By the end of this programme, participants will:
- Gain a comprehensive understanding of reciprocating compressor technology, including design philosophies, key components, and their role in efficient operation.
- Understand the performance characteristics of reciprocating compressors, including efficiency, power, temperature control, and valve behavior under various operating conditions.
- Enhance their operational knowledge, covering best practices for start-up, capacity control, shut-down procedures, and multistage compressor operation.
- Be able to identify and analyze the most common modes of failure, such as wear in valves, piston rings, and packing rings, and understand their impact on compressor performance.
- Develop troubleshooting skills, including diagnosing issues related to vibration, noise, temperature irregularities, and mechanical failures, and apply these techniques to ensure optimal performance and reduce downtime.
- Learn systematic procedures for compressor maintenance, dismantling, and reassembly, along with the ability to document and report faults accurately.
- Acquire the necessary skills to manage and resolve breakdowns, minimizing operational disruptions and improving overall compressor reliability.
DAY 1
Compressor Technology and Components
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- Construction and Design Philosophies: Overview of reciprocating compressor designs and construction principles.
- Compressor Components: Detailed study of key components: frame, cylinders, pistons, rings, piston rods, crank head, crankshaft, connecting rods, bearings, and compartment distance piece. Special focus on valves.
- Auxiliary Systems: Overview of pulsation dampeners, crank mechanisms, cylinder lubrication, cooling systems, and safety devices.
- Vibration: Understanding the causes and management of vibration in reciprocating compressors.
DAY 2
Performance and Efficiency
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- Ideal Gas Compression: Examining discharge temperature and power calculations in ideal gas compression.
- Axial Compression: Analysis of valve behavior, leakage, and internal thermal exchanges.
- Indicator Diagram: Introduction to the indicator diagram and its role in performance assessment.
- Efficiency & Compression Power: Assessing efficiency, compression power, and factors influencing performance.
- Applications: Practical exercises in plotting temperature, power, and efficiency using p/v diagrams.
DAY 3
Compressors Operating on Industrial Processes
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- Start-up, Capacity Control, and Shut-down: Procedures for safe start-up, operation, and shutdown of reciprocating compressors.
- Influence of Operating Conditions: How pressures, gas composition, and inlet temperature affect compressor performance.
- Multistage Compressors: Behavior and operation of multistage compressors, with focus on pressure and efficiency optimization.
- Air Compression Specifics: Addressing challenges such as water condensation and its impact on compressor performance.
DAY 4
Maintenance Practices
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- Forces on Compressor Components: Exploring the effects of pressure, inertia, and friction on bearings and internal components.
- Common Failures and Wear: Identifying typical issues with valves, piston rings, packing rings, and piston rods.
- Dismantling and Reassembly: Step-by-step dismantling and mounting procedures, emphasizing safe practices and thorough documentation.
- Applications: Study of dismantling reports and forces on connecting rods in real-world scenarios.
- Case Studies: Analysis of typical failures encountered in reciprocating compressors and how to address them.
DAY 5
Troubleshooting and Problem-Solving
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- General Troubleshooting: Identifying and resolving issues such as noise, vibration, and temperature abnormalities.
- Multistage Compressor Troubleshooting: Using temperature and inter-stage pressure monitoring to diagnose problems in multistage compressors.
- Applications: Practical troubleshooting exercises, including piston rod run-out and drop monitoring to identify mechanical faults.
