CENTRIFUGAL COMPRESSOR MAINTENANCE AND FAILURE ANALYSIS

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

System Safety Analysis

Human Error
Routine Operations
Emergency Operations

Methods of Analysis

Failures Modes and Effects Analysis (FMEA)
Event Trees
Fault trees

Fault-Tree Construction

Nomenclature
Fault classification
Example

Analysis of in-service experience for repairable systems :

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

INSTRUCT0R & CV

Ir. Joko Waluyo, MT., Ph.D & Team

Formal Education

Education S-1 : Mechanical Engineering, University of Technology Petronas (UTP).
Education S-2 : Mechanical Engineering, Universitas Gajah Mada

Teaching Experience

Teaching several subject both for mechanical and Industrial engineering, at the course:

Fluid Mechanics
Pump and Compressor
- Pressure Vessel and Pipping
- Probability and Statistic
- Piping Networks, and Operation Research.
Experience in Training
- Plant Engineering
- Construction and Operation of Oil and Gas Exploration and Production Plant
- Contraction and Maintenance
- Pipping Design
- Contruction and pre-commisioning based on code oil and gas exploration and production plant
- construction of Oil and Gas equipments projects.

METHODS

In class, discussion, case study, praktikum

PARTICIPANT

Operators, Supervisors, and Engineers

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CENTRIFUGAL COMPRESSOR MAINTENANCE AND FAILURE ANALYSIS