Presenter: Fred Geitner

Process Machinery Engineering Services Mr. Geitner is presently the principal engineer of PMES (Process Machinery Engineering Services), an independent consultant and expert litigation witness in the area of process machinery reliability.  He has over…More

Number of days:4
Date and Venue:
November 30, 2014
Qatar, Ras Laffan

Compressor failures can cause significant problems from delays in production to the possible shutdown of the whole plant. However, good compressor operation and maintenance can cost-effectively maximise compressor life expectancy; while improving its reliability and availability to meet output requirement.


Course approach:

This course aims to provide you with:

  • A very practical, interactive, experiential learning experience
  • A clear methodology applicable to all relevant organisations
  • Industry standard terminology and content
  • Rich content and solutions to site-specific issues
  • Interactive discussions

Key benefits and learning outcomes:

Over this 4-day training course, you will obtain valuable insights into:

  • Evaluating and augmenting the efficiency of compressor operation resulting in reduced energy consumption
  • Improving the knowledge of best practices and troubleshooting techniques to avoid and mitigate compressor failures
  • Defining the technical features and vulnerabilities of dynamic and positive displacement compressors
  • Identifying the criteria that can assist in cost-effective compressor selection
  • Using appropriate maintenance technologies to maximise compressor reliability and availability
  • Benchmarking compressor performance against industry standards


This course is aimed at:

Mechanical Engineers, Maintenance Engineers, Reliability Engineers, Electrical Engineers, Professional Engineers, Operations Managers, Maintenance Managers, Project Managers, Contract Managers, Asset Managers, Technical Managers.  From industries such as  Oil & Gas, Mining, Energy & Utilities, Chemicals & Petrochemicals, Food & Beverage Manufacturing, Agriculture

Course Outline:

Day 1
Session One
Introduction to Compressors

  • Principles of operation, configurations, classifications, ranges of applications, vulnerabilities and limitations of:  1)Ejectors  /  2)Dynamic compressors:  Radial, axial, single-shaft and multi-shaft turbocompressors

Session Two
Introduction to Compressors (continued)

  • Principles of operation, configurations, classifications, ranges of applications, vulnerabilities and limitations of:
  • Displacement compressors: Rotary, screw, sliding vane, liquid ing, reciprocating compressors
  • Non-lubricated process compressors
  • Determining compressor life cycle costs (LCC) to identify the most cost-effective way of compressing gas & air

Session Three
Mechanical Design of Centrifugal Compressors

  • Side streams
  • Rotors
  • Impellers
  • Balancing
  • Rotor dynamics
  • Casings
  • Bearings
  • Seals
  • Couplings
  • Performance controls

Session Four

  • Skill test and assesment
  • Review, summary and Q&A

In this session the course director will review and summarize learnings of the day and answer delegates’ questions.

Day 2
Session One
Design and Materials of Reciprocating Compressor Components

  • Crank case/frame
  • Main bearings
  • Cylinders
  • Piston and rings/bands
  • Valves
  • Packing
  • Seals

Session Two
Design and Materials of Reciprocating Compressor Components (continued)

  • Traditional lubrication vs. mini-lube concepts
  • Auxiliaries:  Cooling principles  /  Cooling systems  /  Pulsation vessels and piping
  • Controls
  • Unloaders
  • Protection philosphies

Session Three
Compressor Characteristics and Selection Criteria

  • Understanding key compressor parameters such as thermodynamics, capacity, power, efficiencies, gas properties and intercooling as they apply to various compressor types
  • Selection criteria of dynamic and displacement compressors:
  • Characteristic curves and their significance to the operator
  • Stability issues and solutions
  • Calculation and sizing methods using examples

Session Four

  • Skill test and assesment
  • Turbo Compressor Group Discussion: What approaches to problems are being used at your facility?
  • Reciprocating Compressor Group Discussion: What are our most urgent problems at your facility and how do you address them?

Day 3
Session One
Compressor Maintenance Strategies, Tactics and Procedures

  • Predictive vs. Preventive Maintenance (PdM vs.PM):
  • PM, PdM, CBM explained as they apply to different compressor types
  • When to apply difference maintenance strategies

Session Two
Applying and determining the frequency of condition based maintenance tactics such as:

  • Performance monitoring
  • Condition monitoring
  • Vibration analysis
  • Oil analysis
  • Ultra sound inspection/analysis
  • Infrared imaging tools

Session Three

  • Operation and Maintenance – Turbocompressors
  • Start-up and shutdown
  • Surveillance and monitoring
  • Safety and emergency shut-down  devices (ESD)
  • Compressor train operation inspection, maintenance, overhaul and repair (IMO&R)
  • Planning and execution of IMO&R
  • Why IMO&Rs campaigns are not always successful
  • Troubleshooting turbocompressor trains

Session Four
Operation and Maintenance – Reciprocating Compressors

  •   Start-up and shutdown
  •   Surveillance and monitoring
  •   Safety and ESDs
  •   IMO&R planning and implementation
  •   Selecting the right program
  •   Alignment and piston rod run-out checks
  •   General suitability of valve materials
  •   Valve constraints
  •   Valve testing
  •   Packing maintenance
  •   Foundations
  •   Inspection and inspection forms
  •   Reports and clearance assurance

Day 4
Session One

  • Operation and Maintenance -Displacement Compressors
  • Troubleshooting and failure analysis
  • Troubleshooting matrices applied:  Typical problems and solutions diagnostic tests  /  Compressed air system evaluation
  • Learning from recent compressor failure incidents examples to prevent functional failures in your compressor operation

Session Two
Implementing Root Cause Failure Analysis (RCFA) to Prevent Recurrence of
Compressor Problems

  • Structured problem solving principles:  Situation Analysis  / Cause Analysis  / Action Generation
  • A practical guide to root cause failure analysis (RCFA)
  • Examples and discussions of attendees’ experiences

Session Three
Repairs and Spares Assessment

  • Extending compressor life: Upgrading, conversion, re-rating, revamping, reapplication and remanufacturing
  • Key principles of repair or replacement decisions:
  • Insurance spares vs. wear & tear parts
  • Vendors’ (OEM) recommended spare parts vs. experience based spare parts lists
  • Comparing  scientific  vs. experience based approaches to establish requisite spares stock levels

Session Four

  • Skill test & assessment
  • Review, summary and Q&A

In this session the course director will encourage delegates to share experiences in relation to the compressor challenges faced at their individual workplace with the aim of finding a suitable solutions.
Possible Topics:

  • Exchange of Reliability and Availability Statistics
  • Turbo Compressors:  Fouling Problems  /  Gas Seals  /  Couplings
  • Reciprocating and other displacement compressors:  /  Valve Problems  /  Piston rod breakage  /  Unloaders  /  Life extension measures


Please Note:
The precise content may change on the day depending on the specific needs of the delegates.

For volume discounts and in-house rates, please contact:
Phindi Mbedzi at 2KG Training
Tell: +27 (0) 11 325 0686
Cell: +27 (0) 71 125 6188

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