Reciprocating Compressors Fundamentals

Introduction

This course is designed for engineers and supervisors involved in the maintenance and troubleshooting of reciprocating compressors. The course provides an in-depth study of reciprocating compressors technology, performance, operation and maintenance. Participants will be able to solve operation and mechanical problems. Participants will practice a complete compressor overhauling and parts inspection at the workshop and report the compressor condition.

Objectives

• Understand the mechanical design of the reciprocating compressor
• Learn the principles of the reciprocating compressors
• Understand the reciprocating compressor performance curve
• Learn the failure analysis and troubleshooting the reciprocating compressor
• Learn the Maintenance of the reciprocating compressors

Training Methodology

The training methodology is interactive with group exercises and is suitable for all employees involved in functions management. The pace and level of the training workshop is customized to the understanding of the delegates. Ongoing back-up and support is available after the training on request to the supplier, and the training course is also available for in-house presentation as well as for “Competency Transfer”.​

Who Should Attend?

This course is designed for mechanical engineers and senior technicians who are responsible for Maintenance and Troubleshooting Reciprocating Compressors

Course Outline

Day 1: Over view

• Consideration in Compressors Selection
  • Discharge pressure required.
  • Capacity required.
  • Power supply characteristics.
  • Availability and cost of cooling water.
  • Space required for the compressor.
  • Compressor weight.
  • Type and size of foundation required
  • Type of control required.
  • Maintenance costs.
  • Budget
• Compression methods and calculation
• Positive-Displacement And Rotodynamic Compressors advantage and  disadvantage
• Introduction To Aerodynamics and positive displacement compressors
  • Definition Of Compressor
  • Comparison between positive displacement and Rotodynamic compressors
  • Types Of positive displacement Compressors
• Reciprocating compressor
• Labyrinth compressor
• Diaphragm compressor
• Screw compressor
• Lobe compressor
• Slide vane compressor
  • Types of turbo compressors
    • Centrifugal compressor
    •  Axial flow compressor
  • Video moves the centrifugal compressor

Day 2: General

• Different types of machine for the compression of gas
• Piston compressors
• Design applications of reciprocating compressors with one or more stages
• Types of construction
• Machines with and without crossheads

Compression cycle of reciprocating compressors and basic calculations

• The ideal cycle of piston compressor
• Real cycle departure from ideal cycle
• Volumetric efficiency
• Example of calculation
• Capacity
• Power
• Compression in several stages
• Allowable pressure and temperature
• Allowable speed
•  Rod loading

Main Parts and Construction

• Frame and crankshaft assembly
• Crosshead
• Connecting rod
• Bearing and bushes
• Cylinders and clearance volume
• Pistons rings and rider rings
• Stuffing boxes
• Valves

Capacity control 

Day 3:

• Auxiliary Systems
  • Frame and cylinder lubrication
  • Cooling system
• Accessories
  • Compressor control system
  • The piping system and gas filters
  • Coolers and cooling system
  • Suction and discharge snubbers
  • Reduction gears, flywheel and coupling
• Compressor Performance
  • Ideal gas compression, power
  • P-V diagram
  • Actual operating conditions, valves behavior
  • Characteristic curves
  • Efficiency

Day 4:

• Compressor Operation
  • Start up and loading system
  • Capacity control
• Maintenance
  • Disassembly and assembly procedures
  • Crankshaft and bearings inspection \ replacement and assembly
  • Web deflection checks and adjustment
  • Inspection repair and installation of cylinders
  • Disassembly and assembly of piston and piston rods
  • Adjusting end clearances of pistons
  • Inspection and replacement of piston and rider rings
  • Packing components inspection and assembly
  • Oil scraper rings replacement
  •  Valves disassembly, inspection and assembly
  •  Frame lubricating system
  •  Cylinder lubricating system
• Pressure Pulsation in Compressor and Piping
• Vibration Monitoring and Control
• Failures Analysis and Troubleshooting
• Pressure Pulsation in Compressor and Piping
• Specification and Selection

Day 5: Troubleshooting and Failure Analysis

• Principles of Troubleshooting
• Monitoring systems
  • Vibration-monitoring basics
  • Vibration Limits
• Symptoms in Compressors                       
• Causes of Failure                                        
  • Compressor stuffing box                          
  • Bearings        
  • Lubrication system                                                 
  • Shaft runout

Compressor Maintenance

• Maintenance Strategies
• Maintenance Programs
  • Lube oil systems
  • Inlet Filtration
  • Sealing systems
  • Shaft Deflection
  • Shaft Alignment
  • Bearings clearance

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