(Talk about advanced planning —the name of the company was se-lected in 1990 and Gibb patientlywaited 15 years for the company tolaunch.) Gibb is a heavy-duty mechanicby trade and an MBA graduate, whohas spent about 25 years fabricating,maintaining, servicing and selling nat-ural gas compression packages. Gibbhas also instructed at ENFORM andwith the University of Calgary’s Facultyof Continuing Education. He is also astrong advocate for lifelong learning.

“Many technical training programsconsist of data dumps,” said Gibb,“mostly from vendors who would rather

Training has been in Bill Gibb’sblood forever. Gibb, managing directorof Industrious Solutions Inc. of Calgary,Alberta, Canada, said, “I’ve been in-volved in training in one capacity oranother since I entered the workforce.I’ve seen and experienced firsthandwhat works and what doesn’t work. Iknew early on that I had a natural abil-ity to help others, and began planningfor the day when I would have myown company that would specialize indelivering effective technical and per-sonal development training.”

That day came in July 2005 whenhe launched Industrious Solutions.

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be doing anything but train clients, andfrom personnel who have no formal in-struction in how to teach adult learners.Technical information is passed on atthese sessions, but little practical appli-cation is provided. Most operators arevisual learners. They need to see dia-grams and images that take the techni-cal information and relate it to theequipment they know. They also needto understand how to handle problems,troubleshoot operations and communi-cate with mechanics, engineers andother service providers. There is a defi-nite need for focused field training toaddress these issues.”

FIELD TRAINING FOR GAS COMPRESSION OPERATORSIndustrious Solutions Works with Producers to Maximize Natural Gas Production

by Delivering Specialized Technical Training Programs for Gas Compressor PackagesBy Neil Purslow

(Left) The different lubrication systems that service a reciprocating compressor are described during a training program. The high-pressure low-volume auxilary lubrication system that services rod packing and cylinder piston rings is detailed, as well as the high-volume low-pressure mainsystem that lubricates crankshafts, connecting rods and crossheads. (Right) This chart explains how compressor valves function. Emphasis isplaced on plate travel and the requirement that valve springs must match the working pressure of the gas to provide proper cushioning. Also dis-cussed is the need for spring tension to match the valves’ travel velocity to prevent the destructive effect of valve plate impact.

(Left) Internal stresses are created when manufacturers’ compressor valve cap bolting procedures are not followed. The design features of thevalve cap O-ring are illustrated to promote an understanding of the sealing effect and principles of O-ring deformation. The rationale for only usingO-ring seals once is also discussed. (Right) This chart explains the unique and critical design features of a spark plug. It also shows the need to fol-low manufacturers’ directions regarding torqueing procedures and the restoration of the heat transfer pathway through the use of new gaskets eachtime a plug is removed and reinstalled.

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a telephone interview process. Oncehe has compiled the results, he devel-ops a site-specific program to addressthe additional skills required at thegas processing facility. After the pro-posal is approved, he prepares a tai-lored program using previously cre-ated visuals and new imagery.

The scope of the program varieswith each delivery based on the needsand abilities of the participants.Additional emphasis may be placed oncertain modules, and the delivery mayswitch between levels depending uponthe audience. Other concepts are alsoaddressed in the programs, such asheat and how it affects the variousstages of compression and what it doesto rings, lubrication oil and equipmentcomponents on a compressor package.

Gibb delivers training programs on-or off-site in settings that are con-ducive to learning. On occasion, fieldlunchrooms have been transformedinto classrooms. Industrious Solutionsprovides the necessary audio-visualequipment required to deliver theprograms anywhere.

At the start of each class, Gibb hasthe participants sign in and provideinformation about their backgroundand work experience. This informa-tion enables him to further customizethe program to the particular group.

“The real value in this type oftraining is relating the theory to real-life situations in plain English,” ex-plained Gibb. “I am in a unique posi-tion because I have commissionedand maintained this equipment andcan relate to what the operators areexperiencing. As well, I can explainin simple terms how the equipment

The goal of Industrious Solutions isto deliver relevant technical trainingthat enables operators to operate gascompression equipment safely and ef-ficiently, Gibb said. The company’sprograms enhance the operators’ skillset in five areas: observation, trou-bleshooting, theoretical understand-ing, equipment utilization and equip-ment ownership. By increasingawareness in these areas, operatorsgain confidence in executing their re-sponsibilities, and with a better under-standing of the equipment andprocesses, their sense of ownership inthe facilities and operations increases.

Gibb delivers his training programsthrough a series of modules. Moduletopics include engines, electric motors,reciprocating and screw compressors,coolers, foundation issues, vibration,pulsation, compressor suction and dis-charge valves, and how gas reactswhen it is compressed. Each moduletopic is available in three levels, de-pending on the depth required.

Because research indicates that 75%of people are visual learners, 15%learn by listening and the remaindercomprehends by reading, Gibb spentconsiderable time developing the vi-suals for his courses. Charts and im-ages include the use of brilliant colorsand hand-developed imagery that re-duces the amount of text required.These factors contribute to thetrainees’ ability to retain the conceptsthey learn, Gibb said.

Before a training program is deliv-ered, Gibb performs a needs assess-ment study to gain an understandingof the skills shortage. The assessmentis performed either on-site or through

functions and what to do to fix andmaintain it.” As an example, a recip-rocating compressor is dependentupon the operator having a clear un-derstanding of the forces at workwhile the gas is being compressed.Compressor rod loading, crossheadpin reversal and the effect that thegas re-expansion event has on theoperation of the suction and dis-charge valves are all explained ineasy-to-understand terms.

Gibb also provides insights aboutwhy certain procedures should be fol-lowed as recommended by equip-ment manufacturers. For instance, theimportance of using a torque wrenchwhen installing spark plugs on an en-gine is stressed because over-tighten-ing causes small hydraulic fracturesinside the plug and unduly com-presses the gasket. This results in volt-age leaks and reduced heat transfer.Often participants have experiencedignition system problems that affectan engine’s performance, but do notknow why it happened. Many sparkplug failures are the result of poor in-stallation practices, he said.

Industrious Solutions also performsroot cause failure analyses. The proc-ess and outcomes are shared withparticipants to help them troubleshoottheir own issues and avoid similarfailures. One such example is thelong-term effect of using air impacttools on compressor valve cap retain-ing bolts. Often in this situation whenthe bolts were tapped on a flat sur-face, fine metal casting granules canbe observed. Observations revealedthat each time the hardened boltswere removed from the softer casting

(Left) This illustration explains how cavitation is caused and its damaging effects. Cavitation is the undesirable repetitive mechanical erosion thatresults from air bubbles entering a cooling system. The result is coolant entering the crankcase and contaminating the engine’s lubrication oil.(Right) This chart explains the naturally occurring torsional effects that occur when a spark plug is fired. The rapid expansion of the combustiongases creates a repetitive winding up and relaxation effect within the crankshaft, which is managed through harmonic dampers.

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This course outline is used to delivera typical Level 2 training program tonatural gas operations personnel. Theprogram is delivered on-site over oneor two days, depending upon the levelof detail required by the participants.

Level 2 — Natural Gas Engine andCompressor Package Training

Listing of Program Topics

Opening — Introduction

Compressor Drivers• Driver options — engine or electric

motor.• Defining high performance — indus-

trial use of equipment.• Understanding the contributing

factors that cause pre-ignition anddetonation — critical intake airtemperature design.

• Fuel systems — component identifi-cation, air/fuel ratios and trou-bleshooting tips.

• Turbochargers — operation and ad-

Natural Gas ReciprocatingCompressors• Gas compressor selection process

— performance software exercise.• Compressor valves — suction and

discharge.• Piston rings — sealing.• Rod packing — function.• Packing vent and drain system op-

tions — examples and function.• Managing mechanical forces.• Controlling cylinder capacity.• Pressure volume — the effect on

valve operation.• Compressor rod loading — limita-

tions and protection.• Crosshead pin reversal — prevent-

ing a failure and examples of oper-ating scenario.

• Compressor lubrication systems —main and auxiliary.

• Component identification — func-tion and troubleshooting tips.

• Compressor fasteners — criticalservice cyclical effects.

Question and Answer Period

COURSE OUTLINEvantages over naturally aspiratedengines.

• Engine lubrication systems — func-tion and components.

• Cooling systems — main, auxiliary,types of coolers and troubleshooting.

• Cooling system fans—prevention ofoverloading and overcooling, andtroubleshooting.

• Understanding cooling systems —preventing cavitation and trou-bleshooting.

• Managing engine crankshaft tor-sional effects — engine loading andfan drives.

• Understanding how crankshaft fail-ures can be prevented.

• Ignition systems — understanding thecritical ignition system components.

Natural Gas Screw Compressors• Screw compressor loading and un-

loading.• Lubrication — flood screw design.• Filtration — inlet and final dis-

charge.

using high-speed air impact tools, asmall amount of metal from thethreads was removed. This problembecomes more pronounced as theequipment ages. Operators are in-structed to follow the manufacturer’smaintenance instructions, use the ap-propriate torque wrenches and limitthe use of air impact tools in criticalfastening situations.

“We have had excellent successwith this approach of using real-lifeexamples in the training process,”said Gibb. “The feedback from op-

erators has been positive and theytake ownership of the equipment.We provide training to engineers,management and administration —to anyone connected to the naturalgas industry. We also offer personaland career development courses,such as effective communications,conflict resolution and goal-setting.All are designed to help opera-tions personnel achieve their careeraspirations.”

Along with delivering trainingprograms and root cause failure

analysis services, Industr iousSolutions also evaluates mainte-nance programs and provides busi-ness development consulting ser-vices. Gibb and his team of gascompression experts provide directindustry experience to gas produc-ers throughout Canada. A

Industrious Solutions Inc. specializes intraining on all aspects of natural gas com-pression. Bill Gibb works directly with pro-ducers to maximize their gas production byproviding customized on-site technical andcareer development training programs.

This illustration explains crosshead pin reversal in a reciprocating gas compressor and identi-fies wear patterns that develop over the service life of the components.

REPRINTED FROM JULY 2009 COMPRESSORTechTwoCopyright Diesel & Gas Turbine Publications

Printed in U.S.A.

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