Program #04:

Air Compressors Maintenance Inspection & Overhaul

Training Descriptions:
This program will provide the participants with the fundamental concepts of the compressed air systems.
Participants will have in depth knowledge of improving performance, proper operation, inspection,
predictive and preventive maintenance and troubleshooting through presentation of actual case studies.

Training Objectives:
By the end of the training, participants will be able to:
 Identification of different components of compressed air systems.
 Specifications of instrument air characteristics and quality parameters.
 Compressor classification and working principles of each type.
 Screw air compressor working theory and practice.
 Air dryers types and working principles
 Air compressor components and its specifications.
 Setting maintenance program to achieve optimum operating conditions.
 Predictive maintenance techniques applicable to instrument air systems.

Training Designed for:

This course is intended for Mechanical Engineers, supervisors and foremen working with instrument air
systems operation and maintenance.

Topics:
DAY ONE:
 PRE-TEST
 Compressed air theory
o Physical units: pressure, temperature, thermal capacity, work, power, volume air flow rate.
o Thermodynamics: gas laws, heat transfer, flow through pipes, throttling
o Air: chemical composition of air, vapour pressure, relative humidity
 Air compressor classification
o Positive Displacement compressors: reciprocating, rotary; screw, roots blowers, sliding vane
types.
o Dynamic air compressors: centrifugal, mixed flow, axial flow
o Multistage compression.
DAY TWO:
 Regulation and Unloading systems
o Regulation in general.
o Pressure relief.
o Suction Loading/ unloading valve
DAY THREE:
 Bearings and lubrication systems.
o Oil free vs. oil flooded air compressors

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 o Friction and bearing types
o Lube oil system components and working principles
DAY FOUR:
 Air cooling and drying
o Intercooling and after-cooling
o Water cooling vs. air cooling systems.
o Moisture traps
o Adsorption dryers.
o Absorption dryers.
o Refrigerant dryers.
o Membrane dryers.
o Air filters.
DAY FIVE:
 Air distribution network improvement and optimization
o Air receiver
o Distribution network dimensioning and design
 Troubleshooting and maintenance program
o Preventive maintenance program
o Predictive maintenance techniques
 Course Conclusion
 POST-TEST and EVALUATION

Training Requirement:
“Hand’s on practical sessions, equipment and software will be applied during the course if required
and as per the client’s request”.

Training Methodology:
This interactive training course includes the following training methodologies as a percentage of the total
tuition hours:-
 30% Lectures, Concepts, Role Play
 30% Workshops & Work Presentations, Techniques
 20% Based on Case Studies & Practical Exercises
 20% Videos, Software & General Discussions
 Pre and Post Test

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