Course Description:

Compressors and engines drivers are often some of the most critical and expensive systems at a production facility, and deserve special attention. Due to many factors, including but not limited to the quality of the initial specification/design, adequacy of maintenance practices and operational factors, industrial facilities can expect widely varying lifecycle costs and reliability from their own installations. This intensive course offers deep view of design, construction, control, operation, maintenance and troubleshooting of these equipment. The course describes principles of operation of (compressor and engines drivers) and how design is adapted to a number of different configurations to meet numerous needs and procedure of major maintenance.

This course is designed to enhance the basic and common knowledge, skills, and attitudes of an individual in operation and maintenance.  The trainees will be able to maintain the compressors and drive engine safely and contribute effectively to the operation of the machinery.

They will learn the basics of evaluation of compressors and engine operation and maintenance planning. The participants will learn the fundamentals of compressors and engine repair and operation by learning the various components that make up the compressors and internal combustion engine.

Course Objectives:

By the end of the course, participants will be able to:

1. Describe the general purpose of compressors in oil and gas industry.
2. Identify the main types of compressors and typical compressors applications (PEFS symbols, appearance).
3. Explain the various types of Engines / Drivers used at own location.
4. Describe the operating principles of the various types of Engines / Drivers at own location.
5. Use the appropriate tools and equipment to maintain Engines / Drivers and auxiliary systems.
6. Explain the operating principle and control for main types of centrifugal compressors, as well as the main components of centrifugal compressor system and their functions.
7. Explain the operating principle and control for main types of reciprocating compressors, as well as the main components of reciprocating compressor system and their functions.
8. Construction and operational constraints compressors &drivers engines.
9. The operation and characteristics of dynamic and PD compressorsas well as compressor systems calculations.
10. List types of bearings and explain statistical nature of bearing life.
11. The advanced information in preventive as well as predictive maintenance of compressors and drives engine.
12. The advanced condition monitoring technologies stressing on vibration and oil analysis.
13. Explain the operating principle and control for main types of axial compressors, as well as the main components of centrifugal compressor system and their functions.
14. Explain the routine monitoring for centrifugal compressor systems (vibrations, temp., lube oil, cooling, dry gas seal, and Surge control system and capacity control ….est.)
15. Describe main problems and troubleshooting for centrifugal compressors.
16. Describe the operating parameters of each Engine / Driver at own location and the importance of maintaining performance within those parameters.
17. Describe the function of individual Engines / Drivers components and auxiliary systems.
18. Evaluate and interpret performance and integrity data of Engines / Drivers.
19. Recognize and respond to abnormal conditions and take appropriate corrective action.

Course Outline:

1. Introduction of compressors.
   1. Compressors (theory of operation, Classifications, applications, selection, codes & standard)
2. Centrifugal compressor
   1. Codes, standard and applications
   2. Main compressor parts (Rotating parts, static parts, clearance & tolerances).
   3. Compressor bearing types for axial & redial loads.
   4. Dry gas seal system (operation, monitoring, control, maintaining & troubleshooting)
   5. Lube oil and bearing lubrication system (operation, monitoring, control, maintaining & troubleshooting)
   6. Surge and ant-surge system control (operation, monitoring, control, maintaining & troubleshooting.
   7. Online condition monitoring system & the role of condition monitoring in compressor maintenance Diagnostic methods.
   8. Compressor maintenance activities:
   9. Preventive maintenance procedures for (daily check, monthly, 3M, 6M, yearly,..).
   10. Predictive maintenance based on (vibration, operation conditions online monitoring, oil analysis,..)
   11. Corrective & repairing procedures ( for compressor parts)
   12. Complete inspection & overhauling procedures.
   13. Compressor troubleshooting MFR software T/S table.
   14. Compressor cases study.
3. Reciprocating compressor
   1. Codes, standard and applications
   2. Main compressor parts and function of each part (moving parts, static parts, clearance & tolerances).
   3. Operation, monitoring, control, maintaining & troubleshooting)
   4. Lube oil and bearing lubrication system (operation, monitoring, and control, maintaining & troubleshooting).
   5. Online condition monitoring system & the role of condition monitoring in compressor maintenance Diagnostic methods.
   6. Compressor maintenance activities:
      1. Preventive maintenance procedures for (daily check, monthly, 3M, 6M, yearly,..).
      2. Predictive maintenance based on (vibration, operation conditions online monitoring, oil analysis,..)
      3. Corrective & repairing procedures ( for compressor parts)
      4. Complete inspection & overhauling procedures.
   7. Compressor troubleshooting MFR software T/S table.
   8. Compressor cases study.
4. Bearings, Lubrication, Vibration Analysis and advanced Predictive Maintenance for Turbo machinery.
   1. Bearings ( Types of Bearings, Thrust Bearings, redial bearings & magnetic bearing)
   2. Bearings lubrication ( pressured oil system, oil bath & greasing)
   3. Lubrication, Viscosity of Lubricants, Non-Newtonian Fluids, and Greases.
   4. Coupling types, selection, application & Alignment methodology.
   5. Alignment as a predictive maintenance program, (cold alignment, hot alignment, thermal grouse techniques).
   6. Used Oil Analysis for condition monitoring
   7. Vibration Analysis and Predictive Maintenance
   8. Vibration Causes, Resonant Frequency, Vibration in Predictive Maintenance, Diagnostics
   9. Intelligent (Smart Transmitters)
   10. Advantages of Intelligent Instrumentation
5. Introduction of driving engines.
   1. Drive engines (theory of operation, Classifications, applications, selection, codes & standard)
6. Introduction to different types of engines such as
   1. Diesel Engine
   2. Gas Engine
   3. Petrol engine
7. Why diesel engines are preferred use in the oil field?
8. Where diesel engines are used in the oil field?
   1. Fire water pump
   2. Gas compressors
   3. Air compressor
   4. Emergency generator
9. Operation principle of diesel engine:
   1. Engine design and function
   2. Start-stop and operation
   3. Parameters to be checked before start-up
   4. Parameters to be witnessed during engine in operation.
   5. Function of built-on engine system
   6. Engine control system
   7. Case study.
   8. Activity – Video, 3D animation, & Open discussion
10. Engine maintenance schedule
    1. Fuel injection equipment
    2. Evaluation of engine operating parameters
    3. Engine Automation and Control System
11. Engine auxiliary systems
    1. Lube oil and lubrication system including cooler, filters, instrumentation and measuring tools
    2. Cooling water and air cooling systems
    3. Fuel system and component
    4. Function of various components that make up the internal combustion engine
    5. Engine performance and control system
    6. Engine testing schedule with load and at no load.
    7. Case study
    8. Activity – Video, 3D animation, & Open discussion
12. Maintenance
    1. Engine component
    2. Preventive and Corrective maintenance
    3. The appropriate tools and equipment required to maintain Engines
    4. Required spare part
13. Troubleshooting and up normal conditions.
    1. Failure analysis
    2. Up normal sound, bearing high temperature
    3. Root cause analysis
    4. Troubles and corrective action