BTS

Practical Pump Technology (API 610) (Selection, Applications, Operation, Troubleshooting, And Maintenance)

This comprehensive course is designed to provide an in-depth perspective of pump technology in terms of selection, operation, maintenance and repair. Topics covered include pump types and terminology, centrifugal and positive-displacement pumps, packing, mechanical seals and sealing systems, bearings, couplings and other vital components. In addition, various pump types will be examined as to how they perform in their respective operating systems and advantages and disadvantages of various pump types will be discussed. Pump operation, trouble-shooting and maintenance will be dealt with in depth. This course provides a comprehensive understanding of the various types of reciprocating, rotary, and centrifugal pumps. This includes piston pumps, plunger pumps, rotary pumps, screw pumps, two- and three-lobe pumps, cam pumps, vane pumps, bellows-type metering pumps, diaphragm pumps, canned motor pumps, and centrifugal pumps. The characteristics, selection criteria, sizing calculations, sealing arrangements, common problems, repair techniques, as well as the preventive and predictive maintenance of these pumps are covered in detail. This course will provide the candidates with a complete and up-to-date knowledge of pumps and their systems. Further, participants will learn more about selection, operation and maintenance strategies which will assist in increasing pump availability and reliability. Upon the completion of this program, the candidates will be able to troubleshoot all types of pump problems. The course will introduce the candidates to the different types of pumps and their associated terminology. Centrifugal and positive displacement pumps, packing, mechanical seals and sealing systems, bearings and couplings will all be discussed. The application of the different types of pumps will be discussed along with their suitability for different operational duties. Pump operation, troubleshooting and maintenance will be dealt with in depth. This course is a MUST for those who use this equipment. It covers how pumps operate and provides the guidelines and rules that must be followed for their successful application.

The Training Course Will Highlight ?

This course provides the following for all types of pumps and bearings:

Basic Design
Specification
Selection Criteria
Sizing Calculations
Sealing Arrangements
Common Operational Problems
All Diagnostics, Troubleshooting

Training Objective

By the end of this course delegates will be able to:

Have an understanding of the different types of pumps
Be able to operate pumps as close as possible to the design efficiency
Monitor pump efficiency, availability and reliability
Have learnt about selection, operation and maintenance strategies
Be able to troubleshoot pump problems
Be able to critically analyze the methodologies employed within the organization and instigate improvements where required
Optimize the operation and maintenance of different types of pumps
Carry out failure analyses on pumps thereby avoiding repetitive failures
Have an understanding of centrifugal and positive displacement pumps, packing, mechanical seals and sealing systems, bearings and couplings
Have an understanding of different parameters affecting the operation of valves
Have the ability to select the right valve for the particular application and to perform the necessary calculation for valve sizing
Have the ability to perform troubleshooting of systems involving valves
Have the ability to decide on the right maintenance plan concerning different types of valves
Maximize the efficiency, reliability, and longevity of all types of pumps
Size and select out of the various types of dynamic and positive displacement pumps using the performance characteristics and the selection criteria that you learn in this program
Carry out diagnostic testing and inspection of critical components with the knowledge of common failure modes of pumps by applying advanced fault detection techniques
Select bearings and lubrication, pump sealing arrangements, meet commissioning requirements, troubleshoot, provide predictive and preventive maintenance, enhance reliability, and reduce cost.
Determine the maintenance required to minimize pump downtime and operating cost and maximize its efficiency, reliability and useful life
Gain a thorough understanding of pump characteristics
Understand all the causes of failures in pumps
Determine all the design features that improve the efficiency and reliability of all pumps
Design different types of pumping systems
Gain a thorough understanding of the various types of sealing arrangements used in compressors

Target Audience

Engineers of all disciplines, Supervisors, Team Leaders and Professionals in Maintenance, Engineering and Production Managers, Technicians, Maintenance personnel, Heads of Maintenance and Operation, Mechanical and Chemical Engineers, Equipment Specialists, Technical Engineers, Operation Engineers, Planning Engineers, Process Engineers, Reliability Specialists, Engineers involved with control and safety valves and pumps of different types, anyone who wishes to update themselves on pump technology, judge the suitability of different types of pumps for their needs, and learn how to operate and maintain them for the benefit of their organizations

Training Methods

Daily Agenda

Introduction: Pumping Systems

Introduction
Pump Types and Terminology
Pump Performance (Centrifugal and Positive Displacement)

Understanding Head

Types of Head: Friction, Pressure, Static & Velocity
Friction in Valves, Piping & Fittings
Calculating Actual Head in a System

Cavitation in pumps and valves

Net Positive Suction Head (NPSH)
Vapour and Gas Cavitation
Flashing versus Cavitation

Pump Types: Positive Displacement Pumps

Reciprocating Pumps
Reciprocating Pump Valves
Rotary Pumps scroll and gear types
Special Application Pumps metering pumps, diaphragm pumps
Failure Mechanisms identification and monitoring

Pump Types: Centrifugal Pumps

Centrifugal Pump Theory
Matching Pumps with Drivers
Pump Wear Rings and Balance Lines
Multi Stage Pumps
Performance Analysis
Failure Mechanisms – identification and monitoring
Failure Mechanisms identification and monitoring

Seals and Bearings

Conventional Packing Glands
Mechanical Seals
Seal Failure Mechanisms
Maintenance and Repair of Mechanical Seals
Bearings failure modes and how to extend life

Achieving Pump Reliability

Sealing Systems
Conventional Packing Glands, Mechanical Seals & Flush Plans
Seal Failure Mechanisms
Maintenance and Repair of Mechanical Seals
Bearings – failure modes and how to extend life
Lubrication
Plain Bearings
Anti-Friction Bearings
Couplings & Alignment
Couplings
Alignment & Balancing
Foundations & Bedplates

Positive Displacement Pumps, Troubleshooting, Maintenance, and Selection of Pumps

Reciprocating Pumps, Piston Pumps, Plunger Pumps, Rotary Pumps, Screw Pumps, Two- and Three-Lobe Pumps
Cam Pumps, Vane Pumps, Bellows-Type Metering Pumps
Diaphragm Pumps
Canned Motor Pumps, Seal-less Pump Motors
Pump Maintenance, Inspection, Overhaul, Diagnoses of Pump Troubles
Troubleshooting of Centrifugal Pumps
Troubleshooting of Rotary Pumps
Troubleshooting of Reciprocating Pumps
Water Hammer
Smart Instrumentation
Pump Selection
Pumping System Calculations
Vibration Analysis and Predictive Maintenance
Diagnostics of Pumping Systems
Pump Drivers

Valves Troubleshooting & Maintenance

High Pressure Drop
Pressure Recovery Characteristics
Flow Choking
High Velocities
Water Hammer
What causes water hammer?
Solutions for water hammer
Troubleshooting the Control & Isolation Valves
Review of common faults
Developing a Preventive Maintenance Plan
Review of the Week & Wrap-Up

Valves Technology

Types of Valves (globe, gate, ball, plug, check)
Flow characteristics
Flow through valves
Valve flow characteristics
Linear, quick opening & equal %
Valve Sizing
Calculating the correct Cv value
Selecting Valve Size Using Valve Coefficient
Calculations for Correct Valve Selection
Sealing performance
Leakage Classifications
Sealing Mechanisms
Valve stem seals

Pump Categories, Centrifugal Pumps and Mechanical Seals

Pump Categories
Centrifugal Pumps: Operation, Casings and Diffusers, Hydrostatic Pressure Tests, Impellers, Hydraulic Balancing Devices, Mechanical Seals, Minimum Flow Requirement, Performance
Characteristics, Cavitation, and Net positive Suction Head
Centrifugal Pump Mechanical Seals, Components, Temperature Control, Seal Lubrication/Leakage, Applications, Types of Mechanical Seals, Common Failure Modes of Seals, Seal Refurbishment
Maintenance Recommended for Centrifugal Pumps
Vibration Analysis and Predictive Maintenance

Accreditation