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June 30, 1998

Revision 1

BATTLE FORCE IMA (BFIMA) TRAINING PROGRAM


ORGANIZATIONAL LEVEL

AIR COMPRESSOR REPAIR


COURSE OUTLINE

MODULE 1 INTRODUCTION AND GENERAL INFORMATION ON


DRESSER-RAND FIVE-STAGE HIGH-PRESSURE AIR
COMPRESSORS
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.

Introduction and General Information


Safety Precautions
Precision Measuring Instruments
Planning the Repair of an Air Compressor
Troubleshooting Procedures

MODULE 2 MAINTENANCE AND REPAIR OF DRESSER-RAND FIVESTAGE HIGH-PRESSURE AIR COMPRESSORS (AIR END)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.
Lesson 6.
Lesson 7.
Lesson 8
Lesson 9.
Lesson 10.
Lesson 11.

Introduction to the IRN20NL High-Pressure


Air Compressor
Air Valves
High-pressure Cylinder Heads, Cylinders, and Liners
High-Pressure Pistons and Seals
Low-Pressure Piston Rods, Pistons, and Rings
Piston Rod Packing Assemblies
Oil Wipers
Low-Pressure Cylinder Block, Head, and Liners
Cooling Systems (IRN20NL Models 7 through 11)
Cooling Systems (IRN20NL-12 and Newer Models)
Operational Testing and Adjustments

MODULE 3 TROUBLESHOOTING, MAINTENANCE, AND REPAIR OF


DRESSER-RAND FIVE-STAGE HIGH-PRESSURE AIR
COMPRESSORS (RUNNING GEAR END)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.

Troubleshooting Procedures
Crossheads, Connecting Rods, and Bearings
Crankshaft and Main Bearings
Oil Systems
Operational Testing and Adjustments

MODULE 4 MAINTENANCE AND REPAIR OF DRESSER-RAND FIVESTAGE HIGH-PRESSURE AIR COMPRESSORS


(CONDENSATE DRAIN SYSTEM)
Lesson 1
Lesson 2
Lesson 3
Lesson 4
Lesson 5

Condensate Drain Systems (IRN20NL 7 through 11)


Demand-Based Condensate Drain Systems
(IRN20NL 12 and Newer Models)
Unloading Systems and Miscellaneous Accessories
Monitoring Systems
Operational Testing and Adjustments

MODULE 5 MAINTENANCE AND REPAIR OF DRESSER-RAND SIXSTAGE HIGH-PRESSURE AIR COMPRESSORS (AIR END)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.
Lesson 6.
Lesson 7.
Lesson 8.
Lesson 9.
Lesson 10.

Introduction to the IRN30NL-3 High-Pressure


Air Compressor
Air Valves
High-Pressure Cylinder Heads, Cylinders, and Liners
Fifth- and Sixth-Stage Pistons and Seals
Pistons, Rods, and Rings (First through Fourth Stages)
Piston Rod Packing Assemblies
Oil Wipers
Cylinder Block, Head, and Liners
Cooling Systems
Operational Testing and Adjustments

MODULE 6 MAINTENANCE AND REPAIR OF DRESSER-RAND SIXSTAGE HIGH-PRESSURE AIR COMPRESSORS (RUNNING
GEAR END)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.
Lesson 6.

Introduction to the IRN30NL-3 High-Pressure


Air Compressor
Crossheads, Connecting Rods, and Bearings
Crankshaft and Main Bearings
Oil Systems
Belt Drive
Operational Testing and Adjustments

MODULE 7 MAINTENANCE AND REPAIR OF DRESSER-RAND SIXSTAGE HIGH-PRESSURE AIR COMPRESSORS


(CONDENSATE DRAIN SYSTEM)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.

Miscellaneous Accessories
Demand-Based Condensate Drain System
Monitoring Systems
Operational Testing and Adjustments

MODULE 8 MAINTENANCE AND REPAIR OF DRESSER-RAND TWOSTAGE LOW-PRESSURE OIL-FREE AIR COMPRESSORS
(AIR END)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.
Lesson 6.
Lesson 7.
Lesson 8.
Lesson 9.
Lesson 10.

Disassembly Procedures
Air Coolers and Moisture Separators
Suction and Discharge Valves
Belts and Sheaves (Pulleys)
Pistons, Piston Rods, and Rings
Cylinder Liners
Air Rod Packing Assemblies
Oil Wiper Assemblies
Cooling Systems
Operational Testing and Adjustments

MODULE 9 MAINTENANCE AND REPAIR OF DRESSER-RAND TWOSTAGE LOW-PRESSURE OIL-FREE AIR COMPRESSORS
(RUNNING GEAR END)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.

Connecting Rods, Connecting Rod Bearings,


and Crossheads
Crankshaft Main Bearings and Oil Seals
Accessory Valves
Lubricating Oil Systems and Pumps
Operational Testing and Adjustments

MODULE 10 MAINTENANCE AND REPAIR OF DRESSER-RAND TWOSTAGE LOW-PRESSURE OIL-FREE AIR COMPRESSORS
(CONDENSATE DRAIN SYSTEM)
Lesson 1.
Lesson 2.
Lesson 3.

Monitor Assembly
Accessory Valves
Operational Testing and Adjustments

MODULE 11 MAINTENANCE AND REPAIR OF DRESSER-RAND TWOSTAGE LOW-PRESSURE OIL-FREE AIR COMPRESSORS
(AIR END)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.
Lesson 6.
Lesson 7.

Disassembly Procedures
Gage Panel and Tubing Removal and Replacement
Coolers
Valve and Cylinder Head Removal, Cleaning,
Inspection, and Installation
Piston and Cylinder Removal, Replacement,
and Adjustment
Oil and Water Pumps
Operational Testing and Adjustments

MODULE 12 MAINTENANCE AND REPAIR OF DRESSER-RAND TWOSTAGE LOW-PRESSURE OIL-FREE AIR COMPRESSORS
(RUNNING GEAR END)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.

Belts and Sheaves (Pulleys)


Guide Piston, Link, and Connecting Rod Removal
Oil and Water Pumps
Crankshaft and Main Bearing Removal, Replacement,
and Adjustment
Operational Testing and Adjustments

MODULE 13 MAINTENANCE AND REPAIR OF DRESSER-RAND TWOSTAGE LOW-PRESSURE OIL-FREE AIR COMPRESSORS
(CONDENSATE DRAIN SYSTEM)
Lesson 1.
Lesson 2.
Lesson 3.

Unloading System Repair


Accessory Valves
Operational Testing and Adjustments

MODULE 14 MAINTENANCE AND REPAIR OF DRESSER-RAND FIVESTAGE HIGH-PRESSURE OIL-FREE AIR COMPRESSORS
(AIR END)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.
Lesson 6.
Lesson 7.
Lesson 8.
Lesson 9.

Disassembly Procedures
Air Flow System
Suction and Discharge Valves
Cylinder Head, Cylinder Liners, and Pistons
Piston Rod Packing
Frame Oil Heads
Fresh Water Cooling System
Seawater Cooling System
Preoperation Procedures

MODULE 15 MAINTENANCE AND REPAIR OF DRESSER-RAND FIVESTAGE HIGH-PRESSURE OIL-FREE AIR COMPRESSORS
(RUNNING GEAR END)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.

Crankshafts, Bearings, and Seals


Lube Oil System
Accessory Valves
Connecting Rods and Crossheads
Preoperation Procedures

MODULE 16 MAINTENANCE AND REPAIR OF DRESSER-RAND FIVESTAGE HIGH-PRESSURE OIL-FREE AIR COMPRESSORS
(CONDENSATE DRAIN SYSTEM)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.
Lesson 6.

Accessory Valves
Automatic Separator Drain System
Manual Drain System
Speed Reducer
Temperature Monitor
Preoperation Procedures

MODULE 17 MAINTENANCE AND REPAIR OF DRESSER-RAND FOURSTAGE HIGH-PRESSURE OIL-LUBRICATED AIR


COMPRESSORS (AIR END)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.
Lesson 6.
Lesson 7.
Lesson 8.
Lesson 9.

Disassembly Procedures
Gage Board and Miscellaneous Piping Repair
Air Flow System
Cooling Water System
Suction and Discharge Valve Repair
Air Cooler and Separator Repair
Cylinder and Cylinder Head Repair
Piston and Connecting Rod Repair
Operational Testing and Adjustments

MODULE 18 MAINTENANCE AND REPAIR OF DRESSER-RAND FOURSTAGE HIGH-PRESSURE OIL-LUBRICATED AIR


COMPRESSORS (RUNNING GEAR END)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.
Lesson 6.

Piston and Connecting Rod Repair


Crankshaft and Main Bearing Repair
Cylinder Lubrication (Manzel)
Lubricating Oil Pump and System
Motor Repair
Operational Testing and Adjustments

MODULE 19 MAINTENANCE AND REPAIR OF DRESSER-RAND FOURSTAGE HIGH-PRESSURE OIL-LUBRICATED AIR


COMPRESSORS (CONDENSATE DRAIN SYSTEM)
Lesson 1.
Lesson 2.
Lesson 3.
Lesson 4.
Lesson 5.
Lesson 6.

Barksdale Automatic Drain Valve


Drain Manifold and Unloader
Final Discharge and Cooling Water Valves
Accessory Valves
Temperature Monitor
Operational Testing and Adjustments