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A compressor mechanic or operator, with the right training, can have an immediate positive impact on your bottom line. In the past, it was possible for these workers to study or apprentice with experienced people for years. This is considered a luxury that can no longer be afforded in today's cost cutting work place.

Our Compressor School was established to make it easy for you to get affordable training from outside experts and to have the sessions in your plant. This specialized training will provide the necessary foundation for your people to make cost saving improvements throughout your compressed air system. 

The training is handled by Air Power USA. This company is a charter member of the Compressed Air Efficiency Council. In addition, they were chosen to be one of only twelve core trainers by the U. S. Department of Energy for the 1998 Compressed Air Challenge Program.

The information below describes the two training choices. The first is a class dealing only with the Rotary Screw type of compressor. The second is a complete program covering all types of compressors. In both cases, you can customize the programs to match your needs.


Rotary Screw School

The Rotary Screw School Program is presented in a single day. The material takes between 5 and 6 hours to cover. The attendees are given a bound workbook that can be used as a permanent reference tool. 

You have the option of using the Rotary Screw School Program or customizing a training session that better fits your needs. It is easy to customize a program. Simply pick the subjects you want covered from the following outline of the complete program.

This training is best held at your plant where it can be customized for the compressors being used in the air system. 

First Session

Part 1: Introduction to Compressed Air

Theory, terminology
Basic airend design
ICFM, ACFM, SCFM
PSIG, PSIA
Compression ratios and efficiency
BHP, HP, KW, Power Cost
Compression process
Types of lubricant cooled rotary screws


Part 2: Lubricant Cooled Rotary Screw Package

Air Compressor design parameters and their effect on operation
Compressed air flow system
Cooling and Lubrication Systems
Motors and Starters

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Part 3: Rotary Screw Maintenance

Rotor clearance
Sealing strip, sealing edge
4-6 Male rotor drive and others
Length to diameter relationship
Bearing design and application
Timing gear drive and pitch line drive
Intake zone and compression zone
Gear drive and direct drive
Two stage and single stage bearing loading
Analyzing airend failures and root causes
Discharge check valves
Shaft seals
High air and oil temperature switch
Inlet filters, types and maintenance
Inlet valves, types and maintenance
Inlet bypass valve, design and use in unloaded and loaded mode
Purge air valve and blow down valve, troubleshooting
Pressure regulator, use in control maintenance and performance
Discharge check valve, how it fits to control system
Minimum pressure valve, design and use
Oil stop valve
Air oil separator and scavenger recovery system, use and troubleshooting
Oil carryover problems
Aftercooler, air, water separator
Air cooled and water cooled
Lubricant cooled units, pump driven, pressure differential
Water cooled, series, parallel, flow temperature control
Air cooled, types and controls
Lubricant temperature control flow valve
How to check thermal valves and high temperature switches
Energy recover of heat of compression
Air ducting, care and troubleshooting
Sizing proper ventilation, air cooled and water cooled
Heat loads by horse power
Pressure regulator
Solenoid valves
Lubricant level
Flexible connections
Cooling heat exchangers and motor


Part 4: Lubricant Coolant for Rotary Screw

Heat of compression, varnish to be avoided
Function of lubricant and coolant
Special requirements of lubricant and coolant
Types of fluids used
What is flash point
Problem environments
Lubricant analysis as a maintenance tool
Matrix list of commercial lubricants


Part 5: Troubleshooting

Special actions and malfunctions
Probable causes to investigate


Part 6: General Tips on Piping

Types of acceptable piping
Sizing, best practice


Part 7: Compressor Capacity Control Systems

Types of controls by function
Throttle modulation
On line, off line, full on and full off
Estimating performance, % capacity flow to % input KW
Other types of modulation
Variable displacement
Variable speed drive
Multiple unit control and system control
Cascade control system
Network, single point control system
Air receiver sizing
Back pressure
High pressure loss between compressor discharge and system
Effect on energy cost
Effective storage, sizing with effective storage


Part 8: Reference 

Summary discussion.
Presentation of reference materials on rotary screw compressors

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Complete Compressor School 


The complete version of the program is presented in a total of 4 sessions with each lasting approximately four hours. The attendees are given a spiral bound workbook that can be used as a permanent reference tool. 

You have the option of using the complete program or customizing a training session that better fits your needs. It is easy to customize a program. Simply pick the subjects you want covered from the following outline of the complete program.

This training is best held at your plant where it can be customized for the compressors being used in the air system. 

First Session 

Part 1: Introduction to Compressed Air

Basic Compressed Air Theory
Basic Terminology
Components of a Compressed Air System
Overview of Compressor Types
Reciprocating, Air Cooled Single Acting
Rotary Oil Cooled, Single Stage
Rotary Oil Cooled, Two Stage
Reciprocating, Water Cooled, Double Acting
Centrifugal
Non Lubricated Versions
Differences between CFM, ACFM, ICFM and SCFM
Specific Power


Part 2: Reciprocating Controls

Single Acting, Free Air Unloading
Double Acting, Total Closure, 2 Step, 3 Step and 5 Step
Plotting Performance Curve


Part 3: Rotary Screw Controls, Oil Cooled

Oil Separation, Inlet Controllers
Blow Down to Reduce Head Pressure
Throttled Inlet Controls
How Modulation Works
How Load, No Load Works
Automatic Control Selection
Variable Speed Drive
Rotor Length Adjustment Controls
Why it Works on the Upper End
Limitations on Lower End


Part 4: Rotary Screw Controls, Oil Free

Single and Two Stage
Why You Can't Run Modulation
Cut In, Cut Out


Part 5: Centrifugal Controls

Explain Theory of Compression
Mass Flow and Problems with Surge
Performance Curves
Blow off Controls
Modulation
Inlet Guide Vane
Blow Down


Part 6: Variable Speed Drive Control

Explain and Review Variable Speed Drive Control
Performance Curves
Don't Confuse % of Full with Specific Power
Compare Operating Cost

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Second Session

Part 1: Air Cooled Reciprocating Compressors

Single Acting
Double Acting


Part 2: Reciprocating Compressors, Double Acting, Water Cooled 

Single Stage
Two Stage
Basic Components

Crosshead
Piston
Piston Rod
Wiper Rings
Packing
Piston Rings
Heads
Valves

Part 3: Reciprocating Compressor Inlet Pipe, Critical Lengths and Sizing

Discharge Pipe, Critical Lengths
Inlet Filters
Start Up Preparations


Part 4: Reciprocating Foundation and Installation Guidelines


Part 5: Reciprocating Trouble Shooting

Maintenance
Controls
Compressor Vibration


Part 6: Reciprocating Compressors Cooling Water Systems 

Series Piping
Parallel Piping
Thermostatic Water Control Valves
Proper Flow and Proper Pressure
Proper Temperature In and Out
Trouble Shooting Water Cooling


Part 7: Reciprocating Closed Cooling Systems

Open Tower, Evaporative
Closed Cooling System with Trim Cooler
Closed Cooling System with Evaporative


Part 8: Tube in Shell Heat Exchangers for Reciprocating Compressors

Floating Tube Nest
Fixed Tube Nest
Single Pass, Two Pass, Four Pass
Zinc Sacrificial Anodes
Parallel and Series Piping


Part 9: Basic Reasons for Cooling Reciprocating Compressors

Aftercooler
Intercooler
Water Jackets in Reciprocating Cylinders
Cooling Water Limitations
Effect on Efficiency and Power Cost

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Third Session

Part 1: Oil Cooled Rotary Screw Compressor

How it works, Bearing Loading, Thermal Control
Efficiency and Performance Curves
Types and Applications of Rotors
Single Stage and Two Stage
Terminology


Part 2: Oil Cooled Rotary Design and Major Systems

Diagram of Major Components
Air Flow System Unit 
Air End
Aftercooler
Motor and Air End
Inlet Filter and Air End
Prefilter and Air End
Air/Oil Separator
Flexible Connections
Piping Connections
Air Cooled Aftercooler with Separator
Inlet Control System


Part 3: Oil Cooled Rotary Lubricant System

Types of Coolants 
Filtration
Sight Glass
Types of Pressure Flow
Coolant Bypass
Level Indicators
Discussion of Piping System
Temperature Control Valves
Cooler Design, Integral and Remote
Water Cooled Coolers
Air Cooled Limitations
Water Cooled Limitations


Part 4: Electric Motor Starter Drive System for Oil Cooled Rotary

Basic Types of Electric Motors
Starters, Full Voltage, Star Delta
Controls
Hard Wire
Solid State Electronic
Drive System, Flange Mounted, Gears, Coupling, Belts

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Part 5: Oil Cooled Rotary Maintenance and Trouble Shooting

Maintenance Procedures for Lubricant and Filters
Drive Motor Lubrication Maintenance
Starter
Power Supply
Cooling Supply
Safety Procedures
Trouble Shooting

Controls
Over Temperature
Loss of Capacity
Excessive Line Current
Cooling
Water in System
Oil Separator Problems

Part 6: Installation Guidelines for Oil Cooled Rotary

Capacity Ratings and Operating Procedures
Controls
Cooling
Heat Recovery
Co-generation
Intake Air 
Compressor Piping
Operating in Parallel with Reciprocating Compressor
Wiring and Power Considerations
Oil Carryover
Effect of Altitude


Part 7: Non Lubricated Rotary Compressor

Air Cooled and Water Cooled
Control Limitations
Maintenance
Single Stage and Two Stage


Part 8: Summary

Selection and Application
Effect on Operating Power Cost

Controls
Pressure
Staging
Cooling
ACFM/FAD
Actual BHP
Packaging

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Forth Session

Part 1: Moisture in Compressed Air

Where it comes from
Dew Point
Effects on Pressure
Effects on Temperature
Pressure Dew Point
Atmospheric Dew Point
Use of Aftercooler and Separator
Use of Filter instead of Separator


Part 2: Types of Dryers

Deliquescent
Refrigerated, Cycling and Non Cycling
Desiccant, Heated, Heaterless, Blower Range, Power Cost Comparison


Part 3: Types of Filters

Particulate
Coalescing
Adsorption
Pressure Drop and Effect on Power Cost


Part 4: Automatic Drain Traps

Mechanical 
Electronic with Timer
Level Operated
Comparison of Air Wasted]

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Part 5: Safety and EPA Compliance

Power Disconnect and Lock Out
Depressurization
Safety Valve
Coded Storage Vessels
Do Not Breathe Air
Use of Plastic Bowls
Do Not Use Solvents
Safety Velocity Fuses (OSHA VALVE)
Only 30 PSIG Blow Off Air


Part 6: Handling Condensate in Compliance with EPA

Basic Federal EPA Controls
Types of Compressor Lubricants
Oil Water Condensate Equipment
Best Available Technology


Part 7: Piping Considerations

Suction Pipe
Air Receiver, Sizing and Use
Drop and Drip Legs
Controlling Pressure Loss
General Rules for Piping, Reciprocating, Rotary and Centrifugal
Typical Compressed Air System Layout
Pressure Drop Chart and How to Use


Part 8: Synthetic Lubricants

Types
Uses and Benefits
Limitations


Part 9: Managing the Compressed Air System

Minimizing the Yearly Power Cost 

Selecting Most Cost Effective Equipment
Controlling the Waste 
Demand Side Control of Usage

Cost of Compressed Air
Typical Plant Survey and System Audit
Demand Side Control

Proper System Design and Layout
Use of Regulators

Air Saving Equipment

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Contact Us

You can easily copy and paste your choices on an e-mail to us at school@compressorwise.com for a quotation on a customized Compressor School to be held at your facility. You can use the same e-mail address if you have any questions. 

We look forward to working with you to deliver a unique and lasting training experience.