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2024

Compressors Operation & Maintenance

Code: Technical

Duration: 5 Days

Location: Doha

Fee: QAR 12,900

Course Overview

Compressors in general run at very high speeds and may be exposed to high polluted environment. 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 requires very complicated monitoring and protection systems.The above very severe operating conditions enhance the machines deterioration. Accurate instrumentation, monitoring, troubleshooting and maintenance programs are essential for maintaining and increasing the available time of the machines. Understanding and learning turbo machinery 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 affects the above will also be discussed during the course.

Course Objectives

Upon completion of this course, the trainees will be aware and understanding of the following:

  • Familiarize participant of different types of compressors
  • Learn how different design parameter affects the machines performance and operation
  • Familiarize participant of 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 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 (Aircrafts- 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- Start up 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 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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