h1>TRAINING CENTRIFUGAL COMPRESSOR MAINTENANCE AND FAILURE ANALYSIS

h2>TRAINING GENERAL DESCRIPTION OF AIR COMPRESSION THEORY

TRAINING FUNDAMENTAL KNOWLEDGE OF COMPRESSOR PRINCIPLE

COURSE DESCRIPTION

Centrifugal compressors play a very essential role in many petrochemical and industrial plants.    Centrifugal compressors runs at very high speeds, exposed to high temperature due to gas (air) compression. Their operation is confined between the Surge and Stonewall limits. The compressor performance also is affected by the variation in operating conditions. These make it very important to learn and understand the centrifugal compressor more deeply for smooth and free trouble operation.

Failure analysis to provide basic concepts, principles, and to introduce the techniques and methodology of reliability assessment and evaluation as applied to mechanical components, equipment, and mechanical plant systems and sub-systems. To improve the understanding of failures as related to their  nodes, causes and effect.

COURSE 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 systematically to analyze root cause of compressor failure
COURSE OUTLINE

Fundamental of thermodynamic
Compression process and work – Isothermal
Adiabatic
Polytrophic
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
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
Gas turbine compressor
Centrifugal compressor
Axial compressor
Compressor performance
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
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
eciprocating 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
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
Operation
Procedure to run and to stop compressor
Capacity control device
Hazard prevention
Automatic operation
Maintenance
Preliminary inspection
Operating condition inspection
Preventive maintenance
Predictive maintenance
Troubleshooting
Introduction
Implications of mechanical reliability
Definition of mechanical reliability
Reliability and rates of failures
11. System Safety Analysis

Human Error
Routine Operations
Emergency Operations
12.Methods of Analysis

Failures Modes and Effects Analysis (FMEA)
Event Trees
Fault trees
13.Fault-Tree Construction

Nomenclature
Fault classification
Example
14.Analysis of in-service experience for repairable systems :

A note on “ failure rate “
Reliability analysis under constant failure rate
System availability
METHODS

In class, discussion, case study, praktikum

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Operators, Supervisors, and Engineers

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