Screw Compressor Maintenance Course

Lesson 1 • Compression Principles and Thermodynamics

Covers gas compression theory, pressure-volume relationships, and heat of compression. Establishes the thermodynamic basis needed for all subsequent maintenance decisions.

Lesson 2 • Compressor Package Components

Identifies auxiliary systems including oil separators, coolers, filters, and control panels. Provides the system-level view required before disassembly procedures are introduced.

Lesson 3 • Oil-Flooded vs. Oil-Free Variants

Distinguishes oil-flooded and oil-free designs by lubrication, sealing, and cooling methods. Prepares students to apply the correct maintenance approach for each type.

Lesson 4 • Screw Compressor Design Overview

Examines rotor profiles, casing geometry, and port timing. Connects mechanical design to performance characteristics students will diagnose later.

Lesson 1 • Pressure Vessel and Piping Compliance

Reviews pressure-equipment inspection requirements, relief valve mandates, and documentation standards. Students understand regulatory obligations before working on pressurised systems.

Lesson 2 • Permit-to-Work Systems

Explains confined-space, hot-work, and general maintenance permit workflows. Students complete sample permits to reinforce safe authorisation practices.

Lesson 3 • Hazard Identification and Risk Assessment

Covers pressure, thermal, electrical, and chemical hazards specific to screw compressors. Students complete a risk assessment before performing any maintenance task.

Lesson 4 • Lockout/Tagout and Energy Isolation

Details energy isolation procedures for electrical, pneumatic, and hydraulic sources. Correct LOTO execution is a prerequisite for all disassembly tasks in later sections.

Lesson 1 • Oil Sampling and Analysis Techniques

Covers sampling port selection, sample handling, and laboratory test interpretation. Students use analysis results to set condition-based oil change intervals.

Lesson 2 • Oil Separator Maintenance

Details coalescing element inspection, differential pressure monitoring, and replacement procedures. Separator condition directly affects oil carryover and downstream contamination.

Lesson 3 • Oil System Flushing and Changeout

Provides step-by-step procedures for draining, flushing, and refilling the oil circuit. Proper flushing prevents cross-contamination when switching lubricant types.

Lesson 4 • Oil Circuit Design and Flow Paths

Traces oil from the separator sump through injection, cooling, and filtration back to the rotors. Understanding flow paths enables accurate fault isolation in later diagnostic sections.

Lesson 1 • Rotor Profile Inspection and Measurement

Teaches visual inspection for scoring, corrosion, and profile wear, plus dimensional measurement techniques. Rotor condition directly determines compression efficiency and clearance settings.

Lesson 2 • Bearing Types and Inspection Criteria

Identifies radial and axial bearing types used in screw compressors and their failure modes. Students apply acceptance criteria to decide between reuse, reconditioning, and replacement.

Lesson 3 • Shaft Seal Inspection and Replacement

Covers mechanical seal and lip seal inspection, leakage assessment, and replacement procedures. Seal integrity prevents oil leakage and maintains internal pressure differentials.

Lesson 4 • Compressor Disassembly and Preparation

Covers safe depressurisation, coupling removal, and casing disassembly sequence. Correct disassembly order prevents component damage and preserves measurement accuracy.

Lesson 1 • Water-Cooled Heat Exchanger Maintenance

Addresses tube bundle inspection, scale removal, and pressure testing for shell-and-tube and plate coolers. Water quality and scale buildup are primary causes of cooling failure.

Lesson 2 • Cooling System Performance Verification

Teaches temperature and pressure differential testing to confirm restored cooling performance. Students document results against design specifications to validate maintenance effectiveness.

Lesson 3 • Inlet Air Filtration Maintenance

Covers filter element inspection, restriction monitoring, and replacement intervals for dry and oil-bath inlet filters. Inlet restriction reduces volumetric efficiency and accelerates rotor wear.

Lesson 4 • Thermostatic Valve Inspection and Testing

Explains thermostatic bypass valve function, testing methods, and replacement criteria. A failed thermostatic valve causes oil overheating or condensate formation in the oil circuit.

Lesson 1 • Coupling Inspection and Replacement

Identifies flexible element, jaw, and disc coupling types, their wear patterns, and replacement criteria. Coupling condition directly affects vibration transmission to compressor bearings.

Lesson 2 • Belt Drive Inspection and Tensioning

Covers belt wear assessment, sheave groove inspection, and tension measurement using deflection and frequency methods. Correct tension prevents slippage, overheating, and premature belt failure.

Lesson 3 • Shaft Alignment Techniques

Teaches dial indicator and laser alignment methods to achieve angular and parallel tolerances. Misalignment is a leading cause of premature bearing and seal failure in compressors.

Lesson 4 • Gearbox Inspection and Maintenance

Covers gear tooth inspection, backlash measurement, oil level checks, and breather maintenance for integral gearboxes. Gearbox condition affects rotor speed accuracy and noise levels.

Lesson 1 • Control System Architecture Overview

Maps the relationship between PLC or microprocessor controllers, sensors, actuators, and HMI displays. System architecture knowledge is required before sensor calibration and fault diagnosis.

Lesson 2 • Data Logging and Trend Analysis

Teaches extraction and interpretation of controller data logs to identify performance trends and early fault indicators. Trend analysis supports predictive maintenance scheduling decisions.

Lesson 3 • Solenoid Valve and Actuator Maintenance

Covers solenoid valve coil testing, spool inspection, and actuator stroke verification. Faulty actuators cause capacity control errors and unplanned shutdowns.

Lesson 4 • Pressure and Temperature Sensor Calibration

Covers calibration procedures for pressure transducers and temperature sensors using reference instruments. Accurate sensors are essential for correct capacity control and safety shutdown response.

Lesson 1 • Systematic Fault Diagnosis Methodology

Introduces structured fault-finding using symptom analysis, cause trees, and elimination logic. A repeatable diagnostic process reduces mean time to repair across all fault types.

Lesson 2 • Predictive Maintenance Planning

Integrates condition-monitoring data into a risk-ranked maintenance schedule with defined trigger thresholds. Students produce a complete predictive maintenance plan for a compressor package.

Lesson 3 • Performance Trend Monitoring

Tracks specific power, volumetric efficiency, and discharge temperature trends to detect internal wear. Performance degradation trends trigger targeted inspections before failure occurs.

Lesson 4 • Thermographic and Ultrasonic Inspection

Applies infrared thermography to detect hot spots and ultrasonic testing to find leaks and bearing defects. Non-contact methods enable inspection during normal compressor operation.