Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Mechanical and Maintenance Engineers
• Rotating Equipment and Reliability Engineers
• Process and Operations Engineers
• Maintenance Supervisors and Technicians
• Condition Monitoring and Vibration Analysts
• Anyone responsible for the operation, inspection, or troubleshooting of centrifugal compressors

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Understand the working principles of centrifugal compressors
• Interpret compressor performance maps and characteristic curves
• Identify common compressor operating problems such as surge and choke
• Apply techniques for performance monitoring and troubleshooting
• Perform maintenance and reliability assessments of compressor systems
• Implement corrective and preventive measures to enhance operational efficiency

DAY 1

Fundamentals of Centrifugal Compressors

• Welcome and Introduction
• Pre-Test
• Overview of Compressor Types and Applications
• Principles of Gas Compression
• Comparison: Centrifugal vs. Positive Displacement Compressors
• Aerodynamic Theory of Compression
• Compressor Components and Functions

• Casing, Impeller, Diffuser, Shaft, Bearings, Seals

• Energy Transfer and Euler’s Equation
• Degree of Reaction and Velocity Triangles
• Basic Performance Terminology

DAY 2

Compressor Design, Construction and Performance

• Compressor Flow Path and Internal Aerodynamics
• Impeller Design and Efficiency Considerations
• Diffusers and Return Channels
• Casing and Nozzle Design
• Rotor Dynamics and Balancing
• Thrust and Axial Forces
• Pressure Ratio, Flow Coefficient, and Efficiency
• Performance Curves and Characteristic Maps
• Influence of Gas Properties and Inlet Conditions
• Design and Material Considerations for Reliability

DAY 3

Operation and Control of Centrifugal Compressors

• Start-up and Shutdown Procedures
• Operating Limits and System Resistance
• Surge and Stonewall Phenomena
• Surge Line, Control Methods, and Anti-Surge Systems
• Choke Conditions and Performance Degradation
• Parallel and Series Operation
• Effect of Speed, Pressure, and Temperature Variations
• Instrumentation and Control Loops
• Monitoring Parameters – Flow, Pressure, Temperature, and Vibration
• Operating Troubles and Their Causes

DAY 4

Maintenance and Reliability Practices

• Routine Inspection and Condition Monitoring
• Lubrication Systems and Oil Management
• Bearing and Seal Maintenance
• Alignment and Balancing Techniques
• Vibration Analysis and Interpretation
• Rotor and Impeller Cleaning and Inspection
• Troubleshooting Mechanical and Process-Related Problems
• Preventive and Predictive Maintenance Strategies
• Reliability Improvement and Life Extension

DAY 5

Troubleshooting and Performance Optimization

• Common Compressor Faults and Failure Mechanisms
• Mechanical, Aerodynamic, and Process Issues
• Systematic Troubleshooting Procedures
• Root Cause Failure Analysis (RCFA)
• Diagnostic Techniques and Data Evaluation
• Performance Testing and Trend Analysis
• Efficiency Improvement and Energy Optimization
• Safety Considerations During Operation and Maintenance
• Post-Test
• Certificate Ceremony