Compressor Types, Design, Operation, Troubleshooting & Maintenance: Professional 5-Day Training Course

Advanced Compressor Engineering Program for KSA, Oman, GCC & Africa

Course Overview

This intensive Compressor Types, Design, Operation, Troubleshooting and Maintenance course provides comprehensive training for professionals across Saudi Arabia (KSA), Oman, UAE, Qatar, Kuwait, Bahrain, and Africa. Designed for compressor engineers, maintenance technicians, operations specialists, and rotating equipment professionals in the oil, gas, petrochemical, and industrial sectors, this program covers all compressor technologies, performance optimization, predictive maintenance, and advanced troubleshooting methodologies.

Target Audience: Compressor engineers, mechanical engineers, reliability engineers, maintenance supervisors, operations managers, and technical professionals in oil and gas facilities, petrochemical plants, and industrial complexes across the Middle East and African energy sectors.

Day 1: Compressor Fundamentals & Classification

Morning Session: Thermodynamic Principles & Compressor Types

• Gas compression fundamentals: thermodynamic cycles, isothermal vs. adiabatic compression

• Compression principles: pressure ratio, volumetric efficiency, isentropic efficiency

• Compressor classification: positive displacement vs. dynamic compressors

• Applications in Saudi Arabia, Oman, GCC: oil and gas production, gas transmission, refrigeration

• Industry standards: API 617, API 618, API 619, ASME, ISO compliance requirements

• Performance parameters: capacity, head, power consumption, efficiency calculations

• Selection criteria for upstream, midstream, and downstream applications

• Compressor terminology and technical specifications

Afternoon Session: Compressor Types Overview

• Centrifugal compressors: single-stage, multi-stage, integrally geared designs

• Reciprocating compressors: single-acting, double-acting, horizontal, vertical configurations

• Screw compressors: oil-flooded, oil-free, twin-screw technology

• Rotary vane compressors: applications and limitations

• Axial compressors: industrial gas turbine applications, power generation

• Scroll compressors: refrigeration and HVAC applications

• Diaphragm compressors: specialty gas and high-purity applications

• Comparison matrix: advantages, disadvantages, and selection guidelines

• Case studies from Saudi Aramco, PDO Oman, and African gas facilities

Day 2: Compressor Design & Engineering

Morning Session: Centrifugal Compressor Design

• Impeller design: open, closed, semi-open configurations, blade geometry

• Diffuser types: vaneless, vaned, volute design considerations

• Stage analysis: velocity triangles, slip factor, diffusion ratio

• Performance curves: head-capacity curves, surge, stonewall, operating range

• Materials of construction: impeller materials, casing design, shaft metallurgy

• Sealing systems: dry gas seals, labyrinth seals, oil seals

• Bearing systems: journal bearings, thrust bearings, magnetic bearings

• Anti-surge systems: detection, control, recycle valve sizing

• Applications in GCC gas processing and LNG facilities

Afternoon Session: Reciprocating Compressor Design

• Cylinder design: bore, stroke, clearance volume optimization

• Valve types: plate valves, poppet valves, ring valves, channel valves

• Piston and rod design: materials, coatings, rod load analysis

• Crankshaft and connecting rods: stress analysis, balancing requirements

• Capacity control methods: clearance pockets, variable speed, suction valve unloaders

• Cooling systems: water jackets, intercoolers, aftercoolers

• Lubrication systems: cylinder lubrication, crankcase lubrication

• Pulsation control: bottle design, acoustic filters, piping layout

• Applications in Saudi refineries and African gas compression

Day 3: Compressor Operation & Performance Monitoring

Morning Session: Operating Procedures & Best Practices

• Pre-start inspection checklists and safety protocols for KSA and GCC facilities

• Normal startup procedures: purging, pressurization, loading sequences

• Steady-state operations: load optimization, efficiency monitoring, parallel operation

• Shutdown procedures: normal, emergency, emergency depressurization

• Operating envelope: surge limit, choke limit, maximum speed, temperature limits

• Load sharing in multiple compressor installations

• Operational challenges: high ambient temperatures in Middle East, sand ingestion, corrosive gases

• Process integration: upstream/downstream equipment coordination

• Fuel gas compression for power generation in UAE and Qatar

Afternoon Session: Performance Testing & Monitoring

• Performance testing: API standards, acceptance tests, field performance verification

• Key performance indicators (KPIs): efficiency, capacity, pressure ratio, power consumption

• Instrumentation: pressure transmitters, temperature sensors, flow meters, vibration probes

• Surge detection and prevention: monitoring systems, anti-surge valve operation

• Vibration monitoring: displacement, velocity, acceleration measurements

• Temperature monitoring: bearing temperature, discharge temperature, critical points

• Pressure pulsation monitoring: in reciprocating compressor systems

• Real-time monitoring systems: SCADA integration, DCS interface, condition monitoring platforms

• Performance degradation tracking in Oman PDO and African installations

Day 4: Compressor Maintenance Strategies

Morning Session: Preventive & Predictive Maintenance

• Maintenance philosophy: time-based, condition-based, reliability-centered maintenance (RCM)

• Inspection intervals: minor inspections, major overhauls, component life cycles

• OEM maintenance recommendations: GE, Siemens, Atlas Copco, Ingersoll Rand, Dresser-Rand

• Maintenance planning for continuous operations in petrochemical plants

• Spare parts management: critical spares inventory, lead times, vendor management

• Outage planning and scheduling for Saudi Aramco and GCC facilities

• Lubrication management: oil analysis programs, contamination control, oil change intervals

• Alignment procedures: laser alignment, coupling alignment, foundation checks

Afternoon Session: Condition Monitoring Techniques

• Vibration analysis: FFT analysis, time waveform, orbit analysis, trending

• Oil analysis: wear metals, viscosity, contamination, additive depletion

• Thermography: bearing temperature, motor temperature, hot spot detection

• Acoustic monitoring: ultrasonic leak detection, valve condition, bearing noise

• Performance monitoring: efficiency degradation, capacity loss, pressure drop trends

• Valve condition monitoring: reciprocating compressor valve health assessment

• Seal gas monitoring: dry gas seal performance, leakage detection

• Predictive analytics: machine learning, AI-driven maintenance in Saudi smart facilities

• Non-destructive testing (NDT): ultrasonic thickness, magnetic particle, dye penetrant

Day 5: Troubleshooting, Failure Analysis & Advanced Topics

Morning Session: Systematic Troubleshooting Methodology

• Common centrifugal compressor problems: surge, fouling, seal failures, bearing issues

• Reciprocating compressor issues: valve failures, piston ring wear, rod load problems

• Screw compressor problems: rotor wear, bearing failures, capacity loss

• Vibration troubleshooting: unbalance, misalignment, resonance, rotor rub, looseness

• Performance problems: capacity reduction, pressure issues, efficiency degradation

• Seal system failures: dry gas seal leakage, contamination, face damage

• Cooling system issues: fouling, inadequate cooling, temperature excursions

• Control system malfunctions: anti-surge valve issues, capacity control problems

• Root cause analysis (RCA): fishbone diagrams, 5-why analysis, failure investigation

Afternoon Session: Major Overhauls & Future Technologies

• Major overhaul procedures: disassembly, inspection, dimensional checks, acceptance criteria

• Centrifugal compressor overhaul: impeller inspection, diffuser cleaning, seal replacement, bearing renewal

• Reciprocating compressor overhaul: valve replacement, piston/rod inspection, cylinder honing, crankshaft inspection

• Balancing procedures: field balancing, shop balancing, dynamic balancing

• Clearance measurements: axial clearance, radial clearance, valve clearances

• Reassembly best practices: torque specifications, assembly sequence, quality checks

• Post-overhaul testing: mechanical run test, performance testing, vibration acceptance

• Upgrade opportunities: efficiency improvements, capacity enhancement, emissions reduction

• Digital transformation: IoT sensors, digital twins, predictive maintenance platforms

• Energy efficiency optimization for sustainability initiatives in Saudi Vision 2030

• Hydrogen compression technologies for future energy transition in GCC

• Carbon capture applications in Middle Eastern and African facilities

• Course review, final Q&A, and certification

Learning Outcomes

Upon completion, participants will master:

• Comprehensive knowledge of all compressor types and technologies

• Design principles and performance characteristics

• Operational excellence and optimization techniques

• Advanced troubleshooting and diagnostic methodologies

• Preventive and predictive maintenance strategies

• Failure analysis and root cause investigation

• Safety protocols and industry best practices

Why Choose This Course for KSA, Oman, GCC & Africa?

✅ Comprehensive coverage of all industrial compressor technologies
✅ Region-specific content addressing desert operations, high temperatures, and corrosive environments
✅ Expert instructors with extensive experience in Saudi Aramco, PDO, ADNOC, and African petroleum companies
✅ Practical case studies from Middle Eastern and African oil, gas, and petrochemical facilities
✅ Hands-on troubleshooting scenarios and real failure analysis examples
✅ API and international standards alignment for global competency
✅ Internationally recognized certification enhancing career opportunities
✅ Networking opportunities with regional compressor professionals

Target Industries & Applications

• Upstream oil and gas: wellhead compression, gas lift, associated gas compression in KSA and Oman

• Gas processing plants: acid gas removal, gas dehydration, NGL extraction across GCC

• LNG facilities: refrigeration compression, boil-off gas compression in Qatar

• Gas transmission: pipeline compression, storage facilities throughout Middle East

• Refineries: hydrogen compression, catalytic reforming, FCC operations in Saudi refineries

• Petrochemicals: ethylene plants, ammonia production, methanol synthesis in SABIC facilities

• Power generation: gas turbine fuel gas compression, air compression in UAE power plants

• Industrial facilities: compressed air systems, nitrogen generation across Africa

Certification & Accreditation

Participants receive an internationally recognized certificate in Compressor Types, Design, Operation, Troubleshooting and Maintenance, highly valued by employers across Saudi Arabia’s energy sector, Oman’s oil and gas industry, GCC petrochemical companies, and African industrial markets.

Enroll now to master compressor technologies critical to Middle Eastern and African oil, gas, and industrial operations!