Reciprocating Compressor : Performance, Control and Special Types


COURSE LEVEL 2 – INTERMEDIATE – Performance, Control, Special Types, Performance Softwares – 32 h
Instructor : Luis Infante (view profile)
Upcoming Session : –

Download Course Brochure :   LEVEL 2 

Reciprocating compressor training program intended for companies in the following areas :
• Chemical and gas processing,
• Gas Transportation
• Refining
• Oil and gas field operation
• Engineering projects and consulting

Forwarded to supervisors, engineers and technicians in operation, maintenance, engineering and selection of reciprocating compressors in the process/energy industry.

The overall objective is to increase operational reliability. The courses are geared towards the operator´s viewpoint, and are generic, non-linked to any brand or model while trying to cover the full OEM spectrum.

The other two levels for this training program are (32 hours each) :
Level 1  Basic : Fundamentals, Configuration & Components
Level 3  Advanced : Diagnostic and Optimization. Valve Behaviour

Levels 1 and 3 correspond to the degree of technical complexity and depth, and are sequential, IE, superior levels require the lower ones. Level 2 – Intermediate requires Level 1 – Basic.

Program oriented toward large size compressors.

Note: Another training program available in complementary area, namely, Electronic Condition Monitoring of Recip Compressors (200 h). Separate release available.

Once the stages have been configured, it is necessary to size the cylinders according to the desired flow or power, and next to check the performance of the various components and parameters, including pulsations.

Here is a comprehensive presentation of the available technology to control power and flow and how it is evolving to flexibilize and automate the machine.

Performance softwares have become a mandatory tool for the engineering of this critical machinery. These programs allow you to configure, size, monitor, diagnose malfunctioning and manage acceptance tests. This course explores popular softwares available as are Ariel Performance Software and ACI eRCM, together with Turbodina´s Maestro2.

Maestro2 is a Turbodina´s own development in simulating multistage reciprocating compressors performance. Not a commercial product.

The course introduces the special types of reciprocating compressors, components and the available technology to attenuate acoustic pressure pulsations in piping.

• Sequentially and completely familiarize the specialized engineer or technician with the reciprocating compression technology.
• Familiarize the attendant with the performance behaviour of the reciprocating compressors and main mechanical components, using characteristic curves and mechanical limits maps.
• Facilitate the ranking of the decision taking process (the most important first)

• Select the appropriate type and size of compressors and components for a given application.
• Understand / anticipate the behaviour of reciprocating compressors before changes in the process and the machine.
• Understand the available mechanisms to adapt compressors to new operating conditions and resolve recurring faults.
• Anticipate potential faults due to abnormal process conditions.
• Identify the most likely causes of failures.
• Identify those areas susceptible to improvements.
• Propose solutions to management on repetitive technical issues.
• Address operational emergencies related to compressors, in the absence of management.
• Compute the key engineering parameters for a proposed application.
• Effectively communicate the above, using the appropriate terminology.
• Select the appropriate bibliographic material.
• Once the operator has the characteristic curves for her/his machine, then she/he can:
• Quantify the flow and power supplied to the network by the compressor at any suction and discharge conditions within the operating range.
• Determine the effect of suction and discharge pressure fluctuations.
• Detect leakages in the dynamic seals of the cylinder with the help of an electronic analyzer.
• Establish design margins for rod overload and low volumetric efficiency regimes.
• Detect revealing signs of poor performance on valves.
• Find the effects of the poor performance in valves.
• Find solutions to poor performance on valves, thus increasing operational reliability.
• Conduct what if analysis.

• Increased operational staff productivity (added domain and motivation)
• Increased supervisory staff productivity (avoids having to go to the field in order to take decisions).
• Savings on parts.
• Increased Production (greater availability)

– Low flow
– High maintenance cost due to engine overload
– Crankshaft failures due to wrong load regime
– Rod breakage
– Valves
– Piston Rings
– Packings
– High discharge temp
– Human errors

• Sizing and preliminary selection
• Special Compresser Configurations and Applications
• Special Cylinder Assemblies
• Special Compresser Valve Designs
• Special Auxiliaries
• Special Drivers
• Couplings. Train Tensional
• Process Requirements And Compressor Design
• Capacity Control
• Performance System Design and Installation Requirements
• Process Requirements and Compressor Design
• Pulsation Attenuation

Wrong Sizing of a Reciprocating Compressor from Luis-Infante