🎯 Course Description:
This intensive 5-day course is designed to provide engineers, technicians, and maintenance professionals with a comprehensive understanding of industrial compressors, including their design, operation, routine maintenance, and troubleshooting techniques.
Covering both dynamic (centrifugal, axial) and positive displacement (reciprocating, screw) compressors, the course dives into performance analysis, failure modes, vibration issues, lubrication systems, and start-up/shutdown procedures. Case studies and hands-on workshops ensure participants can confidently diagnose problems and optimize compressor performance in real-world scenarios.
👥 Who Should Attend:
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Mechanical and maintenance engineers
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Rotating equipment specialists
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Plant and operations personnel
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Maintenance technicians
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Reliability engineers
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Oil & gas and process industry professionals
🗓️ Day 1: Compressor Fundamentals and Classifications
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome, Course Overview, Participant Introductions |
| 09:00 – 10:30 | Compressor Basics – Function, applications, and types |
| 10:30 – 10:45 | ☕ Coffee Break |
| 10:45 – 12:15 | Centrifugal vs Reciprocating Compressors – Operation and comparison |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Positive Displacement Compressors – Reciprocating, screw, scroll |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Dynamic Compressors – Centrifugal, axial flow, multistage configuration |
🗓️ Day 2: Key Components and Operating Principles
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Major Compressor Components – Rotors, valves, pistons, seals, bearings |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Compression Cycle and Performance Parameters – Flow, head, power |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Control Systems – Surge control, anti-stall, capacity control |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Identify components and explain operating cycles |
🗓️ Day 3: Operation and Performance Monitoring
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Startup and Shutdown Procedures – Best practices and system checks |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Performance Monitoring – Flow, vibration, temperature, power draw |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Lubrication and Cooling Systems – Oil systems, water and air cooling |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Analyzing compressor performance trends |
🗓️ Day 4: Maintenance Practices and Scheduling
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Preventive and Predictive Maintenance – Schedules, condition monitoring |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Inspection and Overhaul Procedures – Clearances, wear, alignment |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Spare Parts Management and OEM Guidelines |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Create a maintenance checklist for selected compressor types |
🗓️ Day 5: Troubleshooting and Failure Analysis
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Common Compressor Failures – Surge, vibration, leakage, oil carryover |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Troubleshooting Techniques – Diagnostic flowcharts, case studies |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 03:00 | Group Exercise: Troubleshoot a compressor system using real operating data |
| 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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Compressor classification guide and reference manual
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Troubleshooting flowcharts and failure mode posters
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Maintenance and inspection checklists
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Startup/shutdown operating procedure templates
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Real-world case studies and performance data samples
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Lubrication and cooling system charts
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Excel-based compressor performance monitoring tool
