-
June 30, 1998Revision 1
BATTLE FORCE IMA (BFIMA) TRAINING PROGRAMORGANIZATIONAL
LEVEL
AIR COMPRESSOR REPAIRCOURSE OUTLINE
MODULE 1 INTRODUCTION AND GENERAL INFORMATION ONDRESSER-RAND
FIVE-STAGE HIGH-PRESSURE AIRCOMPRESSORS
Lesson 1. Introduction and General InformationLesson 2. Safety
PrecautionsLesson 3. Precision Measuring InstrumentsLesson 4.
Planning the Repair of an Air CompressorLesson 5. Troubleshooting
Procedures
MODULE 2 MAINTENANCE AND REPAIR OF DRESSER-RAND FIVE-STAGE
HIGH-PRESSURE AIR COMPRESSORS (AIR END)
Lesson 1. Introduction to the IRN20NL High-PressureAir
Compressor
Lesson 2. Air ValvesLesson 3. High-pressure Cylinder Heads,
Cylinders, and LinersLesson 4. High-Pressure Pistons and
SealsLesson 5. Low-Pressure Piston Rods, Pistons, and RingsLesson
6. Piston Rod Packing AssembliesLesson 7. Oil WipersLesson 8
Low-Pressure Cylinder Block, Head, and LinersLesson 9. Cooling
Systems (IRN20NL Models 7 through 11)Lesson 10. Cooling Systems
(IRN20NL-12 and Newer Models)Lesson 11. Operational Testing and
Adjustments
MODULE 3 TROUBLESHOOTING, MAINTENANCE, AND REPAIR OFDRESSER-RAND
FIVE-STAGE HIGH-PRESSURE AIRCOMPRESSORS (RUNNING GEAR END)
Lesson 1. Troubleshooting ProceduresLesson 2. Crossheads,
Connecting Rods, and BearingsLesson 3. Crankshaft and Main
BearingsLesson 4. Oil SystemsLesson 5. Operational Testing and
Adjustments
-
MODULE 4 MAINTENANCE AND REPAIR OF DRESSER-RAND FIVE-STAGE
HIGH-PRESSURE AIR COMPRESSORS(CONDENSATE DRAIN SYSTEM)
Lesson 1 Condensate Drain Systems (IRN20NL 7 through 11)Lesson 2
Demand-Based Condensate Drain Systems
(IRN20NL 12 and Newer Models)Lesson 3 Unloading Systems and
Miscellaneous AccessoriesLesson 4 Monitoring SystemsLesson 5
Operational Testing and Adjustments
MODULE 5 MAINTENANCE AND REPAIR OF DRESSER-RAND SIX-STAGE
HIGH-PRESSURE AIR COMPRESSORS (AIR END)
Lesson 1. Introduction to the IRN30NL-3 High-PressureAir
Compressor
Lesson 2. Air ValvesLesson 3. High-Pressure Cylinder Heads,
Cylinders, and LinersLesson 4. Fifth- and Sixth-Stage Pistons and
SealsLesson 5. Pistons, Rods, and Rings (First through Fourth
Stages)Lesson 6. Piston Rod Packing AssembliesLesson 7. Oil
WipersLesson 8. Cylinder Block, Head, and LinersLesson 9. Cooling
SystemsLesson 10. Operational Testing and Adjustments
MODULE 6 MAINTENANCE AND REPAIR OF DRESSER-RAND SIX-STAGE
HIGH-PRESSURE AIR COMPRESSORS (RUNNINGGEAR END)
Lesson 1. Introduction to the IRN30NL-3 High-PressureAir
Compressor
Lesson 2. Crossheads, Connecting Rods, and BearingsLesson 3.
Crankshaft and Main BearingsLesson 4. Oil SystemsLesson 5. Belt
DriveLesson 6. Operational Testing and Adjustments
-
MODULE 7 MAINTENANCE AND REPAIR OF DRESSER-RAND SIX-STAGE
HIGH-PRESSURE AIR COMPRESSORS(CONDENSATE DRAIN SYSTEM)
Lesson 1. Miscellaneous AccessoriesLesson 2. Demand-Based
Condensate Drain SystemLesson 3. Monitoring SystemsLesson 4.
Operational Testing and Adjustments
MODULE 8 MAINTENANCE AND REPAIR OF DRESSER-RAND TWO-STAGE
LOW-PRESSURE OIL-FREE AIR COMPRESSORS(AIR END)
Lesson 1. Disassembly ProceduresLesson 2. Air Coolers and
Moisture SeparatorsLesson 3. Suction and Discharge ValvesLesson 4.
Belts and Sheaves (Pulleys)Lesson 5. Pistons, Piston Rods, and
RingsLesson 6. Cylinder LinersLesson 7. Air Rod Packing
AssembliesLesson 8. Oil Wiper AssembliesLesson 9. Cooling
SystemsLesson 10. Operational Testing and Adjustments
MODULE 9 MAINTENANCE AND REPAIR OF DRESSER-RAND TWO-STAGE
LOW-PRESSURE OIL-FREE AIR COMPRESSORS(RUNNING GEAR END)
Lesson 1. Connecting Rods, Connecting Rod Bearings,and
Crossheads
Lesson 2. Crankshaft Main Bearings and Oil SealsLesson 3.
Accessory ValvesLesson 4. Lubricating Oil Systems and PumpsLesson
5. Operational Testing and Adjustments
MODULE 10 MAINTENANCE AND REPAIR OF DRESSER-RAND TWO-STAGE
LOW-PRESSURE OIL-FREE AIR COMPRESSORS(CONDENSATE DRAIN SYSTEM)
Lesson 1. Monitor AssemblyLesson 2. Accessory ValvesLesson 3.
Operational Testing and Adjustments
-
MODULE 11 MAINTENANCE AND REPAIR OF DRESSER-RAND TWO-STAGE
LOW-PRESSURE OIL-FREE AIR COMPRESSORS(AIR END)
Lesson 1. Disassembly ProceduresLesson 2. Gage Panel and Tubing
Removal and ReplacementLesson 3. CoolersLesson 4. Valve and
Cylinder Head Removal, Cleaning,
Inspection, and InstallationLesson 5. Piston and Cylinder
Removal, Replacement,
and AdjustmentLesson 6. Oil and Water PumpsLesson 7. Operational
Testing and Adjustments
MODULE 12 MAINTENANCE AND REPAIR OF DRESSER-RAND TWO-STAGE
LOW-PRESSURE OIL-FREE AIR COMPRESSORS(RUNNING GEAR END)
Lesson 1. Belts and Sheaves (Pulleys)Lesson 2. Guide Piston,
Link, and Connecting Rod RemovalLesson 3. Oil and Water PumpsLesson
4. Crankshaft and Main Bearing Removal, Replacement,
and AdjustmentLesson 5. Operational Testing and Adjustments
MODULE 13 MAINTENANCE AND REPAIR OF DRESSER-RAND TWO-STAGE
LOW-PRESSURE OIL-FREE AIR COMPRESSORS(CONDENSATE DRAIN SYSTEM)
Lesson 1. Unloading System RepairLesson 2. Accessory
ValvesLesson 3. Operational Testing and Adjustments
-
MODULE 14 MAINTENANCE AND REPAIR OF DRESSER-RAND FIVE-STAGE
HIGH-PRESSURE OIL-FREE AIR COMPRESSORS(AIR END)
Lesson 1. Disassembly ProceduresLesson 2. Air Flow SystemLesson
3. Suction and Discharge ValvesLesson 4. Cylinder Head, Cylinder
Liners, and PistonsLesson 5. Piston Rod PackingLesson 6. Frame Oil
HeadsLesson 7. Fresh Water Cooling SystemLesson 8. Seawater Cooling
SystemLesson 9. Preoperation Procedures
MODULE 15 MAINTENANCE AND REPAIR OF DRESSER-RAND FIVE-STAGE
HIGH-PRESSURE OIL-FREE AIR COMPRESSORS(RUNNING GEAR END)
Lesson 1. Crankshafts, Bearings, and SealsLesson 2. Lube Oil
SystemLesson 3. Accessory ValvesLesson 4. Connecting Rods and
CrossheadsLesson 5. Preoperation Procedures
MODULE 16 MAINTENANCE AND REPAIR OF DRESSER-RAND FIVE-STAGE
HIGH-PRESSURE OIL-FREE AIR COMPRESSORS(CONDENSATE DRAIN SYSTEM)
Lesson 1. Accessory ValvesLesson 2. Automatic Separator Drain
SystemLesson 3. Manual Drain SystemLesson 4. Speed ReducerLesson 5.
Temperature MonitorLesson 6. Preoperation Procedures
-
MODULE 17 MAINTENANCE AND REPAIR OF DRESSER-RAND FOUR-STAGE
HIGH-PRESSURE OIL-LUBRICATED AIRCOMPRESSORS (AIR END)
Lesson 1. Disassembly ProceduresLesson 2. Gage Board and
Miscellaneous Piping RepairLesson 3. Air Flow SystemLesson 4.
Cooling Water SystemLesson 5. Suction and Discharge Valve
RepairLesson 6. Air Cooler and Separator RepairLesson 7. Cylinder
and Cylinder Head RepairLesson 8. Piston and Connecting Rod
RepairLesson 9. Operational Testing and Adjustments
MODULE 18 MAINTENANCE AND REPAIR OF DRESSER-RAND FOUR-STAGE
HIGH-PRESSURE OIL-LUBRICATED AIRCOMPRESSORS (RUNNING GEAR END)
Lesson 1. Piston and Connecting Rod RepairLesson 2. Crankshaft
and Main Bearing RepairLesson 3. Cylinder Lubrication
(Manzel)Lesson 4. Lubricating Oil Pump and SystemLesson 5. Motor
RepairLesson 6. Operational Testing and Adjustments
MODULE 19 MAINTENANCE AND REPAIR OF DRESSER-RAND FOUR-STAGE
HIGH-PRESSURE OIL-LUBRICATED AIRCOMPRESSORS (CONDENSATE DRAIN
SYSTEM)
Lesson 1. Barksdale Automatic Drain ValveLesson 2. Drain
Manifold and UnloaderLesson 3. Final Discharge and Cooling Water
ValvesLesson 4. Accessory ValvesLesson 5. Temperature MonitorLesson
6. Operational Testing and Adjustments
