Location

Date

Duration

Language

Discipline

Introduction

Pumps Troubleshooting means to find the root cause behind the problems or failures of the pump. Troubleshooting is a complete exercise involves number of activities that need to be practiced carefully and accurately for the troubleshooting to be successful. A good monitoring system, enough instrumentations, adequate data recording system, expert edition process of the accumulated data, right technique and analysis, need to be available. Of course troubleshooter must be deeply understand and familiar with the machine he is troubleshooting, the design, operation, oil systems, flushing systems, bearings, balancing systems, type of mechanical seals, and the application.

The course will discuss all aspects concerning pumps, familiar the participant with the details of pumps, different designs, application, operation, maintenance and potential problems and their possible root causes, and methods of eliminating or reducing the failure causes, methods analysis to find out the root causes of failures, and methods of curing such problems. A successful troubleshooting method increase the uptime of machines, increase the profitability of the plant, and assure more safety for machines and personnel and minimize the cost of maintenance. will discuss different aspects of pipeline pigging and its different applications for the pipelines.     

Objective

• Deep understanding of the pumps’ different designs for different applications
• Familiarize the participants with different auxiliary systems for pumps, oil system, mechanical seals, flushing systems, balancing systems and alike
• Learn the performance, limit of operations and common causes of failures of pumps
• Learn methods of failure analysis, like oil analysis, vibration measurements, etc…
• Learn the principles and elements of troubleshooting methodology
• Learn the appropriate strategy of maintenance 

Audience

The course is designed for plant safety specialists, maintenance engineers and technicians, maintenance planners, system engineers and operators in the power generation, oil, chemical, paper and other processing industries involved in pumps selection, specification, procurement, inspection, troubleshooting or repair. Mechanical and operation engineers and senior technicians who are responsible for specifying, selecting, operating, and troubleshooting and maintaining pumps.

Content

Day One

1. Pumps: Performance, Control and Operation

Manufacturer Characteristic Curves

          How to obtain pump performance curves experimentally

          How to calculate pump performance curves operated at different speed

How to calculate pump performance curves for different impeller size

How to correct pump characteristics for fluid viscosity

Effect of suction conditions on pump characteristics

Positive displacement pumps Metering Feature

Limits of Operation

ISO and ASME characteristic curves

          Preferred range of operation

          Allowable range of Operation

          Pump cavitation, NPSH_R

               Pumps minimum flow rate limit

Pumps Controls

          Pump and System interaction

          Variation of operating conditions

          Protective controls

          Capacity control

          Modification by speed variation

          Modification by valve positioning

Day Two

2. Pumps: Selection, Standards, and Specifications

Pumps Standards:

          ANSI, HI, API, ASME, ISO standards

          How standards differ

          Standards tolerances

Pumps Application

          Boiler Feed Pumps

                    Pump capacity, suction conditions, and discharge pressure

          Condensate Pumps

                    Extremely low NPSH_A

          Water works

                    Ground and surface water sources

          Petroleum refinery service pumps (API-610)

Production, transportation and refining, high degree of standardization

          Chemical pumps

The widest variety of pumping problems, corrosive and corrosive-abrasive liquids

          Paper stock and process pumps

                    Similar to chemical pumps, non-clogging impellers

          Sewage and waste water

                    Submersible pumps

          Food and beverage sanitary pumps

                    Cleanliness and Contamination problems and Dispensing

          Air conditioning and refrigeration pumps

                    Sodium chloride and calcium chloride brines    

The piping system to serve

          System Head curve

                    How to calculate friction loss

          Suction system configurations, NPSH_A

                    How to calculate NPSH_A

Pumps ratings

          Head, Capacity and Power

          Manufacturer Data

                    How to read through the manufacturer catalogues

          Manufacturer Selector Chart

Specifications and inquiries

          Preparing pump inquiries

          Inquiries for specific services

                    Water works services

                    Chemical services

                    Petroleum services

Day Three

3. Pumps: Design, Materials and Seals

Types of Pumps

          Positive displacement pumps

          Rotary Pumps

          Dispensing Pumps

                    Metering Feature

          Centrifugal pumps

          Axial flow pumps

          Multistage pumps

Special design pumps

          Vertical pumps

          Seal-less magnetic drive pumps

          Submersible wastewater pumps

          Multi-phase pumps

Pumps fittings

          Standard fitted pump

          All bronze, all iron, acid-resisting and salt water pumps

Material Selection, pH value, and galvanic corrosion

Mechanical seal selection

          Single seals

          Double seals

          Cartridge seals

          Dry gas seals

Seal flush and circulation plans

Day Four

4. Pumps: Failure Analysis, Troubleshooting and Maintenance 

The six sigma problem solving method ‘DMAIC’

(Development, Measurement, Analysis, Improvement, and Control Phases)

Pump condition monitoring

          Vibration Analysis

                    Vibration severity charts

          The head-Flow Method

                    Shut-off Head Method

          Thermodynamic Method

          Balance Flow Measurement

Reasons for Failures

          Mechanical

                    Mechanical seal

                    Shaft deflection

                    Lubrication system

                    Balancing system 

          Operational

                    Reduced NPSH

                    Low flow operation

                    Cavitation

                    Parallel flow operation

          Maintenance Strategies

                    Preventive Maintenance

                    Predictive Maintenance

                    Proactive Maintenance

Day Five

5. Case Studies
   1. system resistance reduction
   2. system resistance increase
   3. pump internal wear
   4. pump internal leakage
   5. pump foundation deterioration
   6. cavitation effect
   7. erosion and corrosion effect
   8. wearing ring problem

6. Delegates case studies

Each group supposes to bring with them their own cases in order to analyze them and come up with the root cause behind the failure. The case should be supported with the necessary documents: the pump catalogue, the piping system, the type of service, the description of the problem, and the measurement carried out.

Certificate

TRAINIT ACADEMY will award an internationally recognized certificate(s) for each delegate on completion of training.

Methodology

The training course will be highly participatory and the course leader will present, guide and facilitate learning, using a range of methods including formal presentation, discussions, sector-specific case studies and exercises.  Above all, the course leader will make extensive use of real-life case examples in which he has been personally involved. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences.  Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Case studies & Practical Exercises
• 10% Role Play
• 10% Videos, Software or Simulators (as applicable) & General Discussions

Fees

£5,500 per Delegate. This rate includes participant’s manual, Hand-Outs, lunch, coffee/tea on arrival, morning & afternoon of each day.