Centrifugal Compressor Design, Operation, Maintenance & Troubleshooting
Master API 617 Standard from Practical Case Studies & Engineering Exercises !
- Level
- Intermediate
- Type
- Classroom
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About Training
Upon completion of this course, participants will have gained a thorough understanding of the various centrifugal (i.e. turbo) compressor configurations available to virtually every industrial user. Items discussed include mechanical design features, sizing and application criteria, maintainability, reliability, vulnerability and troubleshooting issues. Participants will:
- Learn simple techniques and short-cut methods of machinery selection, which can take the place of tedious hand calculations and will serve as rapid means to determine sensitivity or influence of parameter changes on equipment performance.
- Be able to determine the most appropriate and efficient matching of compressor to driver.
- Also acquire knowledge of operating and maintenance issues by getting to know mechanical design, machinery components, piping design, as well as proven approaches to monitoring, troubleshooting and maintenance of compressor.
Training Objectives
Centrifugal Compressors of several types, which have widely varying configurations and applications, are used extensively in the process industries. These compressors represent a significant part of the capital and operating costs of most plants, so that optimizing their selection is of major economic importance.
- The course is devoted to design features, efficiencies, operating characteristics, reliability and maintenance implications of centrifugal compressors.
- This course will cover the operating principles of centrifugal compressors, specifications, their design, thermodynamics, effects of efficiency on operating costs, energy usage, effect on plant costs, special materials of construction, selection, troubleshooting and maintenance.
- The course will also cover plant run-length extension surveys, organizing for successful turnarounds and ongoing reliability improvement, and preventive vs. predictive maintenance strategy decisions.
- The course will provide the participant with a basic, as well as advanced, centrifugal and reciprocating compressor technology inventory required to successfully select, apply, troubleshoot and maintain compression equipment.
Audiences
This course is intended to be of direct use by persons in staff positions (e.g., Senior Technicians, Operators, Supervisors, Superintendents) and corporate engineering, plant planning and design, systems design, equipment selection and evaluation, and equipment maintenance areas.
Instructor
Mamdouh Motea Youssef
Mamdouh Motea Youssef is a Rotating Equipment's and Condition Monitoring Consultant with 43+ years of experience in the upstream oil and gas industry, in Machinery Maintenance and Vibration Analysis and 30 years experience in training field.
He began his career in 1981 as a Mechanical Maintenance Engineer at Egyptian Army. He has extensive hands-on experience in centrifugal compressor installation, alignment, commissioning, operation, maintenance, troubleshooting, and condition monitoring. His career includes leadership roles in major refinery and LNG projects, as well as machinery inspection, RCFA, vibration analysis, and predictive maintenance. Since 1998, he has been actively involved in technical training and OJT, and has delivered training across Egypt, Saudi Arabia, UAE, Kuwait, Oman, Iraq, Syria, and Libya.
From 2016 to 2018, he served as Chairman’s Assistant for Engineering Affairs at Ameria Petroleum Refining Company (APRC), Alexandria, Egypt. Since 2018, he has worked extensively as a Mechanical Instructor, Consultant, and Troubleshooting Engineer, delivering training in reliability and condition monitoring, including vibration analysis, thermography, oil analysis, and related disciplines. He also works as a Consulting Engineer for major oil and gas companies in Egypt and the Gulf region, supporting the diagnosis and resolution of complex issues involving rotating equipment.
Daily Aims
Overview
- Compression Methods
- Positive-Displacement And Rotodynamic Compressors
Introduction To Aerodynamics and positive displacement compressors
- Definition Of Compressor
- Compressors selection and sizing.
- Comparison between positive displacement and Rotodynamic compressors.
- Types Of positive displacement Compressors
- Reciprocating compressor
- Labyrinth compressor
- Diaphragm compressor
- Screw compressor
- Lobe compressor
- Slide vane compressor
- Relative Compressions Of Various Compressors Types
Consideration in Compressors Selection
- Discharge pressure required.
- Capacity required.
- Power supply characteristics.
- Availability and cost of cooling water.
- Space required for compressor.
- Compressor weight.
- Type and size of foundation required.
- Type of control required.
- Maintenance costs
- Budget
Case Study for Reciprocating Air Compressor
Centrifugal Compressor Fundamentals + API
- API 617 9th Edition - purpose, scope and four-part structure
- API terminology and datasheets
- Purchaser/vendor responsibilities
- API 617 mechanical-design philosophy
Case Study : Selecting an API 571 Centrifugal
Principles of centrifugal compressors
- Type of Turbo machinery
- The Eulers’ Equation
- The degree of reaction
- Theoretical H-Q Curve
- Theoretical Power-Q curve
- The effect of outlet blade angle
- Function of the diffuser
Centrifugal Compressors Technology
- Basic Components and their function
- Centrifugal Classification
- Compressors Arrangements
- Performance Curves
- Surge line and Stonewall
- Speed limits
- System Resistance
- Inlet Conditions Effects
- Required Speed Calculation
- Parallel and Series Operation
Centrifugal Compressor Design and Construction
- Function of Compressor components
- Compressor Casing
- Casing
- Diaphragms
- Nozzles
- Compressor Rotor
- Shaft
- Impellers
- Balancing Piston
- Thrust Collar
Case Study For LNG Centrifugal Compressor
Compressor arrangements
- Auxiliary Systems
- Compressor Seals
- Compressor Bearing
- Lubrication Systems
- Loop Oil Systems
Centrifugal Compressor Performance & Control
- The Performance Curves
- Limits of Flow rates
- Surge line and Stone line
- Limits of operating speed
- First and second critical frequency
- Effect of speed variation
- Effect of inlet conditions
- Effect of gas molecular weight
- Volume ratio effect
- Performance of different types of compressors
- How compressor components affect performance
- Performance estimation
Case Study For VRU centrifugal Compressor
Compressors Control System
- Capacity Regulation System
- Anti - Surge control system
- Alarm and trip System
- Vibration control system
- Bentley Nevada system
- Vibration instrumentation
- Velocity transducer
- Accelerometer
- Proximity probe
Compressors shaft alignment and dynamic balancing
Compressors operation (start up and shutdown)
- The compressor permissive to start
- Typical compressor valve arrangement
- Prestart valve positions
- Purge cycle
- The anti surge control valve position
- Normal start up
- Normal shut down
- Emergency shut down
Case Study for Refrigeration Compressor
Troubleshooting and Maintenance
- Non Destructive Inspection Troubleshooting
- Principles of troubleshooting
- Lubrication systems
- Seals System
- Cleaning and Flushing
- Alignment and Balancing
- Condition monitoring systems
- Pressure and temperature measurements
- Effective Diagnoses systems
- Vibration Analysis
- Auxiliary System monitoring
Case Studies & Discussions, Last Day Review will be carried out.
The support tools four video movie about the principle and maintenance of the centrifugal compressors.
Training Schedule
| Code | Start Date | End Date | Locations | Cost | Instructor |
|---|---|---|---|---|---|
| PST0451-202601 | Kuala Lumpur, Malaysia | USD 3,450 | Mamdouh Motea Youssef |
Why Choose This Training
Credibility
Align with API/ASME standards. Trusted by major operators.
Expert Instructors
Led by industry veterans with real field experience.
Real Case Studies
Practical application of concepts through real world scenarios.
Practical Skills
Hands on calculations and decision making for FFS outcomes.
Trusted by Operators
Delivered to Aramco, ADNOC, SABIC, and other major operators.
Global Training Standard
Recognized across major industries by PetroSync's proven approach.
Professional Training Aligned with Industry Standards
Practical, industry ready training designed for real work environments
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