🎯 Course Description:
This intensive 5-day program focuses on the operation, maintenance, troubleshooting, and performance optimization of reciprocating compressors widely used in oil & gas, petrochemical, and industrial facilities.
Participants will gain practical insights into compressor components, working principles, common issues, and best maintenance practices to ensure safe, efficient, and reliable operation.
👥 Who Should Attend:
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Maintenance Engineers and Technicians
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Operations and Process Engineers
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Reliability and Asset Management Professionals
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Mechanical Inspectors and Supervisors
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Equipment Maintenance Planners
🗓️ Day 1: Introduction and Fundamentals of Reciprocating Compressors
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome, Course Overview, Participant Introductions |
| 09:00 – 10:30 | Types and Applications of Reciprocating Compressors |
| 10:30 – 10:45 | ☕ Coffee Break |
| 10:45 – 12:15 | Basic Operating Principles – Compression cycles, thermodynamics |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Main Components – Cylinders, pistons, valves, crankshaft |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Compressor Performance Parameters and Specifications |
🗓️ Day 2: Operation and Safety Practices
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Start-up and Shutdown Procedures |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Safety Considerations – Overpressure protection, alarms, interlocks |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Operational Challenges – Surge, pulsation, and vibration control |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Simulated start-up and troubleshooting scenarios |
🗓️ Day 3: Maintenance Techniques and Practices
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Routine Inspection and Lubrication |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Valve and Seal Maintenance |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Crankcase and Cylinder Maintenance |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Hands-on valve and seal inspection techniques |
🗓️ Day 4: Troubleshooting and Condition Monitoring
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Common Failures and Root Cause Analysis |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Vibration Analysis and Monitoring |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Oil Analysis and Other Diagnostic Techniques |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Case Study: Diagnosing compressor failure scenarios |
🗓️ Day 5: Advanced Topics and Reliability Improvement
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Performance Optimization Techniques |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Reliability Centered Maintenance (RCM) for Reciprocating Compressors |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 03:00 | Group Exercise: Develop maintenance and monitoring plans |
| 03:00 – 03:15 | ☕ Coffee Break |
| 03:15 – 04:30 | Final Q&A, Feedback, Course Wrap-Up & Certificates |
📂 Course Materials Provided:
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Reciprocating compressor operation and maintenance manuals
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Inspection checklists and maintenance schedules
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Troubleshooting and diagnostic guides
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Case study documentation
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RCM templates and planning tools
