Course Details

Objective

By attending this course you will gain an understanding of the characteristics of various types of Reciprocating Rotary pumps and compressors and their components. The course will provide engineers and technicians with information for the optimal selection, operation and maintenance of positive displacement pumps as well as positive displacement and dynamic compressors.

Content

DAILY OUTLINE

A- POSITIVE DISPLACEMENT PUMPS

1. Positive displacement pumps
   1. External gear pumps
   2. Internal gear pumps 
   3. Archimedes screw pumps
   4. Twin-rotor screw pumps
   5. Triple-rotor and 5-rotor screw pumps
   6. Twin-rotor geared-screw pumps
   7. Progressive cavity pumps
   8. Lobe pumps (including circumferential piston pumps)
   9. Vane pumps
   10. Peristaltic pumps(including rotary peristaltic pumps)
   11. Rotary eccentric piston pumps
   12. Axial and radial piston pumps
   13. Inline piston pumps
   14. Descaling pumps
   15. Plunger pumps(includes horizontal and vertical)
   16. Syringe pumps
   17. Diaphragm pumps (includes mechanical and hydraulic actuation)
   18. Air-operated double-diaphragm pumps
   19. Metering pumps (flow within + 0.1% to + 3% with substantial dp changes)
   20. Direct-acting reciprocating pumps (includes pneumatic, hydraulic and steam actuation)
   21. Non-metallic positive displacement pumps
   22. Sealless positive displacement pumps
   23. Hydraulic motors
2.  Pump theory
   1. Positive displacement pumps
   2. Rotary positive displacement pump theory
   3. Reciprocating positive displacement pump theory 
   4. Positive displacement pump curves
   5. Classification of positive displacement pumps by application
   6. Classification of other pump types by application
3.  Pumps and piping systems
   1. Pump hydraulic data
      1. Hydraulic tolerances 
      2. General 
      3. Rotodynamic pumps
      4. Positive displacement pumps 
      5. Pump H and Q at maximum efficiency qmax 
      6. Minimum pump flow
      7. Devices for obtaining a minimum flow
   2.  Water hammer
      1. Hydraulic gradient 
      2. Causes of water hammer 
      3. Pump behaviour after power loss
   3. Pressure pulsations
      1. Rotodynamic pumps
      2. Positive displacement pumps
4. Materials for pumps
   1. Introduction
   2. Typical materials
   3. Corrosion and erosion
   4. Abrasion resistant materials
   5. Materials resistant to cavitation damage
   6. Material selection
5. Process seals and sealing
   1. Reciprocating rods
      1. Lip seals
      2. Soft packing
   2. Process liquid seals for reciprocating rods
      1. Operating principles 
      2. Design variations
      3. Packing material
      4. External systems
      5. Maintenance
      6. Trouble-shooting
   3. Process liquid seal selection
      1. Process liquid
      2. Size, speed and pressure
      3. Local environment
   4. Cost
   5. Standardisation
6. Ancillary equipment
   1. Accumulators
   2. Pulsation dampers
   3. Instrumentation
7. Quality, inspection and testing
   1. Corrosion resistance
   2. Non-destructive testing
   3. Repairs
   4. Welding
   5. Inspection
8. Installation and maintenance
   1. Tanks, valves and sumps
   2. Care and maintenance
      1. General considerations
      2. Commissioning
      3. Care of equipment 
      4. Preventative maintenance 
      5. Trouble-shooting guides 
      6. Stocking spare parts
9. Pump selection
   1. General operating conditions
      1. Liquid properties and operating conditions
   2. Selection of pump according to duty and capabilities
   3. Selection of pump according to hydraulic performance
   4. Pumps for liquid-solid mixtures

B- Compressor content

1.  Introduction
   1. What is a Compressor?
   2. How Compressors work?
   3. Compressor Classification and Type Selection
2. Different Types of Compressors
   1. Dynamic Compressor Training
   2. Ejector
   3. Radial / Centrifugal
   4. Axial 
   5. Positive Displacement Compressor Training 
      1. Rotary Compressor 
      2. Sliding Vane
      3. Liquid Ring 
      4. Screw 2.2.1.4. Lobe (Roots)
   6. Reciprocating Compressor
      1. Trunk type
      2. Crosshead Type
3. Detailed Description of Popular, Industrial Compressors
   1. Operation Principle of Utility Air Compressors
      1. Screw Compressor – Skid Mounted
         1. Principle of operation
         2. Control System and Lube oil circuit
      2. V–Type, Trunk and Crosshead Compressor – Skid Mounted 
         1. Multi Stage, Trunk and Crosshead, principle of operation
         2. Air and Cooling Circuit
      3. Horizontal, Balanced, Opposed, Multi Stage Compressor
   2. Operation Principle and Maintenance concepts of Process Gas Compressors
      1. Double Acting, Single and Multi Stage Reciprocating Compressor
         1. Principle of Operation 
         2. Lubrication
         3. Crankcase Main Bearing / Con-rod Big End Bearing
         4. Cylinder and Packing Lubrication
         5. Crankcase / Crank Shaft / Connecting Rod / Crosshead
         6. Valves
         7. Compressor Piston, Piston Elements, Piston Rod Reversal, Piston Runout and Piston End Clearances
         8. Stuffing Box and Rod Packing elements
         9. Compressor Cylinder Cooling System / Inter Cooling / After Cooling
         10. Control System
         11. Compressor Capacity Controls
         12. Intake Unloader Valve
         13. Clearance Pocket Unloading
      2. Centrifugal Compressors 
         1. Centrifugal Compressor Working Principle
         2. Capacity
         3. Head
         4. Compressor Surge / Compressor Surging and Compressor Anti Surge
         5. Thrust Balancing
         6. Lube Oil System
         7. Seal Oil System
         8. Component Arrangement
         9. Sealing Arrangement
         10. Dry Gas Seal
         11. Bearing Arrangement
4. Troubleshooting & Maintenance
   1. Principles of troubleshooting
      1. Principles
      2. Failure modes 
      3. Reasons of Failure  
         1. Mechanical seals
         2. Bearings
         3. Shaft deflection
         4. Cavitation in pumps
         5. Surge in compressors
            1. Causes of compressor surge
            2. Surge and compressor performance 
            3. Anti-surge methods
         6. Statistics of more frequent troubles
5. Maintenanceof Pumps and Compressors.
   1. Maintenance strategies 
   2. Measuring methods
   3. . Monitoring and Data collection 
      1. Condition monitoring 
      2. Vibration.
      3. Thermography

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

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