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CBF127: Compressor, Blower, and Fan Maintenance Training Course
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CBF127: Compressor, Blower, and Fan Maintenance Training Course

Contact Us Today: info@PiControlSolutions.com, Tel: (832) 495 6436

Duration: 2 Days Classroom or 16 hours Online
Audience: Maintenance Engineers, Mechanical Technicians, Plant Engineers, Compressor Operators, Industrial Maintenance Staff, and Supervisors.
Prerequisites: Basic mechanical knowledge and/or a 3-year associate's diploma in a technical field. Some experience with rotating machinery is preferred.
Course Material: Compressor maintenance training slides and certificate of completion.

Course Description:

This comprehensive industrial compressor servicing training course covers all aspects of compressor, blower and fan maintenance for industrial applications. Participants will learn about different types of compressors, including reciprocating, centrifugal, rotary screw, and positive displacement systems. The course emphasizes preventive maintenance strategies, compressor inspection and testing techniques, and safety procedures.

Students will understand the importance of proper maintenance in extending equipment life, reducing downtime, and improving compressor reliability and efficiency. The training includes hands-on components covering disassembly, compressor overhaul services, repair procedures, and reassembly techniques. Special focus is given to lubrication systems, capacity control, vibration analysis techniques, surge protection, and component identification.

Learning Outcomes

By the end of the course, attendees will possess comprehensive skills in industrial compressor operation and care, and troubleshooting. Participants will understand the difference between positive displacement and dynamic compressors, including reciprocating, centrifugal, rotary screw, and dynamic compression systems, along with their operational principles and maintenance needs.

Students will grasp preventive maintenance schedules, routine compressor inspection and testing procedures, and be equipped to perform daily, weekly, monthly, quarterly, and yearly maintenance tasks. Attendees will gain expertise in troubleshooting common problems in reciprocating compressors and solutions, such as how to troubleshoot high discharge pressure in compressors, vibration problems, and surge conditions.

Participants will learn about oil analysis and monitoring for compressor lubrication systems, best lubrication practices for rotary screw compressors, oil selection, filtration requirements, and proper bearing maintenance. Students will also master safety procedures, lockout/tagout requirements, and emergency shutdown and safety procedures for compressors.

The course will enable attendees to develop maintenance programs, interpret predictive maintenance tools for industrial compressors, and implement energy efficiency optimization in compressor systems.

Syllabus

Introduction to Compressor Maintenance

  • Gas compressor fundamentals
  • Compressor vs pump differences
  • Maintenance training overview
  • Component identification and function
  • Benefits of proper maintenance
  • How to extend compressor life through preventive maintenance
  • Life cycle cost analysis

Important Definitions and Technical Terms

  • Physical units (pressure, temperature)
  • Bernoulli's principle applications
  • Specific heat capacity calculations
  • Gas laws (Boyle's, Charles, Ideal Gas Law)
  • Heat transfer principles (conduction, convection, radiation)
  • Dew point and humidity relationships

Types of Compressors

  • Positive displacement vs dynamic compression
  • Reciprocating piston compressors
  • Single-stage and two-stage systems
  • Rotary screw compressors
  • Centrifugal compressors
  • Multi-stage compression systems
  • Compressor selection criteria

Compressor Peripherals

  • Seals (wet seals, dry seals, single, tandem, double)
  • Bearings and bushings
  • Motor bearings and lubrication
  • Filtration systems (inlet filters, air line filters)
  • Drain traps and moisture separators
  • Aftercoolers and intercoolers
  • Air dryers (refrigerated, desiccant)

Start Up and Safety Procedures

  • Pre-startup checklists
  • Safety equipment requirements
  • Lockout/tagout procedures
  • Safety valve operation and selection
  • Pressure vessel safety
  • Emergency shutdown procedures

Compressor Troubleshooting

  • Systematic troubleshooting approach
  • Common problems and solutions
  • Vibration analysis and monitoring
  • Performance testing procedures
  • Diagnostic tools and techniques
  • Root cause analysis methods

Preventive Maintenance Programs

  • Maintenance scheduling and planning
  • Preventive maintenance checklist for centrifugal compressors
  • Daily, weekly, and monthly inspection routines
  • Oil change intervals and procedures
  • Filter replacement schedules
  • Belt tension and alignment
  • Valve maintenance and testing

Compressor Surge

  • Surge phenomena and causes
  • Vibration monitoring systems
  • Compressor surge control methods and protection systems
  • Recirculation valve operation
  • Protection and safety systems
  • Surge margin calculations

Industrial Blowers

  • Blower types and applications
  • Positive displacement blowers
  • Centrifugal and multi-stage blowers
  • Axial and regenerative blowers
  • Vapor recovery systems
  • Blower types and their maintenance requirements

Lubrication and Oil Systems

  • Compressor lubricant types
  • Synthetic hydrocarbons (PAO)
  • Polyol esters and polyglycols
  • Oil selection criteria
  • Oil analysis and monitoring
  • Contamination control

Maintenance Checklists and Record Keeping

  • Daily maintenance procedures
  • Weekly inspection routines
  • Monthly and quarterly checks
  • Step-by-step guide to compressor disassembly and inspection
  • Annual overhaul procedures
  • Documentation requirements
  • Maintenance record systems

Remote Monitoring and Predictive Maintenance

  • Modern monitoring technologies
  • Data-driven maintenance strategies
  • Condition-based maintenance
  • Energy efficiency optimization
  • Energy efficiency optimization
  • Integration with plant systems
  • Future maintenance trends

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