Euro-training Center
 Compressor & Pump Technology (E6024) QR Code

Compressor & Pump Technology

Overview:

Introduction:

This course provides a comprehensive understanding of the various types of reciprocating, rotary, and dynamic compressors and pumps. This includes trunk piston, sliding crosshead piston, diaphragm, rotary screw, straight lobe, sliding vane, liquid ring, centrifugal, and axial compressors as well as piston pumps, plunger pumps, rotary pumps, screw pumps, two- and three-lobe pumps, cam pumps, vane pumps, bellows-type metering pumps, diaphragm pumps, canned motor pumps, and centrifugal pumps. Bearings are also covered thoroughly. The characteristics, selection criteria, sizing calculations, sealing arrangements, common problems, repair techniques, as well as the preventive and predictive maintenance of these compressors and pumps, are covered in detail.

This course is a must for those who use this equipment. It covers how compressors, pumps, and bearings operate and provides the guidelines and rules that must be followed for their successful application

Course Objectives:

At the end of this course the participants will be able to:

  • Maximize the efficiency, reliability, and longevity of all types of compressors, pumps, and bearings
  • Size and select out of the various types of dynamic and positive displacement compressors, and pumps using the performance characteristics and the selection criteria that you learn in this course
  • Carry out diagnostic testing and inspection of critical components with the knowledge of common failure modes of compressors, pumps, and bearings by applying advanced fault detection techniques
  • Select bearings and lubrication, compressor and pump sealing arrangements, meet commissioning requirements, conduct vibration and used oil analyses, troubleshoot, provide predictive and preventive maintenance, enhance reliability, and reduce cost
  • Determine the maintenance required to minimize compressor and pump downtime and operating cost and maximize their efficiency, reliability, and longevity
  • Gain a thorough understanding of compressor and pump characteristics and compressor surge and surge prevention systems
  • Understand all the causes of failures in compressors and pumps
  • Determine all the design features that improve the efficiency and reliability of all compressors and pumps
  • Design different types of compressor and pumping systems
  • Gain a thorough understanding of the various types of sealing arrangements used in compressors and pumps

Targeted Audience:

  • Operation and Maintenance Operators
  • Supervisors & Technicians
  • Facility Engineers
  • Utility Engineers
  • Anyone requiring a working level knowledge of rotating equipment & compressors
  • Technical Professionals dealing with condition monitoring, reliability and integrity analysis

Course Content:

Unit 1: Gas Laws, Compressor Types, and Applications:

  • Perfect and Imperfect Gases
  • Compressor Polytropic Efficiency and Power Requirements
  • Compressor Volumetric Flow Rate and Volumetric Efficiency
  • Rotary and Reciprocating Compressors
  • Dynamic Compressors (Centrifugal and Axial)
  • Compressor Performance Measurement
  • Receivers, Compressor Control, and Compressor Unloading Systems
  • Preventive Maintenance and Housekeeping

Unit 2: Positive Displacement Compressors:

  • Performance of Positive Displacement Compressors
  • Reciprocating Compressors
  • Reciprocating Compressors Troubleshooting and Maintenance
  • Diaphragm Compressors
  • Rotary Screw Compressors and Filter Separators
  • Straight Lobe Compressors
  • Recent Developments in Liquid/Gas Separation Technology

Unit 3: Dynamic Compressors:

  • Dynamic Compressor Technology
  • Centrifugal and Axial Compressors
  • Simplifies Equations for Determining the Performance of Dynamic Compressors
  • Centrifugal Compressors – Components, Performance Characteristics, Balancing, Surge Prevention Systems and Testing
  • Choking, and Anti-Choking Systems
  • Compressor Auxiliaries, Off-Design Performance, Stall, and Surge

Unit 4: Dynamic Compressors Performance, Compressor Seals, and Compressor System Calculations:

  • Dynamic Compressors Performance
  • Surge Limit, Stonewall, Prevention of Surge, Anti-Surge Control Systems
  • Compressor Seal Systems
  • Gas Seals, Liquid Seals, Liquid Bushing Seals, Contact Seals, Restricted Bushing Seals, Seal Liquid leakage System
  • Dry Seals, Advanced Sealing Mechanisms, and Magnetic Bearings
  • Compressor System Calculations
  • Sizing of Compressor System Components, Sizing of Gas Receiver

Unit 5: Bearings, Lubrication, Vibration Analysis, and Predictive Maintenance:

  • Bearings, Types of Bearings, Thrust Bearings
  • Lubrication, Viscosity of Lubricants, Non-Newtonian Fluids, and Greases
  • Used Oil Analysis
  • Vibration Analysis and Predictive Maintenance
  • Vibration Causes, Resonant Frequency, Vibration in Predictive Maintenance, Diagnostics
  • Diagnostic Testing

Unit 6: Pump Categories, and Centrifugal Pumps:

  • Pump Categories: Dynamic (Centrifugal) and Positive Displacement (Reciprocating and Rotary)
  • Centrifugal Pumps: Operation, Casings and Diffusers, Hydrostatic Pressure Tests, Impellers, Hydraulic Balancing Devices, Mechanical Seals, Minimum Flow Requirement, Performance Characteristics, Cavitation, and Net Positive Suction Head

Unit 7: Centrifugal Pump Mechanical Seals:

  • Centrifugal Pump Mechanical Seals, Components, Temperature Control, Seal Lubrication/Leakage, Applications, Types of Mechanical Seals, Common Failure Modes of Seals, Seal Refurbishment
  • Maintenance Recommended for Centrifugal Pumps
  • Vibration Analysis and Predictive Maintenance

Unit 8: Positive Displacement Pumps:

  • Reciprocating Pumps, Piston Pumps, Plunger Pumps, Rotary Pumps, Screw Pumps, Two- and Three-Lobe Pumps
  • Cam Pumps, Vane Pumps, Bellows-Type Metering Pumps
  • Diaphragm Pumps
  • Canned Motor Pumps, Seal-less Pump Motors

Unit 9: Troubleshooting of Pumps:

  • Pump Maintenance, Inspection, Overhaul, Diagnoses of Pump Troubles
  • Troubleshooting of Centrifugal Pumps
  • Troubleshooting of Rotary Pumps
  • Troubleshooting of Reciprocating Pumps
  • Water Hammer
  • Bearings
  • Used Oil Analysis
  • Smart Instrumentation

Unit 10: Pump Selection:

  • Pumping System Calculations
  • Design and selection of Different Pumping Systems for the Oil and Gas Industry, and the Power Generation Industry
  • Vibration Analysis and Predictive Maintenance
  • Control Valve Selection, Cavitation, and Noise
  • Actuators, Positioners, and Accessories
  • Diagnostics of Pumping Systems
  • Pump Drivers
  • Motors
  • Variable-Frequency Drives

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