RECIPROCATING COMPRESSORS OVERHAUL, PERFORMANCE & MAINTENANCE OPTIMIZATION
Enhancing Reliability, Efficiency, and Longevity of Reciprocating Compressors through Precision Overhaul and Maintenance Excellence
Course Schedule
| Date | Venue | Fees |
|---|---|---|
| 26 – 28 Feb 2025 | Kuala Lumpur, Malaysia | USD 2495 per delegate |
| 16 – 18 Apr 2025 | Dubai, UAE | USD 2495 per delegate |
Course Introduction
Reciprocating compressors remain vital in many process industries, especially in high-pressure and gas handling applications. However, they are subject to frequent mechanical stresses, making precision overhaul and performance optimization essential for operational continuity and safety.
This 3-day intensive course delivers practical, hands-on knowledge in the overhaul, diagnostics, and maintenance of reciprocating compressors. Participants will learn to identify early signs of wear or failure, implement best practices in disassembly and reassembly, and apply condition monitoring to extend equipment life and performance.
Course Objectives
By the end of this course, participants will be able to:
• Understand the working principles and configurations of reciprocating compressors
• Execute proper disassembly, inspection, and reassembly during overhaul
• Identify causes of compressor inefficiency and mechanical failure
• Apply condition monitoring tools to assess health and predict failures
• Develop an effective preventive maintenance and performance improvement plan
Key Benefits of Attending
• Learn best practices in overhaul and precision alignment of reciprocating compressors
• Reduce mechanical failure rates through structured inspection and diagnostics
• Understand performance factors and optimize for energy efficiency
• Enhance mechanical integrity, safety, and reliability
• Cut maintenance costs by reducing unplanned interventions
Intended Audience
This program is designed for:
• Mechanical and maintenance engineers
• Rotating equipment technicians and supervisors
• Plant reliability engineers
• Maintenance planners and condition monitoring specialists
• Compressor operators and OEM service coordinators
Individual Benefits
Key competencies that will be developed include:
• Overhaul, reassembly, and clearance checks of critical compressor parts
• Condition monitoring using vibration, pressure, and temperature data
• Troubleshooting common compressor problems
• Root cause failure analysis and reliability improvement planning
• Hands-on knowledge of valve, piston, and cylinder component wear
Organization Benefits
Upon completing the training course, participants will demonstrate:
• Improved equipment uptime and MTBF (mean time between failures)
• Reduced maintenance cost and emergency breakdowns
• Higher compressor efficiency and reduced energy consumption
• More accurate planning of overhauls and spare parts inventory
• Enhanced mechanical integrity and safety compliance
Instructional Methdology
The course follows a blended learning approach combining theory with practice:
• Strategy Briefings – Compressor design, operating limits, and maintenance philosophy
• Case Studies – Real failures and best-practice overhauls in oil, gas, and chemical plants
• Workshops – Disassembly plans, condition-based assessments, reassembly procedures
• Peer Exchange – Troubleshooting challenges and success stories from participants
• Tools – Templates for overhaul documentation, inspection logs, and condition monitoring reports
Course Outline
DETAILED 3-DAY COURSE OUTLINE
Training Hours: 7:30 AM – 3:30 PM
Daily Format: 3–4 Learning Modules | Coffee breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: Compressor Fundamentals and Mechanical Overview
Module 1: Operating Principles and Component Functions (07:30 – 09:30)
• Types of reciprocating compressors and applications
• Cylinder design, crankshaft mechanics, pistons, valves, and seals
• Performance curves and compression ratios
Module 2: Key Failure Modes and Root Causes (09:45 – 11:15)
• Mechanical wear, lubrication failure, overheating, liquid slugging
• Symptoms and early signs of wear and misalignment
• Design vs. operational failure sources
Module 3: Planning an Overhaul – Pre-Inspection & Documentation (11:30 – 01:00)
• Pre-overhaul condition monitoring and reporting
• Safety, rigging, and parts preparation
• Disassembly planning and tolerances tracking
Module 4: Workshop – Condition Review and Overhaul Readiness (02:00 – 03:30)
• Participants evaluate overhaul readiness from a sample compressor history
Day 2: Overhaul, Inspection and Reassembly
Module 1: Step-by-Step Disassembly Techniques (07:30 – 09:30)
• Disassembling valves, cylinder heads, pistons, and crankcases
• Inspection of liners, rods, gaskets, packing rings, and bearings
• Shaft runout and alignment checks
Module 2: Component Inspection and Defect Identification (09:45 – 11:15)
• Wear pattern recognition and measurements
• Valve failure and reconditioning
• Bearing clearance and wear assessment
Module 3: Precision Reassembly and Alignment (11:30 – 01:00)
• Assembly techniques for valves, piston rings, crankcases
• Shaft alignment using dial indicators and laser alignment
• Clearance setting and torque sequencing
Module 4: Workshop – Reassembly Plan and Tolerance Checklist (02:00 – 03:30)
• Participants create a full reassembly plan using case specifications
Day 3: Troubleshooting and Maintenance Optimization
Module 1: Troubleshooting Common Operational Issues (07:30 – 09:30)
• Low discharge pressure, vibration, leaks, overheating
• Using vibration and thermographic data for fault analysis
• Evaluating lubrication system performance
Module 2: Performance Monitoring and KPI Analysis (09:45 – 11:15)
• Measuring volumetric efficiency and pressure differential
• Tracking compressor reliability and failure frequency
• Using CMMS data to forecast maintenance needs
Module 3: Predictive Maintenance and Condition-Based Programs (11:30 – 01:00)
• Predictive tools: vibration analysis, oil analysis, temperature trends
• Maintenance strategies: time-based vs. condition-based
• Creating a PM checklist and monitoring schedule
Module 4: Final Workshop – 90-Day Compressor Reliability Plan (02:00 – 03:30)
• Teams create a short-term improvement plan
• Group presentations and instructor feedback
Certification
Participants will receive a Certificate of Completion in Reciprocating Compressors Overhaul, Performance & Maintenance Optimization, validating their expertise in maintaining, diagnosing, and improving reciprocating compressor systems.