DAY 1 – Compressor Fundamentals & Thermodynamics (Foundation Strong Karna)
1.1 Why Compressors are Critical in Process Plants
Role in Refinery, Petrochemical, Fertilizer, Hydrogen, Gas Processing
Compressor vs Pump (compressibility effect)
CAPEX vs OPEX sensitivity
1.2 Gas Laws & Compression Theory
Ideal vs Real Gas behavior
Boyle, Charles, Combined gas law
Compressibility factor (Z)
Reduced pressure & temperature
1.3 Compression Processes
Isothermal
Isentropic
Polytropic (REAL PLANT)
Efficiency definitions & confusion cleared
1.4 Key Performance Parameters
Suction / Discharge pressure
Flow rate (ACFM, SCFM, Nm³/hr)
Head, Work, Power
Temperature rise logic
Deliverable:
✔ Thermodynamics calculation sheet (basic)
DAY 2 – Types of Compressors & Selection Logic
2.1 Positive Displacement Compressors
Reciprocating compressors
Screw compressors (Oil flooded vs Oil free)
Lobe / Roots blower
2.2 Dynamic Compressors
Centrifugal compressor
Axial compressor (overview)
2.3 Selection Criteria (MOST IMPORTANT)
Pressure ratio vs flow map
Gas molecular weight effect
Continuous vs intermittent service
Turndown requirement
2.4 Real Industry Examples
Hydrogen recycle compressor
Instrument air compressor
Natural gas booster compressor
Deliverable:
✔ Compressor selection decision matrix
DAY 3 – Centrifugal Compressor Deep Dive
3.1 Construction Details
Impeller types (Open, Closed, Semi‑open)
Diffuser, volute, casing
3.2 Performance Curves
Head vs Flow
Surge line
Stonewall / choke
Operating point movement
3.3 Surge Phenomenon (INTERVIEW + PLANT FAVORITE)
Why surge happens
What actually happens inside compressor
Surge damage consequences
3.4 Anti‑Surge System Basics
Recycle line logic
Control valve sizing philosophy
Response time importance
Deliverable:
✔ Surge explanation diagram + operating logic
DAY 4 – Reciprocating Compressor Deep Dive
4.1 Construction & Working
Cylinder, piston, rings
Suction & discharge valves
Clearance volume effect
4.2 Capacity Control Methods
Clearance pockets
Speed control
Suction valve unloaders
4.3 Pulsation & Vibration
Why pulsation occurs
Pulsation bottles function
API 618 basics
4.4 Common Failures
Valve failures
Overheating
Lubrication issues
Deliverable:
✔ Failure troubleshooting checklist
DAY 5 – Compressor Auxiliaries & Protection Systems
5.1 Lubrication System
Oil pumps (main, auxiliary, emergency)
Filters, coolers
5.2 Sealing Systems
Dry gas seal
Oil seal
Packing (reciprocating)
5.3 Protection Logic
High vibration
High discharge temperature
Low lube oil pressure
5.4 Trip vs Alarm Philosophy
Deliverable:
✔ Compressor protection cause‑effect table
DAY 6 – EPC Design, PFD, P&ID & Datasheets
6.1 Compressor PFD Development
Where compressor sits in process
Recycle, vent, drain philosophy
6.2 Compressor P&ID Symbols & Logic
Minimum required valves
Start‑up vs normal operation
Bypass philosophy
6.3 Datasheet Walkthrough
What vendors REALLY look at
Common mistakes by process engineers
6.4 Layout & Installation Considerations
Foundation
Maintenance clearance
Noise & safety
Deliverable:
✔ Compressor datasheet filling guide
DAY 7 – Troubleshooting, Case Studies & Master Logic
7.1 Real Plant Problems
Compressor trips at start‑up
Cannot achieve discharge pressure
Excessive power consumption
7.2 Misdiagnosis by Vendors (Reality)
When problem is NOT compressor
System resistance mistakes
7.3 Saudi / Middle East Case Studies
Hydrocarbon gas compressor
Recycle valve wrong sizing case
7.4 Engineer’s Checklist
Before blaming compressor
Before modifying process
Final Deliverables:
✔ Complete compressor design & troubleshooting handbook
✔ Interview‑ready concepts
✔ EPC + O&M confidence
Excel calculation sheets
Real P&ID marked explanations
Vendor datasheet comparison
Certification.
Aug 29, 2026 
