Course Details

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

• Mechanical and Maintenance Engineers
• Rotating Equipment and Reliability Engineers
• Process and Operations Engineers
• Maintenance Supervisors and Technicians
• Condition Monitoring and Vibration Analysts
• Anyone responsible for the operation, inspection, or troubleshooting of centrifugal compressors

• 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:

• Differentiate between various rolling element and plain bearing types and select the most appropriate bearing for specific industrial applications.
• Master lubrication fundamentals, including oil and grease properties, application methods, and contamination control.
• Conduct systematic disassembly, inspection, and reassembly procedures for various bearing installations.
• Identify, classify, and determine the root causes of all common bearing failure modes (e.g., fatigue, wear, corrosion).
• Apply modern predictive and preventive maintenance techniques, including vibration analysis and thermography, to monitor bearing health.
• Develop and implement a proactive bearing reliability program to reduce costs and improve machinery efficiency.

DAY 1

Centrifugal Compressor Fundamentals and Performance

• Role, applications, and classifications of centrifugal compressors in industrial plants 
• Gas compression principles, thermodynamics, and centrifugal compression fundamentals 
• Major compressor components: impellers, diffusers, casings, rotors, bearings, seals, and couplings 
• Impeller and diffuser functions and their influence on compressor performance 
• Compressor performance parameters: capacity, flow, pressure ratio, head, efficiency, and power 
• Performance curves, operating limits, and interpretation of compressor maps 
• Compressor piping systems, auxiliary systems, and associated components 
• Compressor control, monitoring, and key operating parameters 
• Factors affecting compressor performance, efficiency, and reliability 
• Practical evaluation of compressor performance and identification of performance deterioration

DAY 2

Centrifugal Compressor Design, Operation, Surge Control, and Troubleshooting

• Mechanical design features and configuration of centrifugal compressors 
• Rotor dynamics, balancing requirements, and critical speed considerations 
• Impeller design considerations, side streams, and internal flow paths 
• Bearing, seal, coupling, and dry gas seal arrangements 
• Multi-stage compressor configurations and operating considerations 
• Lubrication, sealing, and auxiliary systems 
• Normal and off-design operating conditions and operating best practices 
• Stonewall/choke and surge conditions: characteristics, causes, and consequences 
• Anti-surge control systems, surge prevention, and operational response 
• Systematic troubleshooting, fault diagnosis, and early detection of operating problems

DAY 3

Centrifugal Compressor Maintenance, Reliability, Condition Monitoring, and Troubleshooting

• Centrifugal compressor inspection requirements and maintenance strategies 
• Compressor train maintenance, shutdown, overhaul, and reassembly fundamentals 
• Inspection and assessment of rotors, impellers, bearings, seals, casings, and couplings 
• Common failure mechanisms: vibration, seal and bearing failures, fouling, erosion, and corrosion 
• Vibration analysis and condition monitoring for compressor health assessment 
• Performance monitoring, operating trends, and early fault identification 
• Preventive and predictive maintenance planning and execution 
• Root Cause Failure Analysis (RCFA) for recurring compressor problems 
• Advanced troubleshooting using practical compressor failure and performance case studies 
• Strategies for improving compressor efficiency, availability, reliability, and long-term asset performance