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Led by Senior Rotating Equipment Engineer Simulacrum
Pumps and compressors from classification and selection through centrifugal and rotary pump systems, compressor types (reciprocating, screw, centrifugal), compressor operation, anti-surge control, maintenance, troubleshooting, and safety.
Led by Senior Rotating Equipment Engineer Simulacrum
The question
A process plant contains hundreds of pumps and dozens of compressors consuming 60–70% of its electrical energy — and the rotating equipment engineer must be fluent in both. This module covers the classification (dynamic vs. PD, pump vs. compressor), the fundamental physics difference between liquid pumping and gas compression (compressibility, temperature rise, intercooling), performance parameters for both (pump curve vs. compressor performance map with surge and choke lines), six plant utility systems and the rotating equipment serving each, and the six API standards governing design.
Outcome
The student can classify rotating equipment, explain the compressibility difference, list performance parameters for both, describe six plant systems, and name the six API standards. (Pumps and compressors in the process plant)
Sub-units
Led by Senior Rotating Equipment Engineer Simulacrum
The question
A pump never operates in isolation — it works as part of a system including piping, vessels, and control loops. This module covers series and parallel pump operation (constructing the combined pump curve and predicting flow increase on steep vs. flat system curves), four rotary PD pump types (gear, screw, lobe, vane) and the application for each, viscosity correction for centrifugal pumps using the Hydraulic Institute method and the ~500 cSt crossover point with PD, pump system integration with the process, and multi-pump manifold design for operational flexibility.
Outcome
The student can construct the combined parallel pump curve, describe four rotary PD types, explain the viscosity correction and crossover point, and describe multi-pump manifold design. (Centrifugal and rotary pump systems)
Sub-units
Led by Senior Rotating Equipment Engineer Simulacrum
The question
The three main compressor types serve different flow and pressure ranges — centrifugal for high flow, reciprocating for high pressure or difficult gases, screw for moderate applications. This module covers centrifugal compressors (multi-stage design, the performance map with surge and stonewall boundaries), reciprocating compressors (cylinder and valve operation, double-acting design, three capacity control methods — speed, valve unloaders, clearance pockets), screw compressors (oil-injected vs. oil-free, the built-in volume ratio concept), and compressor selection criteria matching type to service.
Outcome
The student can describe all three compressor types, read a performance map, describe reciprocating capacity control methods, compare oil-injected and oil-free screw compressors, and select the correct type for a given service. (Compressor types)
Sub-units
Led by Senior Instrumentation & Control Engineer Simulacrum
The question
The compressor is typically the most expensive and most critical rotating equipment in the plant — a trip can shut down the entire process. This module covers centrifugal compressor startup (lube oil, seal gas, anti-surge valve open, critical speed traverse), reciprocating startup and capacity management, anti-surge control (the surge control line, the anti-surge valve's 1–2 second response requirement, and what happens when it fails), three process control methods ranked by efficiency (speed > throttle > recycle), and compressor performance monitoring using vibration, bearing temperature, and efficiency trending.
Outcome
The student can describe both startup sequences, explain the anti-surge control mechanism, describe three capacity control methods for reciprocating compressors, rank the process control methods by efficiency, and describe the performance monitoring programme. (Compressor operation and control)
Sub-units
Led by Senior HSE Engineer Simulacrum
The question
Compressor maintenance determines whether the machine runs for 5 years between overhauls or trips every 6 months. This module covers centrifugal compressor overhaul (rotor extraction, impeller inspection, labyrinth seal replacement, dynamic balancing, dry gas seal maintenance), reciprocating compressor valve maintenance (the #1 cause of downtime), piston rings and packing, troubleshooting centrifugal surge and vibration from the frequency spectrum, troubleshooting reciprocating discharge temperature and knocking noise, and compressor safety — high-pressure gas hazards, LOTO with depressurisation verification, and the five automatic trip conditions.
Outcome
The student can describe the overhaul scope for both compressor types, diagnose surge and high vibration in centrifugal compressors, diagnose valve leakage and knocking in reciprocating compressors, and describe the safety hazards and emergency trip conditions. (Compressor maintenance, troubleshooting, and safety)
Sub-units