation, and the auxiliary systems required for oil separation and cooling. The coverage extends to the sophisticated world of dry gas seals (DGS), detailing the aerodynamic principles of "spiral grooves" that create a non-contacting seal face, significantly reducing friction and wear compared to traditional wet seals.

Furthermore, the training addresses the integration of these two technologies, focusing on the critical support systems like seal gas filtration, heating, and monitoring. Attendees will learn to troubleshoot common issues such as rotor-to-rotor contact, oil carryover, and dry gas seal contamination. By the end of this program, participants will be able to optimize the performance of screw compressor packages and ensure the longevity of dry gas seals through proper operational procedures and proactive maintenance strategies.

COURSE OBJECTIVES:

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

1. Explain the operating principles of oil-injected and oil-free screw compressors.
2. Identify the internal components, including rotors, bearings, and slide valves.
3. Analyze the screw compressor performance curve and capacity control methods.
4. Describe the gas and oil flow paths within a typical compressor package.
5. Understand the aerodynamic principles of dry gas seals (DGS).
6. Differentiate between single, tandem, and double dry gas seal configurations.
7. Operate the DGS support system, including filtration and pressure control.
8. Identify the causes of screw compressor vibration and noise.
9. Perform routine maintenance and inspection on screw compressor packages.
10. Troubleshooting dry gas seal leakage and contamination issues.
11. Manage the startup and shutdown sequences for screw gas compressors.
12. Evaluate the impact of gas composition changes on compressor performance.
13. Execute oil separation and filtration system maintenance.
14. Ensure safe operation through the understanding of protection and alarm systems.

TARGET AUDIENCE:

This course is intended for Mechanical Engineers, Maintenance Technicians, Compressor Operators, and Reliability Specialists involved in the operation and upkeep of gas compression packages.

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.