Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Mechanical, Maintenance, and Reliability Engineers
• Rotating Equipment and Plant Engineers
• Maintenance Technicians and Supervisors
• Process and Utilities Engineers
• Equipment Inspectors and Condition Monitoring Specialists
• Anyone involved in screw compressor operation and maintenance

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Understand the operating principles and design of screw compressors
• Differentiate between oil-injected and oil-free compressor types
• Identify key components and their functions
• Perform routine maintenance and troubleshooting
• Analyze performance data and detect abnormalities
• Apply best practices to enhance reliability and efficiency

DAY 1

Screw Compressor Fundamentals and Operating Principles

• Principles of Gas Compression and Positive Displacement Compression 
• Role and Applications of Screw Compressors in Industry 
• Oil-Flooded and Oil-Free Screw Compressor Types 
• Single-Screw and Twin-Screw Designs 
• Compression Cycle and Thermodynamic Fundamentals 
• Rotor Profiles, Male and Female Rotor Interaction 
• Volume Ratio (Vi) and Compression Efficiency 
• Compressor Performance Characteristics and Operating Limits 
• Capacity Control, Load/Unload Operation, and Variable Volume Ratio Control 
• Major Components, Auxiliary Systems, Instrumentation, Safety Interlocks, and API 619 Requirements

DAY 2

Screw Compressor Operation and Performance Optimization

• Pre-Start Inspection and Commissioning Requirements 
• Safe and Effective Compressor Startup and Normal Operating Procedures 
• Monitoring Pressure, Temperature, Flow Rate, Power Consumption, and Vibration 
• Compressor Loading, Unloading, and Capacity Regulation Techniques 
• Volume Ratio and Compressor Efficiency Optimization 
• Performance Testing and Operating Curve Analysis 
• Energy Efficiency and Power Consumption Management 
• Lubrication Management, Oil Quality, and Cooling System Monitoring 
• Bearings, Seals, Mechanical Reliability, and Compressor Protection Systems 
• Operating Challenges, Corrective Actions, Condition Monitoring, and Reliable Operation Best Practices

DAY 3

Screw Compressor Troubleshooting, Inspection, and Maintenance

• Maintenance Philosophy and Preventive, Predictive, and Corrective Maintenance Strategies 
• Daily, Weekly, Monthly, and Annual Maintenance Activities 
• Maintenance Planning, Documentation, Safe Isolation, and Lockout/Tagout 
• Inspection of Rotors, Bearings, Shaft Seals, Couplings, Gears, and Drive Systems 
• Lubrication System, Filters, Separators, and Cooler Inspection and Maintenance Alignment, Mechanical Integrity, Clearance Measurement, and 
• Adjustment 
• Compressor Overhaul, Disassembly, Reassembly, Pressure Testing, and Verification 
• Troubleshooting Methodology and Root Cause Analysis 
• Diagnosis of High Temperature, Vibration, Noise, Reduced Capacity, Oil Leakage/Carryover, and Component Failures 
• Predictive Maintenance, Fault Identification, Reliability Improvement, and Case-Based Troubleshooting