:: DEFINE | Management Consultancy & Training Provider In UAE, Abu Dhabi,Dubai,Saudi Arabia ::

BASIC PUMP TECHNOLOGY

Location

Dubai, UAE

Date

From Date: 21-Oct-2024
To Date: 25-Oct-2024

Duration

5 Days

Language

English

Discipline

Introduction

Ref No:   ME042
Title:     Basic Pump Technology
Start Date:  21 October 2024  End Date:25 October 2024
Venue:     Dubai, UAE
Fee:     $5,500

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

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

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

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

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
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

Course Details