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Circle Circle
ME - 40
5 days
Doha
23 October, 2022
7200 QAR

Compressor Design, Selection, Installation, Operation, Maintenance and Troubleshooting Virtual

Course Overview

Compressors play a very essential role in Air, Land, and Sea Applications. These include Aircrafts Engines, Gas Turbines, and Automotive, Cruise, and Marine Vehicles as well as many petrochemical and industrial plants.

Compressors in general run at very high speeds and may be exposed to highly polluted environments. The compressor operation is confined between the Surge and Stonewall limits. The compressor performance also is affected by the variation in operating conditions. Large centrifugal stresses make the gas turbine operating under very critical conditions require very complicated monitoring and protection systems.

The above very severe operating conditions enhance the deterioration of the machine. Accurate instrumentation, monitoring, troubleshooting, and maintenance programs are essential for maintaining and increasing the available time of the machines. Understanding and learning turbomachinery more deeply help smooth and free trouble operation.

During the course, the performance, operation limits, control system, and failure analysis are going to be addressed thoroughly. Parameters that affect the above will also be discussed during the course.

Course Objectives

By the end of the training, participants will be able to:-

  • Familiarize participants with different types of compressors
  • Learn how different design parameter affects the performance and operation of the machine
  • Familiarize participants with the different types of compressor maps or head-mass flow correlations
  • Deepen the participants understanding of the limits of the compressor operation
  • Enable participants to read and calculate the performance curves of compressors
  • To familiarize the participant with control and protection systems of the compressor
  • To familiarize the participants with failure analysis of compressors

Who Should Attend?

  • Engineers of any discipline, technician, technologists, and other technical
  • Personnel involved in compressors operation, selection, maintenance, control, troubleshooting, and failure analysis.

Course Contents

Module (01) Classifications of Compressors

  • Function
  • Different types (Axial – Centrifugal – Mixed- Reciprocating)
  • Applications (Aircraft- Automotive- Industrial – Pipelines – Marine Vessels)
  • Working Fluid (Air – Gases)

Module (02) Centrifugal Compressor

  • Types
    • (Single –Multi-stage)
    • Entry Types (Single – Double)
    • Pre-whirl (Positive- Negative)
    • Compressor Casing (horizontal or vertical split)
    • Compressor elements (IGV- Impeller- Diffuser- Volute/Manifold- Exit Guide)
    • Impeller blades (radial-backward-forward)
    • Impeller geometry (shrouded – unshrouded)
    • Inducer (full-half-non)
    • Diffuser (vaneless- vaned- cascade- pipe)
    • Exit passage (volute/scroll – manifold)
  • Shock Losses
  • Slip factor
  • Compressor map (Effects of Speed and efficiency)
  • Surge Control Methods (Bleed – Variable guide vanes)
  • Vibration Control

Module (03) Axial Compressors

  • Compressor elements (IGV- Rotor- Stator)
  • Single versus double spool types
  • The Performance Curves
  • Compressor map
  • Comparison with centrifugal compressors
  • Limits of Flow rates
  • Surge line and Stone line
  • Limits of operating speed
  • Effect of different parameters (speed variation- inlet conditions- Gas molecular weight)

Module (04) Reciprocating Compressors

  • Applications (Air – Land – Sea)
  • Reciprocating compressors coupled to Superchargers- turbochargers
  • Classification
  • Cylinder arrangement
  • Mechanical construction
  • Compression cycle and useful calculations
  • Systems (Fuel – Ignition – Lubrication system – cooling)

Module (05) Compressor Performance and Control

  • Factors affecting Performance
  • Performance Enhancement
  • Performance Degradation
  • Control and Protection
  • Start-up and Shutdown sequencing

Module (5) Compressor Operation

  • Pre- Startup Checks
  • Startup Procedures
  • Normal Operation Conditions
  • Shutdown Procedures

Module (07) Troubleshooting and Maintenance

  • Troubleshooting
  • Principles of troubleshooting
  • Lubrication systems
  • Seals System
  • Alignment and Balancing
  • Pressure and temperature measurements
  • Effective Diagnoses systems
  • Vibration Analysis
  • Component Repairs
  • Erosion and Fouling

Module (08) Compressor Failure

  • Why does the compressor fail?
  • Failure Causes (Aerodynamic – Mechanical)
  • Effects of Failure (critical issues for compressors in aircraft engines)
  • Problem Solving Process / Techniques
  • Gathering Data / Evidence
  • Situation Analysis
  • Action Generation
  • Decision Making

Module (09) Compressor alignment methods

  • Straight edge and feeler gauge
  • Rim and face
  • Reverse dial indication
  • Cross dialing
  • Laser alignment
  • Mathematical alignment formula calculations

Module (10) Soft foot correction and tolerances

  • Soft foot definition
  • Effects of soft foot
  • Types of soft foot
  • Measuring soft foot
  • Correcting soft foot

Module (11) Reliability, Monitoring and Maintenance Programs

  • Reliability and Maintainability
  • Reliability Techniques
  • Human and System Reliability
  • Reactive Maintenance (Washing)
  • Preventive Maintenance (Lubrication)
  • Predictive Maintenance (Boroscope analyses)
  • Reliability Centered Maintenance
  • Maintenance Organization
  • Materials and Cost Control
  • Mobile Equipment’s, Facilities and Services
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