Compressor Course

Lesson 1 • Thermodynamic Principles of Compression

Examines isothermal, adiabatic, and polytropic compression processes. Links thermodynamic theory to practical energy requirements in compressor design.

Lesson 2 • Properties of Compressible Gases

Covers ideal and real gas laws, molecular behaviour, and compressibility factors. Establishes the physical basis for all subsequent compression calculations.

Lesson 3 • Pressure, Temperature, and Flow Relationships

Defines pressure ratios, temperature rise, and volumetric flow conversions. Provides the measurement vocabulary used throughout the course.

Lesson 1 • Capacity Control Methods

Explains unloaders, clearance pockets, speed variation, and suction valve unloading. Matches control strategy to process demand and energy cost.

Lesson 2 • Volumetric Efficiency and Clearance

Calculates volumetric efficiency from clearance volume, pressure ratio, and gas properties. Demonstrates how clearance pockets affect capacity.

Lesson 3 • Mechanical Components and Assembly

Identifies pistons, cylinders, crankshafts, connecting rods, and crossheads. Connects component geometry to force transmission and stroke mechanics.

Lesson 4 • Piston Rod and Packing Systems

Details rod loading, packing ring materials, and lubrication requirements. Rod load limits protect crankshaft and frame integrity.

Lesson 1 • Rotary Vane and Lobe Compressors

Covers sliding-vane geometry, lobe rotor profiles, and their respective pressure and flow limits. Positions these machines relative to screw compressors in the selection matrix.

Lesson 2 • Scroll Compressor Operation

Describes fixed and orbiting scroll geometry, compression pockets, and discharge timing. Scroll machines are common in low-capacity, oil-free applications.

Lesson 3 • Twin-Screw Compressor Principles

Explains male and female rotor meshing, built-in volume ratio, and axial flow path. Internal compression ratio determines efficiency at a given pressure ratio.

Lesson 4 • Oil-Flooded vs. Oil-Free Screw Designs

Contrasts oil injection for sealing and cooling against dry-running designs with timing gears. Purity requirements drive the selection between these two configurations.

Lesson 1 • Multi-Stage Compressor Configurations

Covers interstage cooling, intercoolers, and sidestream arrangements in multi-stage machines. Staging strategy balances compression work and discharge temperature limits.

Lesson 2 • Impeller Aerodynamics and Euler Work

Applies Euler turbomachinery equation to relate blade geometry to head and work input. Velocity triangles are the core analytical tool for impeller design.

Lesson 3 • Diffuser and Volute Design

Explains kinetic energy recovery in vaneless and vaned diffusers and the volute. Diffuser geometry strongly influences stage efficiency and operating range.

Lesson 4 • Surge, Stall, and Choke

Defines surge line, stall inception, and choke limit on the compressor map. Understanding these boundaries is essential for safe and efficient operation.

Lesson 1 • Blade Profile Aerodynamics

Covers NACA and controlled-diffusion airfoil profiles, incidence, and deviation angles. Profile losses determine stage efficiency and stall margin.

Lesson 2 • Stall and Surge in Axial Machines

Distinguishes rotating stall from surge and explains their onset mechanisms in axial stages. Stall margin is the primary design safety parameter.

Lesson 3 • Multi-Stage Matching and Off-Design

Analyses stage stacking, mismatching at off-design speeds, and remediation strategies. Front-stage stall at low speed is a key multi-stage challenge.

Lesson 4 • Variable Inlet Guide Vanes and Stators

Explains how variable geometry shifts the surge line and extends the operating range. Scheduling logic links vane angle to speed and pressure ratio.

Lesson 1 • Lube Oil System Design

Details oil reservoir, pumps, coolers, filters, and pressure control for bearing lubrication. Oil system reliability directly determines compressor availability.

Lesson 2 • Labyrinth and Buffered Seal Designs

Describes labyrinth tooth geometry, buffer gas injection, and leakage rate estimation. These seals are used where small leakage is acceptable.

Lesson 3 • Bearing Types and Lubrication Requirements

Compares journal, tilting-pad, and rolling-element bearings and their oil film requirements. Bearing selection affects rotor dynamics and maintenance intervals.

Lesson 4 • Dry Gas Seal Systems

Explains spiral-groove geometry, gas film stiffness, and seal gas supply requirements. Dry gas seals are standard on modern high-speed centrifugal compressors.

Lesson 1 • Anti-Surge Control System Design

Defines the surge control line, recycle valve sizing, and response time requirements. Anti-surge control is the primary protective system for dynamic compressors.

Lesson 2 • Safety Shutdown and Alarm Systems

Defines trip logic, alarm setpoints, and safety instrumented function requirements for compressors. Protective systems must meet process safety integrity targets.

Lesson 3 • Speed and Capacity Control Strategies

Covers variable-speed drives, inlet guide vane control, and throttling for capacity regulation. Each method has distinct efficiency and range implications.

Lesson 4 • Load Sharing Between Parallel Compressors

Explains equal-surge-margin and equal-head load-sharing strategies for parallel machines. Proper load sharing prevents one machine from surging whilst another is overloaded.

Lesson 1 • Rotor Balancing and Alignment

Explains single-plane and multi-plane balancing, residual unbalance limits, and shaft alignment methods. Unbalance and misalignment are leading causes of bearing failure.

Lesson 2 • Spare Parts and Maintenance Planning

Defines critical spare classification, inventory strategy, and maintenance work order systems. Spare parts availability directly affects mean time to repair.

Lesson 3 • Failure Mode and Root Cause Analysis

Applies failure mode analysis and root cause investigation to compressor incidents. Identifying root causes prevents recurrence and improves maintenance strategy.

Lesson 4 • Condition Monitoring Techniques

Covers vibration analysis, thermodynamic performance trending, and oil analysis for early fault detection. Monitoring data drives predictive maintenance decisions.