Operation, Maintenance and Troubleshooting

Two Seperate Bookable Courses

Course one

• Pumps - Types, Operation, Selection and Specifications

Course Two:

• Pumps, Seal and Bearings - Troubleshooting and Maintenance

These Courses You Will:

• Understand the characteristics of various types of pumps
• Learn the most appropriate pump for the right application
• Learn how to calculate the performance of pumps
• Understand how different parameters affect pump operation
• Learn how to select the most economical seals and bearings
• Learn how to apply the related standards and specifications

Who should attend:

Heads of Maintenance and Operation, Mechanical and Chemical Engineers, Equipment Specialists, Technical Engineers, Rotating Equipment Engineers, Vibration Monitoring Engineers, Planning Engineers, Lubrication Managers and Plant Engineers.

Pumps - Types, Operation, Selection and Specifications

Day One - Saturday, 21 June 2003

Types of Pumps

• Pumping methods
  •  Centrifugal, lifting, forcing

• Pumps classifications, range of operation
  •  Rotodynamic, positive displacement, rotary

• Rotary pumps
• Internal gear, external gear, loop, sliding-vane
• Comparison between different types of rotary pumps
• Dynamic pumps
• Centrifugal and axial
• Comparison between centrifugals and rotary pumps
• Pump performance curves, measurements and calculation
• H-Q, P-Q, Eff-Q, NPSH-Q curves
• Characteristics of the pump curves
• Euler's versus actual pump curves
  
  1. Different types of losses, prewirl, hydraulic losses, mechanical losses and volumetric losses

• Factors affecting pump performance curves
• Similarity laws, specific speed and specific diameter
  
  1.   Effect of speed variation, effect of impeller diameter trimming

Day Two - Sunday, 22 June 2003

Pumps Operation and Control

• Major items in pump operation
• Basic concepts of pump operation
• Piping system
• Pump curves versus system curves
• Operating point
• System H-Q curve calculation
• Pressure drop due to piping
• Pressure drop due to piping fittings and equipments
• Pump load
• Sizing suction piping
• Sizing discharge piping
• NPSH available

•  Method of calculation

• Suction system configuration

•  NPSH required, measurement, calculation, standards, cavitation

• Design operating conditions
• Normal operating range, minimum and maximum flow rate limits
• API standard recommendations
• Off -design operation and power losses
• Pump surging
• Surge prevention
• Parameters affecting the pump operation
• Capacity Regulation
• Methods of capacity control
• Bypass systems
• Recirculation systems
• Automatic recirculation control
• Minimum required flow rate
• Control methods and power saving
• Series and parallel operation
• Why series and parallel connection
• As a method of capacity control
• Multistage pumps
• Trouble free operation
• Operation under cavitating conditions
• Ways of reducing cavitation
• Super cavitating pumps
• Operation at reduced flow rate
• Pump starting and shutdown
• Motor load at starting and at shutdown
• Priming, self-priming, methods of priming
• Pumps while running
• Operating difficulties

•  Operation problems and solutions

Day Three - Monday, 23 June 2003

Selection And Specifications

• Pump standards
• Standards in USA
• HI standards
• Other standards
• Universal standards
• API standards and specifications
• Pump selection
• Procedure to choose pumps
• Factors affecting pump selection
• Manufacturer data and curves
• Liquid properties
• Ph number
• Material selection
• Hot and cold applications
• Slurry
• Pump performance curve correction
• Pumps applications and selection
• Pumping arrangement
• Prime movers
• Economical consideration

•  Special applications

• Advantages and disadvantages of centrifugal pumps
• Features of other types of pumps
• Pump inquiries
• Ordering requirements
• Essential data required

Course Two

Pumps, Seal and Bearings - Troubleshooting and Maintenance

Day One - Tuesday, 24 June 2003

Packing and Mechanical Seals

• Packing
• Shaft sealing
• Packing sizing
• Packing material
• Packing installation
• Mechanical seals
• Mechanical seal life
• Basic concepts of mechanical seals
• Comparison with thrust bearings
• Mechanical seal components
• Types of mechanical seals
• Pusher and non-pusher type
• Balanced and un-balanced type
• Seals configurations
• Single seal
• Multiple seal
• Tandem type
• Double seal
• Dual seal
• Mechanical seal components
• Primary components
• Secondary components
• Elastomers
• Seal flushing systems
  
• Seal flushing arrangements

• Comparison between packing and mechanical seal

Bearings

• Hydraulic loads
• Radial load
• Axial load
• Shaft deflection
• Axial load balancing
• Balance disk
• Impeller arrangement

•  Double suction pumps

• Bearing functions
• Anti-friction bearings
• Bearing loads
• Maximum-capacity bearings
• Bearing misalignment capacity
• Bearing arrangements
• Ball bearing fits, housing fits and shaft fits
• Hydrodynamic bearings
• Self- and non-self-aligning bearings
• Lubrication methods

Day Two - Wednesday, 25 June 2003

Troubleshooting And Maintenance

• Principles of troubleshooting
• Objective of machinery troubleshooting
• Failure analysis
• Failure causes
• Failure modes
• Symptom

• Classes of troubles
• Real hydraulic problems
• Real mechanical problems
• Unreal hydraulic problems
• Methods of diagnosis
• Mechanical failure approach
• Using performance curves
• Monitoring and Data collection
• Types of collected data
• Data recording options
• Well-organised data requirement
• Main problems of the centrifugal pumps
• Causes of pump failure
• Improper repair/installation
• Improper operation
• Causes due to fluid
• Causes due to gas pockets
• Classification of causes
• Suction troubles
• System troubles
• Mechanical troubles
• Mechanical seals failure
• Why seals fail
• Mechanical seals troubleshooting
• Bearing failure
• Bearing life
• Bearing lubrication
• Shaft deflection
• Misalignment
• Problems caused by shaft deflection
• Cavitation
• Types of cavitation
• Failure due to cavitation
• Cavitation diagnosis
• Reducing and eliminating causes of cavitation
• Minimum flow rate problems
• Failure due to reduced flow rate
• Bypass systems a solution to reduced flow problems
• Pumps maintenance

For more information, email us: training@kupic.net