Pideya Learning Academy

Inspection and Overhaul of Compressor Systems

Upcoming Schedules

  • Live Online Training
  • Classroom Training

Date Venue Duration Fee (USD)
20 Jan - 24 Jan 2025 Live Online 5 Day 2750
31 Mar - 04 Apr 2025 Live Online 5 Day 2750
14 Apr - 18 Apr 2025 Live Online 5 Day 2750
30 Jun - 04 Jul 2025 Live Online 5 Day 2750
21 Jul - 25 Jul 2025 Live Online 5 Day 2750
29 Sep - 03 Oct 2025 Live Online 5 Day 2750
10 Nov - 14 Nov 2025 Live Online 5 Day 2750
24 Nov - 28 Nov 2025 Live Online 5 Day 2750

Course Overview

Compressor systems are indispensable components of modern industrial operations, supplying compressed air and gas required for driving processes across oil and gas production, petrochemicals, energy generation, and manufacturing plants. Their uninterrupted performance ensures not only productivity but also operational safety and energy efficiency. With these systems operating under high pressure and extreme mechanical loads, the risks associated with component failure, performance degradation, and downtime are considerable. Therefore, a well-structured maintenance and overhaul strategy is essential to ensure optimal functioning and cost-effective asset management.
To address this critical industry need, Pideya Learning Academy offers the Inspection and Overhaul of Compressor Systems training—a highly specialized course tailored to build advanced competencies in managing the performance and reliability of compressor equipment. The course equips participants with technical knowledge and maintenance strategies that align with global engineering and safety standards.
Industrial trends reinforce the importance of this subject area. A 2023 study by Grand View Research valued the global industrial air compressor market at over USD 32 billion, forecasting a CAGR of 4.5% through 2030. Simultaneously, research from the International Society of Automation (ISA) reveals that unplanned equipment failures cost manufacturers an estimated USD 50 billion annually. A significant proportion of this loss is linked to inadequate preventive maintenance and inspection programs—underscoring the need for a skilled workforce capable of implementing systematic and proactive overhaul procedures.
The Inspection and Overhaul of Compressor Systems course from Pideya Learning Academy delivers in-depth coverage of compressor types, configurations, internal mechanisms, and performance monitoring techniques. Participants will benefit from a structured and insightful learning experience that blends theory with real-world industry insights. Key highlights of the training include:
Comprehensive understanding of compressor classifications, mechanical assemblies, and typical wear and failure patterns.
Structured methodologies for planning and conducting major inspections and overhauls, including teardown and reassembly protocols.
Introduction to vibration analysis, thermodynamic performance diagnostics, and condition monitoring for predictive maintenance.
Detailed review of safety practices and compliance with ISO/ASME mechanical integrity standards.
Techniques to develop and implement preventive maintenance programs that maximize uptime and minimize operating costs.
Case-based learning on failure root causes and maintenance optimization strategies derived from actual field operations.
Application of data-driven decision-making tools to prioritize interventions and support lifecycle asset management.
The program’s content is carefully curated to support professionals in improving their diagnostic accuracy, boosting equipment availability, and reducing the likelihood of unscheduled downtimes. Moreover, the course emphasizes alignment with international standards, promoting operational excellence and sustainability.
Delivered by experienced facilitators with deep industry knowledge, the training offers a rich learning environment that encourages knowledge sharing and skills enhancement. The course structure promotes a progressive learning path, allowing participants to deepen their understanding through each module and connect theoretical concepts with technical challenges encountered in industrial settings.
By the conclusion of the training, participants will have the expertise to interpret performance indicators, identify emerging maintenance needs, and conduct overhaul procedures with confidence. More importantly, they will be positioned to play a critical role in strengthening maintenance strategies, improving plant efficiency, and contributing to long-term asset reliability within their organizations.

Key Takeaways:

  • Comprehensive understanding of compressor classifications, mechanical assemblies, and typical wear and failure patterns.
  • Structured methodologies for planning and conducting major inspections and overhauls, including teardown and reassembly protocols.
  • Introduction to vibration analysis, thermodynamic performance diagnostics, and condition monitoring for predictive maintenance.
  • Detailed review of safety practices and compliance with ISO/ASME mechanical integrity standards.
  • Techniques to develop and implement preventive maintenance programs that maximize uptime and minimize operating costs.
  • Case-based learning on failure root causes and maintenance optimization strategies derived from actual field operations.
  • Application of data-driven decision-making tools to prioritize interventions and support lifecycle asset management.
  • Comprehensive understanding of compressor classifications, mechanical assemblies, and typical wear and failure patterns.
  • Structured methodologies for planning and conducting major inspections and overhauls, including teardown and reassembly protocols.
  • Introduction to vibration analysis, thermodynamic performance diagnostics, and condition monitoring for predictive maintenance.
  • Detailed review of safety practices and compliance with ISO/ASME mechanical integrity standards.
  • Techniques to develop and implement preventive maintenance programs that maximize uptime and minimize operating costs.
  • Case-based learning on failure root causes and maintenance optimization strategies derived from actual field operations.
  • Application of data-driven decision-making tools to prioritize interventions and support lifecycle asset management.

Course Objectives

After completing this Pideya Learning Academy training, the participants will learn:
Core principles of compressor mechanics, types, and operational dynamics.
Industry-approved inspection protocols for evaluating internal components and systems.
Best practices for performing major overhauls, including rotor balancing and seal replacement.
Risk-based approaches to identify early signs of performance degradation.
Safety and regulatory considerations during disassembly and reassembly procedures.
Troubleshooting methodologies for typical failure modes such as surge, vibration, and overheating.

Personal Benefits

Elevated technical proficiency in compressor systems and maintenance.
Expanded capability to lead and execute major inspection and overhaul tasks.
Improved confidence in applying fault analysis and root cause diagnostics.
Recognition as a technically competent professional in your field.
Competitive edge in career advancement opportunities.

Organisational Benefits

Strengthened maintenance planning and resource allocation.
Minimized equipment downtime and associated financial losses.
Enhanced workplace safety and compliance with international standards.
Improved asset lifecycle management and return on investment.
Boosted productivity through streamlined compressor performance.

Who Should Attend

This course is designed for professionals who are directly involved in the inspection, operation, and maintenance of compressor systems, including:
Maintenance engineers and technicians
Reliability engineers and planners
Asset integrity specialists
Mechanical engineers in oil & gas, petrochemicals, and manufacturing
Operations and plant personnel responsible for equipment health monitoring

Course Outline

Module 1: Fundamentals of Compression Technology
Classification and industrial applications of compressors Basic thermodynamics of gas compression Compression cycle analysis (isentropic, polytropic) Major mechanical components and configurations Efficiency parameters in compression systems Overview of overhaul and service intervals
Module 2: Compressor Configuration and System Integration
Flow path analysis and compression stages Suction and discharge pressure relationships Influence of ambient conditions on performance Control philosophies: load/unload, variable speed Impact of auxiliary systems on main unit output Layout considerations for operational efficiency
Module 3: Inspection Methodologies for Compressor Systems
Pre-inspection checklists and planning Techniques for visual inspection and measurement Non-destructive testing (NDT): ultrasonic, radiographic, dye penetrant Detecting thermal fatigue, corrosion, and erosion Predictive diagnostics: infrared thermography and oil analysis Inspection recordkeeping and condition-based tagging
Module 4: Disassembly, Overhaul, and Reassembly Procedures
Safe shutdown and lockout-tagout (LOTO) procedures Sequence of disassembly and part preservation Overhaul of reciprocating and rotary components Inspection of wear rings, sleeves, and piston rods Shaft alignment and concentricity tolerances Reassembly protocols and dynamic balancing
Module 5: Compressor Bearings and Load-Carrying Mechanisms
Overview of hydrodynamic, rolling element, and magnetic bearings Failure analysis: fatigue, spalling, and lubrication starvation Oil film thickness and bearing clearance calculations Lube oil system diagnostics and maintenance Filtration techniques and contamination control Trending bearing temperatures and vibration profiles
Module 6: Sealing, Gasket, and Isolation Systems
Types of dynamic and static sealing technologies Material selection for high-pressure and temperature sealing Installation and torqueing of gasketed joints Troubleshooting leaks and seal degradation Compression packing systems and flushing plans Preventive strategies to reduce leak incidence
Module 7: Mechanical Components and Structural Elements
Rotordynamics and balancing theory Shaft deflection analysis and critical speed zones Static component integrity: housings, diffusers, volutes Wear part replacement criteria and tolerances Precision alignment tools and methods Surface finish standards and tolerances
Module 8: Valves, Actuators, and Regulation Devices
Suction, discharge, and unload valve configurations Diagnostic indicators of valve failure modes Stroke calibration and actuator tuning Pressure and flow regulation strategies Electronic and pneumatic actuation systems Smart valve diagnostics and cloud-enabled controls
Module 9: Electrical Drives and Power Control Systems
Motor selection: synchronous vs. asynchronous Electrical load analysis and power factor correction Motor protection devices and fault detection Panel board layout and sensor interfacing SCADA integration and I/O mapping Variable Frequency Drives (VFDs) and soft starters
Module 10: Thermal Management and Heat Dissipation
Overview of air-cooled, water-cooled, and oil-cooled systems Inspection of intercoolers, aftercoolers, and radiators Heat exchanger fouling and efficiency monitoring Coolant selection and quality management Thermal cycling and stress on components Control of thermal expansion and material fatigue
Module 11: Vibration Monitoring and Acoustic Diagnostics
Sources and classifications of mechanical vibration Use of accelerometers and spectrum analyzers Cross-phase analysis and resonance detection Sound mapping for leak detection and safety compliance ISO standards for vibration severity limits Correction strategies: isolation mounts, balancing, bracing
Module 12: Operational Diagnostics and Failure Analysis
Structured fault-finding approach for compressor units Trend analysis of operating data Root Cause Failure Analysis (RCFA) methodologies Use of CMMS and reliability-centered maintenance tools Troubleshooting of surge, choke, and pulsation Case review: catastrophic failures and lessons learned
Module 13: Occupational Safety and Operational Protocols
Mechanical and process safety standards Hazardous area classification and equipment zoning Handling pressurized systems and pressure relief devices Personal Protective Equipment (PPE) and hazard communication Emergency procedures and evacuation planning Internal auditing and safety compliance management
Module 14: Reliability Engineering and Preventive Maintenance
Condition-based vs. time-based maintenance strategies Establishing critical spares and inventory management MTBF (Mean Time Between Failures) analysis Digital maintenance systems and KPI dashboards Lifecycle cost optimization and asset care planning Scheduling inspections using reliability-centered frameworks
Module 15: Emerging Trends in Compressor Technology
Digital twins for compressor system modeling Internet of Things (IoT) in compressor diagnostics Predictive analytics using machine learning Remote condition monitoring and cloud-based alerts Sustainable design and energy recovery systems Green refrigerants and carbon reduction technologies

Have Any Question?

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