Learning Objectives

Upon successful completion of this course, participants will be able to:

1. Fundamentals of Air Compressors in Industrial Applications

• Understand the role of instrument and utility air compressors in industrial plants.
• Differentiate between instrument air vs. utility air systems.
• Identify types of air compressors:
• Reciprocating compressors.
• Rotary screw compressors.
• Centrifugal compressors.

2. Principles of Compressor Operation

• Explain compression cycles and air delivery principles.
• Understand pressure, temperature, and flow characteristics.
• Learn lubrication and cooling system requirements for compressors.

3. Air Quality Requirements for Instrumentation and Process Control

• Understand ISO 8573 air quality standards for compressed air systems.
• Learn about moisture, oil, and particulate contamination control.
• Implement drying and filtration techniques (desiccant and refrigerated air dryers, coalescing filters, separators).

4. Compressor System Components and Control Mechanisms

• Identify key compressor system components (intake filters, intercoolers, aftercoolers, receivers, valves, pressure switches, and controls).
• Understand automatic load/unload controls and pressure regulation.
• Explore compressor sequencing and energy efficiency techniques.

5. Routine Inspection and Preventive Maintenance

• Perform daily, weekly, and monthly inspections on compressors.
• Learn lubrication practices and cooling system maintenance.
• Implement vibration analysis and condition monitoring techniques.
• Understand belt tension, coupling alignment, and filter replacement.

6. Troubleshooting and Fault Diagnosis

• Identify common compressor issues and failure modes:
• Overheating.
• Low air pressure.
• Excessive moisture in the air system.
• Unusual noise and vibration.
• Use diagnostic tools for air compressor fault detection.
• Implement corrective actions for mechanical and electrical faults.

7. Energy Efficiency and Optimization of Air Compressors

• Reduce compressed air leaks and system inefficiencies.
• Optimize air demand and pressure settings for energy savings.
• Implement variable speed drives (VSDs) and energy recovery solutions.

8. Case Studies and Practical Applications

• Analyze real-world compressor operation and maintenance scenarios.
• Participate in hands-on compressor servicing exercises.
• Develop a maintenance schedule and troubleshooting guide for plant air compressors.

Target Audience

• Plant operators and maintenance technicians
• Reliability and mechanical engineers
• Instrumentation and process control engineers
• Utility and facilities managers
• Safety and compliance officers