Maintain Compressors and Pressure Valves

OVERVIEW

This course will equip attendees on the principles of the operation and maintenance of valves, and compressors one at a time. Valves,and compressors applications are extensively useful in many process industries. Understanding how to operate the valves, pumps & Compressors correctly as well as knowing the appropriate maintenance and troubleshooting methods are vital for trouble-free plant operation. During the course participant’s discussion, comments, and bringing up their own problems are welcomed and encouraged.

Power Plant and other petrochemical industries do deal with different types of valves. All piping systems are fitted with valves for controlling purposes or safety requirements. Understanding the function of each valve type will have an important reflection on the process quality, equipment and plant reliability, and the economics of the whole activity. Different application needs to select the appropriate valve type of a particular flow characteristics. Operation of the valve also affects the system and the process. Understanding the problems associated with valves is essential for diagnosis and troubleshooting and the needed maintenance for the particular type of valves.

OBJECTIVES

Attendees will be able to implement the following skills:

• Describe the behaviour and the technology of compressors,
• Provide the maintaining solutions applied in their compression units,
• Establish a diagnosis of the incidents and participate in the troubleshooting meetings.
• An understanding of valve characteristics and different parameters affecting the operation of valves
• Knowledge of the main types of valves and the ability to select the right valve for the particular application including Control Valves, Non-Return Valves and Safety Valves
• The ability to perform the necessary calculation for valve sizing
• Knowledge of valve control systems including actuators and positioned
• An understanding of the problems associated with valves like flashing, slamming and water hammer
• The ability to perform troubleshooting of systems involving valves and making decisions on the right maintenance plan concerning different types of valves

METHODOLOGY

• Functional approach for a better understanding.
• Interactive course.
• Numerous examples and cases studies from the Oil & Gas production industry and analysis of manufacturer file.

COURSE OUTLINE

Day 1

Valves Technology

Types of Valves (globe, gate, ball, plug, check) > Flow Characteristics

• Flow through Valves
•  Valve Flow Characteristics
• Linear, Quick Opening & Equal %

Valve Sizing

• Calculating the Correct CV Value
• Selecting Valve Size Using Valve Coefficient
• Calculations for Correct Valve Selection

Day 2

Sealing Performance

• Leakage Classifications
• Sealing Mechanisms
• Valve Stem Seals

Valves Troubleshooting & Maintenance

High-Pressure Drop

• Pressure Recovery Characteristics
• Flow Choking
• High Velocities
  High-Pressure Drop
  Pressure Recovery Characteristics
  Flow Choking
  High Velocities

Day 3

Water Hammer

• What causes water hammer?
• Solutions for Water Hammer

Troubleshooting the Control & Isolation Valves

• Review of Common Faults
• Developing a Preventive Maintenance Plan

Review of the Week & Wrap-Up

Day 4

Compressor working principles, types, operational aspects

• Classification, Types of compressors
• Operational principles and constructional features

Centrifugal compressors:

• Different types of centrifugal compressors.
• Component parts and architecture of a centrifugal compressor.
• Technology of the essential components: stater, rotor, bearings, thrust bearing, seals.
• Vibrations, critical speed, dynamic balancing.
• Auxiliary equipment: lubrication system, buffer gas, balancing line…
• Safety parameters: axial displacement, vibrations, bearing and thrust bearing temperatures, oil pressure…

Day 5

Reciprocating compressors:

• Different types of reciprocating compressors.
• Component parts and architecture of a reciprocating compressor.
• Technology of the essential components: cylinder, piston, valves, sealing systems, crankshaft, connecting rod…
• Auxiliary equipment: lubrication of motion parts and cylinders, cooling interstage and cooling devices systems, connections to the flare.

Rotary compressors:

• Different types: screw, liquid ring, lobes, sliding vanes…
• Component parts and architecture of a rotary compressor.
• Auxiliary equipment: lubrication system.
• Typical using.