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Reciprocating Compressor Operation and Maintenance

OBJECTIVE

  • Give general description of air compression theory to optimalize compression process efficiently
  • Give fundamental knowledge of compressor principle and air state of condition in compression process
  • Give fundamental structure of compressor to ensure safe operating installation in all condition can be achieved.
  • Give the knowledge to condition compressor operation and its maintenance to avoid the same failure. Be able to modify operating condition.
  • Give the knowledge to determine disturbance source, be able to think sistematically to analyse root cause of compressor failure

 

COURSE OUTLINE

1. Fundamental of Thermodynamic

  • Compression Process and Work
    • Isothermal
    • Adiabatic
    • Polytrophic

2. Fundamental Theory of Compressor

  • Compressor Development History
  • Compressor Classification
  • Compressor Work Cycle
    • Theoretic Cycle
    • Semi Theoretic Cycle
    • Actual Cycle
  • Centrifugal Compressor
  • Head, Losses and Efficiency
  • Characteristic at Each Speed
  • Compressor Installation

3. Dynamic Compressor

  • Performance and Condition Definition
  • Type of Centrifugal Compressor
    • High Casing
    • Horizontal Split Casing
    • Vertical Split Casing
  • Package Assembly
  • Multi Casing Unit
  • Centrifugal Compressor Application
  • Characteristic of Centrifugal Compressor
  • General detail of Centrifugal Compressor
    • Impeller
    • Diaphragm
    • Inter Stage Packing
    • Rotor assembly
    • Casing
    • Journal and Thrust Bearing
    • Shaft seals
    • Seal and lubrication system
    • Gas Cooling
  • Pressure Ratio and Centrifugal Characteristic Curve
  • Control of Capacity
    • Load Curve
    • Control Method
    • Surge Control
    • Parallel Operation
    • Unloading Start
  • Inner Gear Air Centrifugal Compressor
    • Modulation Pressure Control
    • Dual Step Capacity Control
    • Auto Dual Control
    • Axial Flow Compressor

4. Gas Turbine Compressor

  • Centrifugal Compressor
  • Axial Compressor
  • Compressor Performance

5. Pressure Loss at Gas Pipe Installation

  • Definition and Accuracy
  • Factors to Estimate Friction Loss
  • Pressure Gradient In Pipe
  • General Equation of Various Gas
  • Natural Gas Piping Equation
  • Vacuum Piping Equation
  • Fitting Pressure Loss
  • Flexible Pipe Pressure Loss

6. Fundamentals of Piston Compressor

  • Gas Compression Usage
  • Compression Method
  • Type of Compressor
  • Compressor Principles
  • Standard, Symbol and Definition
  • Measurement Unit
  • Basic Thermodynamic Theory
    • Compressibility
    • Multi Stage Compressor
    • Power Consumption
    • Positive Displacement Compressor
    • Isothermal Basis
    • X-Factor
    • Compressibility Correction
    • Discharge Temperature
    • Application of Theory
  • Reciprocating Compressor
  • Clearance Control
  • Clearance Control and Variable Compression Ratio
  • Effect Of Heat Specific Ratio to Horse Power
  • Peak Horse Power and Break Horse Power
  • Effect of Compressibility
  • Effect of Altitude
  • Reciprocating Compressor
    • Definition
    • Characteristic
    • Classification
    • Cylinder
    • Valve
    • Cylinder Cooling
    • Non-Cooled Cylinder
    • Air Cooling Cylinder
    • Capacity Control
    • Manual Control
    • Main Automatic Control
    • Load Depletion to Start
    • Types of Control
    • Constant Speed Control
    • Suction Side Throttling
    • Variable Speed Control

7. Installation, Operation and Maintenance

  • Installation
  • Placement
  • Suction Condition
  • Foundation
  • Piping
  • Electric Cabling
    • Field Testing
  • Commissioning
  • Running Test
  • Operation
    • Responsibility
    • Recording
    • Cleaning
    • Lubrication
    • Safety
    • Initial Start
    • Capacity Control
    • Spare Parts
    • Trouble Shooting
  • Inspection and Maintenance
  • Preventive Maintenance
  • Predictive Maintenance

8. Operation

  • Procedure to Run and to Stop Compressor
  • Capacity Control Device
  • Hazard Prevention
  • Automatic Operation

9. Maintenance

  • Preliminary Inspection
  • Operating Condition Inspection
  • Preventive Maintenance
  • Predictive Maintenance
  • Troubleshooting

 

TARGET PESERTA

Mechanical & Rotating Engineer/ Supervisor/Foreman,Plant Maintenance Engineer/Supervisor/Foreman,  Production Operation Engineer/Supervisor/Foreman, Process Engineer/Supervisor, Everybody or professional who wants to broaden knowledge or gain benefit from this course

 

TRAINING METHOD

Presentation

Discussion

Case Study

Evaluation

 

FACILITIES

Training Kit,

Handout,

Certificate,

Lunch + 2x Coffee Break

Souvenir

Pick Up Participant (Yogyakarta)

 

Form Pre-Registrasi

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