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Course Details

BASIC PUMP TECHNOLOGY

Location
Dubai, UAE
Date
From Date: 23-Oct-2022   
To Date: 27-Oct-2022
Duration
5 Days
Language
English
Discipline
Introduction

Ref No:        ME042
Title:            Basic Pump Technology
Start Date:  23 October 2022 End Date: 27 October 2022  
Venue:         Dubai, UAE
Fee:             $4,500

In any of the 5 star hotels. The exact venue will be informed once finalized.

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
  • Exercise the troubleshooting on real cases
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

COURSE DAILY OUTLINE 

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, NPSHR
  • Pumps minimum flow rate limit
  • Pumps Controls

Pumps Controls

  • Pump and System interaction
  • Variation of operating conditions
  • Protective controls
  • Capacity control
  • Modification by speed variation
  • Modification by valve positioning

Day Two

  1. 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 NPSHA
  • 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, NPSHA
  • How to calculate NPSHA

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

  1. 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

  1. Case Studies???????
    • system resistance reduction
    • system resistance increase
    • pump internal wear
    • pump internal leakage
    • pump foundation deterioration
    • cavitation effect
    • erosion and corrosion effect
    • wearing ring problem
       
  2. 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.

NOTE:
Pre & Post Tests will be conducted
Case Studies, Group Exercises, Group Discussions, Last Day Review & Assessments will be carried out.

Certificate

Define Management Consultancy & Training Certificate of course completion will be issued to all attendees.

Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions, and motivate everybody find the right answers.
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.
Very useful Course Materials will be given.

  • 30% Lectures
  • 30% Workshops and work presentation
  • 20% Group Work& Practical Exercises
  • 20% Videos& General Discussions
Fees
4,500 US$ per participant for Public Training includes Materials/Handouts, tea/coffee breaks, refreshments & Buffet Lunch

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