INTRODUCTION FOR OPERATIONS & MAINTENANCE OF AIR COMPRESSORS: CURRENT AND COMMON ENGINEERING PROBLEMS & SOLUTIONS IN INDUSTRY

Compressed air is used widely throughout industry and is often considered the “fourth utility” (after electricity, water and gas) at many facilities. Almost every industrial plant, from a small machine shop to an immense pulp and paper mill have some type of compressed air system. In many cases, the compressed air system is so vital that the facility cannot operate without it. A properly managed compressed air system can save energy, reduce maintenance, decrease downtime, increase production throughput, and improve product quality.

The course is designed for participants who have little or no knowledge of air compressors. This course is also designed to introduce the participants to the various compressor terminologies frequently used, the various types of compressors used, the various parts and to some basic design.

The overall objective is to give the participants a functional knowledge of basic compressor theory.

Air compressors have their fair share of engineering problems in industry.

The said problems could be classified into:-

• Problems which could be identified and solved immediately, with little or no financial implications or loss in production and a drop in quality levels;
• Problems which could be identified and cannot be solved immediately, with little or no knowledge of its implications;
• Problems which recur frequently and cannot be solved permanently etc;

 Some of the reasons for these are due to:-

• Incompetent staff;
• A vast variety of equipment;
• Many moving (sliding, reciprocating, rotating) components etc.

WHO SHOULD ATTEND

Manufacturing, process, executives, managers, maintenance personnel, operation managers and etc.

This course is industry designed, to provide a broad understanding of the improvement methodology, concepts, and process. The methodology is presented with case studies and examples drawn from service, business process and manufacturing applications. The integration of manufacturing and maintenance is also addressed. With a heavy practice orientation, as much as a third of your time will be spent working through interactive practical exercises and assessments. This course is designed as an introduction to concepts and methodology.

COURSE OBJECTIVES

This training program is designed to provide an understanding of engineering related problems related to industry globally and a clear sense of what is required to effectively  structure, establish measurements and solve problems. Participants will learn the goals and deliverables behind the solutions. Methodology as well as the most commonly used tools within each phase will be discussed. Participants will also learn how to support a problem solving initiative within their organization.

LEARNING OUTCOME

On successful completion of this course, the participant should be able to:-

• Understand the benefits and implications of air compressors engineering problem solving program, and relate the concepts to the overall business mission and objectives.
• Think about his/her organization as a collection of processes, with inputs that determine the output.
• Use the concept of air compressor engineering problem solving to evaluate the capability of a process or organization.
• Recognize the engineering problem solving model used to improve processes.
• Recognize the organizational factors that are necessary groundwork for a successful engineering problem solving program.
• Integrate air compressor engineering problem solving program effort with other process improvement initiatives.

TRAINING METHODOLOGY

• The latest educational methods and strategies will be utilized.
• The course is designed to maximize delegate participation.
• Questions and answers are encouraged throughout and at the daily wrap-up sessions. This gives participants the opportunity to discuss with others and the presenter their specific problems and appropriate solutions.
• The course shall be conducted through lectures, case studies, group discussions and exercises to reinforce participant’s learning.

COURSE FORMAT

The course consists of formal content presentation interspersed with content quiz sessions.

The presenter’s style involves intensive participant participation.

MEASUREMENT METHODS

The course consists of formal content presentation interspersed with content quiz sessions.

The presenter’s style involves intensive participant participation.

COURSE CONTENT

DAY 1

Module 1 : Will the Stand-By Air Compressors Start-Up?   

• Initial Investigation
• Detailed Investigation
• Problem Identification
• Solutions
• Lessons Learnt

Module 2 : Sequencing Control

• Why is measuring flow important to measure demand?
• What is wrong with using pressure to calculate flow?
• Does the SC work with any type of air compressor?
• The SC interface to each air compressor
• SC’s software
• Remote monitoring capabilities

Module 3 : Compressed Air Controls for Industry – Problem and Solutions

• Controls and System Performance
• Individual Compressor Control Strategies
• Multiple Compressor Control
• Multiple Compressor Control with VSD

Module 4 : Compressor Sequencer: Problems and Solutions for Industrial Applications

• Introduction to Sequencers
• Cascade Sequencers
• Target Sequencer
• Custom Sequencers
• Common Sequencer Problems
• Problems Unique to “Vendor Sequencers
• Problems Unique to “Third-party Sequencers”
• How to Select, Install, Operate & Maintain a Sequencer Correctly

Module 5 : Automating & Monitoring Your  Compressed Air System: Problems and Solution for Industrial Applications

• Managing Multiple Compressors for Maximum Energy Efficiency
• Monitoring your compressed air system made easy
• Maintaining efficiency and energy cost savings

DAY 2

Module 6 : Environmentally Considerate Compressor Fluids

• Why do compressors need fluids?
• Base stocks commonly used in compressor fluids
• Study of Biodegradability

Module 7 : Evaluating Central Compressed Air Management Systems

• Cascade Control Settings
• Case Study
• Operating Sequence
• Results of Continuous Monitoring
• Design Faults
• Recommendations

Module 8 : Easy-to-Implement Master Control and Monitoring Systems

• Compressor Controls
• The Key Performance Indicator (KPI): kW/100 cfm
• Factories Should Use kW/100 cfm as a Key Performance Indicator
• Accumulated Intelligence makes it Easy to Save
• Control Strategies
• Data Collection
• Communicating the Data

Module 9 : Partially-Loaded Air Compressors in Industry

• Step #1: Measure energy costs of air compressors
• Step #2: Manage Compressed Air Demand Events
• Step #3: Identify Inappropriate Uses of Compressed Air

Module 10 : Monitor of Air Compressors: A Case Study

Q&A Session

 End of Program

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