Course Table of Air Compressor Maintenance

Course Table of Contents 1. Introduction to Compressors What is a Compressor? How Compressors work? Compressor Classification and Type Selection. Skill test and assessment

2. Different Types of Compressors Dynamic 2.1.1. Ejector 2.1.2. Radial (Centrifugal) Compressor 2.1.3. Axial Compressor Positive Displacement 2.2.1. Rotary Sliding Vane Compressor o Liquid Ring Compressor o Screw Compressor o Lobe (Roots) Compressor o 2.2.2. Reciprocating Trunk type o Crosshead Type o Skill test and assessment

3. Detailed Description of Popular, Industrial Compressors Operation Principle and Maintenance of Air Compressors 3.1.1. Screw Compressor - Skid Mounted. Screw Compressor, principle of operation o Control System and Lube oil circuit o Routine Maintenance for Lubricant-Free Rotary Screw Comp ressor o 3.1.2. V - Type, Trunk and Crosshead Compressor - Skid Mounted Multi Stage, Trunk and Crosshead, principle of op eration o Air and Cooling Circuit o 3.1.3. Horizontal, Balanced, Opposed, Multi Stage Compressor 3.1.4. Skill test and assessment 3.2. Operation Principle and Maintenance concepts of Process Gas Compressors 3.2.1. Double Acting, Single and Multi Stage Reciprocating Compressor Principle of Operation o Lubrication of Reciprocating Compressor o Crankcase Main Bearing / Con-rod Big End Bearing o Cylinder and Packing Lubrication o Crankcase / Crank Shaft / Connecting Rod / Crosshead o Operation Problems and Maintenance of Compressor Valves o Piston, Piston Elements, Rod Reversal, Runout and Piston End Clearances o Stuffing Box and Rod Packing elements o

Compressor Cylinder Cooling System / Inter Cooling / After Cooling Compressor Control System o Capacity Controls o Intake Valves Unloading o Clearance Pocket Unloading o 3.2.2. Centrifugal Compressors Centrifugal Compressor Principle o Capacity of Compressor o Head of Compressor o Surging and Anti Surge o Thrust Balancing o Lube Oil System o Seal Oil System o Component Arrangement o Sealing Arrangement o Dry Gas Seal o Bearing Arrangement o Routine Maintenance for Centrifugal Air Compressors o 3.2.3. Skill test and assessment o

OVERHAUL AND REPAIR OF RECIPROCATING COMPRESSORS Rule of Thumb for General Running Clearances. o Compressor Alignment. o Web Deflection Measurements. o Compressor Cylinder Alignment. o Foundation Problems and Repairs. o Compressor Bearing Maintenance and Replacement. o Cylinder Repair and Maintenance. o Compressor Piston Maintenance. o Rebuilding Compressor Pistons. o Installing Pistons Bn Piston Rods. o Setting Piston End Clearances. o Inspection and Reconditioning Piston Rods. o Manufacture of Compressor Piston Rods. o Other Compressor Component Repairs o TROUBLESHOOTING COMPRESSOR PROBLEMS Introduction. o Compressor Problems. o Typical Compressor Problems. o Troubleshooting Lubrication Systems. o Significance of Intercooler Pressures. o Interstage Pressures. o Belt Drives. o Motor Controls. o Diagnostic Tests. o Evaluating Reciprocating Compressor Condition Using Ultrasound and Vibration Patterns. o

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Compressor Service Technician Reports. Basic Air Compressor System Evaluation.

PREVENTIVE MAINTENANCE FOR RECIPROCATING COMPRESSORS Introduction. o Compressor Maintenance. o Emergency Repairs Should Be Minimized. o Effectiveness of Preventive Maintenance. o Compressor Preventive Maintenance Program. o Spare Parts. o Vendor Selection. o Personnel Training. o Maintenance Contractors. o Predictive Maintenance. o Integrated Condition Monitoring Systems. o