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Maximum efficiency, reliability, and longevity of compressors, and bearings are of great concern to many industries. These objectives can only be achieved by understanding the characteristics, selection criteria, sizing calculations, sealing arrangements, common problems, repair techniques, as well as their preventive and predictive maintenance. This course is a MUST for those who use this equipment. It covers how compressors and bearings operate and provides the guidelines and rules that must be followed for their successful application. Their basic design, specification and selection criteria, sizing calculations as well as all maintenance issues including vibration analysis, and used oil analysis are discussed in detail.

Objectives

To provide a comprehensive understanding of the various types of compressors, and bearings so participants can specify, select, size, commission and maintain compressors and bearings for their applications.
To achieve reduced capital, operating and maintenance costs along with increase in efficiency.Who Should Attend

Process engineers, design engineers, consulting engineers, plant engineers, project managers, piping engineers, maintenance managers, water treatment plant managers, facility managers and technicians and technologists. The course will be of great interest to chemical process industries, oil and gas industries, manufacturing plants, power generation plants, defence establishment, and others industries and organizations that must use compressors and bearings.Special Feature

The following is included with your registration:A manual (500 pages) authored by the instructor covering the topics listed in the outline.
A book titled “Electrical Equipment Handbook” (600 pages) published by McGraw-Hill in 2003. This book includes the predictive maintenance required for mechanical and electrical equipment. The instructor has also authored this book.

Program Outline

Day IFaculty: Philip Kiameh, University of Toronto/Ontario Power GenerationGAS LAWS AND COMPRESSION PRINCIPLES

Introduction, symbols, compressor operation, first law of thermodynamics, second law of thermodynamics.
Ideal or perfect gas laws, Boyle’s law, Charles’ law, Amonton’s law, Dalton’s law, Amagat’s law, Avogrado’s law.
Heat and work, property relationships, perfect gases, imperfect gases.
Vapor pressure, partial pressures, critical conditions, gas mixtures, the mole.
Volume percent of constituents, molecular weight of a mixture, specific gravity and partial pressure, specific heats.
Pseudo-critical conditions and compressibility, weight-basis items, compression cycles, compressor polytropic efficiency.
Compressor power requirement, compressibility correction, multiple staging.
Compressor volumetric flow rate, cylinder clearance and volumetric efficiency, cylinder clearance and compression efficiency, Appendix A.

COMPRESSOR TYPES AND APPLICATIONS

Introduction, positive displacement compressors.
Rotary compressors, rotary lobe compressors, rotary vane compressors, rotary screw compressors, rotary liquid ring compressors.
Reciprocating compressors.
Dynamic compressors, centrifugal compressors, principle of operation of centrifugal compressors, centrifugal single-stage (low ratio) compressors, centrifugal single stage integral gear compressors, centrifugal multi-stage horizontally split compressors, centrifugal multi-stage with side loads compressors, centrifugal multi-stage (barrel) compressors, centrifugal multi-stage integral gear compressors.
Axial flow compressors, axial horizontally-split compressors.

COMPRESSORS

Compressor types: positive displacement (reciprocating and rotary), and dynamic (centrifugal and rotary), compressor operation, gas laws.
Compressor performance measurement, inlet conditions, compressor performance, energy available for recovery.
Positive displacement compressors, reciprocating compressors, trunck piston compressors, sliding crosshead piston compressors, diaphragm compressors, bellows compressors.
Rotary compressors, rotary screw compressor, lobe type air compressor, sliding vane compressors, liquid ring compressors.
Dynamic compressors, centrifugal compressors, axial compressors
Air receivers, compressor control, compressor unloading system.
Intercoolers and aftercoolers, filters and air intake screens
Preventive maintenance and housekeeping

PERFORMANCE OF POSITIVE DISPLACEMENT COMPRESSORS

Compressor performance, positive displacement compressors.
Reciprocating compressor rating, reciprocating compressor sizing.
Capacity control, clearance pockets, compressor performance.
Reciprocating compressors, compressor valves.
Reciprocating compressor leakage, screw compressor leakage.

Day IIRECIPROCATING COMPRESSORS

Introduction, crankshaft design, bearings and lubrication systems.
Connecting rods, crossheads, frames and cylinders, compressor cooling.
Pistons, piston and rider rings, valves, piston rods, packings.
Cylinder lubrication, distance pieces

RECIPROCATING AIR COMPRESSORS TROUBLESHOOTING AND MAINTENANCE

Introduction, location, foundation, air filters and suction lines.
Air-receiver location and capacity, starting a new compressor.
Lubrication, non-lubricated cylinders, valves, piston rings.
Intercoolers and aftercoolers, cleaning, packing.

DIAPHRAGM COMPRESSORS

Introduction, theory of operation, compressor design.
Materials of construction, accessories, cleaning and testing.
Applications, automotive air bag filling, petrochemical industries.
Limitations, installation and maintenance.
Diaphragm compressor specification.

ROTARY SCREW COMPRESSORS AND FILTER SEPARATORS

Twin-screw machines, compressor operation, applications of rotary screw compressors.
Dry and liquid injected compressors, operating principles, flow calculation.
Power calculation, temperature rise, capacity control, mechanical construction.
Industry experience, maintenance history, performance summary.
Oil-flooded single-screw compressors.
Selection of modern reverse-flow filter separators, conventional filter-separators and self cleaning coalescers, removal efficiencies, filter quality.
Selection of the most suitable gas filtration equipment, evaluation of the proposed filtration configuration, life-cycle-cost calculations, conclusions.
Coke fuel, Introduction, Properties and Usage, Other coking processes.

STRAIGHT LOBE COMPRESSORS

Applications, operating characteristics, operating principle.
Pulsating characteristics, noise characteristics, torque characteristics.
Construction, rotors, casing, timing gears, bearings.
Staging, higher compression ratios, power reduction, installation.

RECENT DEVELOPMENTS IN LIQUID/GAS SEPARATION TECHNOLOGY

Introduction
Removal mechanisms
Liquid/gas separation technologies
Gravity separators
Centrifugal separators
Mist eliminators
Filter vane separators
Liquid/gas coalescers.
Selection of liquid/gas separation equipment
Formation of fine aerosols.
Ratings and sizing of separation equipment.

Day IIIDYNAMIC COMPRESSORS TECHNOLOGY

Introduction
Centrifugal compressors technology
Axial compressors overview.

CENTRIFUGAL AND AXIAL COMPRESSORS

Principle of operation of centrifugal and axial flow compressors, characteristics of centrifugal and axial flow compressor.
Surging, choking, bleed valves, variable stator vanes, inlet guide vanes.

CENTRIFUGAL COMPRESSORS –COMPONENTS, PERFORMANCE CHARACTERISTICS, BALANCING, SURGE PREVENTION SYSTEMS AND TESTING

Introduction
Casing Configuration
Construction features
Diaphragms
Interstage seals
Balance piston seals
Impeller Thrust
Performance Characteristics
Slope of the centrifugal compressor head curve
Stonewall
Surge
Off-design Operation
Rotor Dynamics
Rotor Balancing
Surge Prevention Systems
Surge Identification
Liquid Entrainment
Instrumentation
Cleaning Centrifugal Compressors
Appendix A (Boundary Layer)
Definition
Description of the Boundary Layer
Separation; Wake

COMPRESSOR AUXILIARIES, OFF-DESIGN PERFORMANCE, STALL, AND SURGE

Introduction
Compressor auxiliaries
Compressor off-design performance, low rotational speeds, high rotational speeds.
Performance degradation.

DYNAMIC COMPRESSORS PERFORMANCE

Description of a centrifugal compressor, centrifugal compressor types.
Compressors with horizontally-split casings, centrifugal compressors with vertically-split casings, compressors with bell casings, pipeline compressors.
Performance limitations, surge limit, stonewall, prevention of surge.
Anti-surge control systems.

COMPRESSOR SEAL SYSTEMS

Introduction, the supply systems, the seal housing system, the atmospheric draining system, the seal leakage system, the drainer, the vent system, the degassing tank, the supply system, the seal housing system.
Gas seals, liquid seals, liquid bushing seals, contacts seals, restricted bushing seals, seal supply systems, flow through the gas side contact seal, flow through the atmospheric side bushing seal, flow through the seal chamber, seal liquid leakage system.

DRY SEALS, ADVANCED SEALING MECHANISMS AND MAGNETIC BEARINGS

Introduction, background, dry seals, operating principles, operating experience, problems and solutions, upgrade developments of dry seals, prevention of dry gas seal failures by gas conditioning, need for training, minimizing the risk of sealing problems.
Magnetic bearings, operating principles, operating experience and benefits, problems and solutions, development efforts, thrust-reducing seals, integrated designs.

COMPRESSOR SYSTEM CALCULATIONS

Calculations of air leaks from compressed-air systems, annual cost of air leakage.
Centrifugal compressor power requirement.
Compressor selection, calculations of air system requirements.
Characteristics of reciprocating compressors, blowers.
Selection of compressor drive.
Selection of air distribution system, water cooling requirements for compressors.
Sizing of compressor system components, sizing of air receiver.
Calculations of receiver pump-up time.

WORKSHOP –CASE STUDIES

Under the guidance of the instructor, perform the following activities:
Design and select different compressor systems for the Oil and Gas industry.
Design and select different compressor systems for the Power Generation industry.

BEARINGS

Types of bearings, ball and roller bearings, stresses during rolling contacts.
Statistical nature of bearing life, materials and finish, sizes of bearings, types of rolling bearings, thrust bearings.

LUBRICATION

Viscosity of lubricants, viscosity units, significance of viscosity, flow through pipes, variation of viscosity with temperature and pressure, temperature effect, viscosity index, effect of pressure
on viscosity.
Non-Newtonian fluids, greases, VI improved oils, oils at low temperatures, variation of lubricant viscosity with use, oxidation reactions, physical reactions, housing and lubrication, lubrication of antifriction bearings.

USED OIL ANALYSIS

Proper lube oil sampling technique, test description and significance, visual and sensory inspections, chemical and physical tests, water content, viscosity, emission spectrographic analysis, infrared analysis, total base number (TBN), total acid number (TAN), particle count, summary.

VIBRATION ANALYSIS AND PREDICTIVE MAINTENANCE

Application of sine waves to vibration, multimass systems, resonance, logarithms and decibels (db), use of filtering.
Vibration instrumentation, velocity transducer, acceleration transducer, transducer selection, time domain, frequency domain, machinery example, vibration analysis.
Vibration causes, forcing frequency causes, unbalance, misalignment, mechanical looseness, bearing defects, gear defects, oil whirl, blade or vane problems, electric motor defects, uneven loading,
drive-shaft torsion.
Resonant frequency, vibration severity, a case history (condensate pump misalignment), vibration in predictive maintenance: diagnostics (identifying the characteristic vibration patterns of common faults; looseness of anti-friction bearings, journal bearings and gears).

INTELLIGENT (SMART) TRANSMITTERS

Introduction, evolution of temperature transmitters, two-wire analog temperature transmitters.
Microprocessor-based transmitters (smart transmitters), smart (intelligent) pressure transmitters.

ADVANTAGES OF INTELLIGENT INSTRUMENTATION

Introduction, comparison between intelligent and non-intelligent instrumentation, conclusion

CONTROL VALVE SELECTION, CAVITATION AND NOISE

General categories of control valves, sliding stem valves, ball valves, eccentric plug valves, butterfly valves, valve selection, material selection, trim parts, rangeability, pressure drop.
End connections, shutoff capability, flow capacity, valve sizing, choked flow, viscous flow, piping consideration, gas and steam sizing.
Cavitation fundamentals, cavity behavior and negative effects of cavitation, system design consideration, control-valve consideration, control-valve evaluation, sizing, and selection.
Noise terminology, sources of valve noise, mechanical noise, hydrodynamic noise, aerodynamic noise, noise control, quiet valves, path treatment.

ACTUATORS, POSITIONERS AND ACCESSORIES

Pneumatic actuators, specification for automated valves (pneumatic and electric actuators), NEMA guidelines, performance characteristics, duty cycle, stalling, speed control of pneumatic actuators, speed control of electric actuators, modulating.
Selection of pneumatic actuators for linear-shaft valves, actuator sizing for linear valves, actuator thrust outputs, double acting piston, fail-safe alternative.
Accessories for linear pneumatic actuators, actuator designs, control accessories and options for pneumatic actuators, pilot valves, limit switches.
Positioners, positioner applications, volume boosters, transducers, instrument signals, split ranging.
Electric actuators, limit switches, control circuit, torque protection, potentiometer, position transmitter, proportional controller.
Electronic positioner, dead band, electronic speed control circuit, motors and accessories, contactors and relays, components of electric actuators.

LIVE LOADING, DIAGNOSTIC TESTING OF CONTROL VALVES, AIR AND MOTOR-OPERATED CONTROL VALVES

Live loading, valve maintenance.
AOV diagnostic testing, diagnostic system operation, control signal, hysterisis, bench set, I/P transducers, benefits of diagnostic testing, diagnostic system applications.
Motor-operated valves diagnostics

After Participating in his Course, You will be Able to:Size and select out of the various types of dynamic and positive displacement compressors using the performance characteristics and the selection criteria that you learn in the course.

Carry out diagnostic testing and inspection of critical components with the knowledge of common failure modes of compressors and bearings by applying advanced fault detection techniques.
Select bearings and lubrication, compressor sealing arrangements, meet commissioning requirements, conduct vibration and used oil analyses, troubleshoot, provide predictive and preventive maintenance, enhance reliability, and reduce cost.
Determine the maintenance required to minimize compressor downtime and operating cost and maximize its efficiency, reliability, and useful life.
Gain a thorough understanding of compressor surge and surge prevention systems.
Understand all the causes of failures in compressors.
Determine all the design features that improve the efficiency and reliability of all compressors.
Design different types of compressor systems.
Gain a thorough understanding of the various types of sealing arrangements used in compressors.

Instructor

Philip Kiameh, M.A.Sc., B.Eng., D.Eng., P.Eng. (Canada) has been a teacher at University of Toronto, Canada for 20 years. During this period, he taught courses and seminars to working engineers and professionals around the world. He wrote 6 books for working engineers. Four of them have been published by McGraw-Hill, New York.
Prof. Philip Kiameh performed research on power generation equipment with Atomic Energy of Canada Limited at their Chalk River and Whiteshell Nuclear Research Laboratories. He also has more than 27 years of practical engineering experience with Ontario Power Generation (formerly, Ontario Hydro - the largest electric utility in North America). While in Ontario Hydro, Prof. Philip Kiameh worked as Training Manager, Engineering Supervisor, System Responsible Engineer and Design Engineer. During this period, he was the manager of a section that provided training for the staff at the power stations. This training covered all the equipment and systems used in power stations. Philip was also responsible for the operation, maintenance, diagnostics, and testing of gas turbines, steam turbines, generators, motors, transformers, inverters, valves, pumps, compressors, instrumentation and control systems. Further, his responsibilities included designing, engineering, diagnosing equipment problems and recommending solutions to repair deficiencies and improve system performance, supervising engineers, setting up preventive maintenance programs, writing Operating and Design Manuals, and commissioning new equipment. Professor Philip Kiameh was awarded his Bachelor of Engineering Degree "with distinction" from Dalhousie University, Halifax, Nova Scotia, Canada. He also received a Master of Applied Science in Engineering (M.A.Sc.) from the University of Ottawa, Canada. He is also a member of the Association of Professional Engineers in the province of Ontario, Canada.

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Training Courses