PUMPS AND PUMPING SYSTEMS: PRACTICAL APPROACH FOR EFFECTIVE OPERATION, MAINTENANCE AND TROUBLESHOOTING COURSE

PUMPS AND PUMPING SYSTEMS: PRACTICAL APPROACH FOR EFFECTIVE OPERATION, MAINTENANCE AND TROUBLESHOOTING COURSE

Course Description

DURATION

14 hours (Two (2) days)

 

TARGET GROUP

  • Maintenance and production staff – supervisors, foreman and technician
  • Procurement and inventory executives
  • Senior plant and control room operators
  • Contractor and pump supplier
  • Sale and application engineers

 

TARGETED INDUSTRY/INDUSTRIES

Oil & Gas, Petrochemicals, Power Plant, Renewal Energy Plant, Co-Generation Plant and all industries that are using air compressors and compressed air systems.

 

CERTIFICATION

Not applicable.

 

COURSE OVERVIEW

This Pumps and Pump Systems course emphasizes pumps and the systems that run them. The course is geared toward operation and maintenance personnel with responsibility for pump specification, installation, and operating efficiency at their facility. This course begins with basic pump functions and features so that participants can learn how to properly specify a pump for a given system, followed by pump selection, pump installation.

 

COURSE OBJECTIVE

  • To acquire information and familiarization on pumps and pumping systems, and their applications
  • To provide a wide range of knowledge on pump technology, their components and related equipment
  • To explore best practices and guideline on pump installation
  • To enhance skill in operating and maintenance aspects of pumping systems
  • To troubleshoot pump malfunction, problems and issues related to piping systems

 

COURSE OUTCOMES

At the end of the course, the delegates will be able to: –

  • Contribute to the pump selection process through improved knowledge of the hydraulic performance and behavior of pumps and their operating limitations
  • Understand pumping system characteristics and the interaction of pumps and systems for single and multiple pump installations
  • Recognize operating conditions which cause pump and system operating problems
  • Understand the process of pumps’ condition monitoring and maintenance system

 

TRAINING METHODOLOGY

  • Lecture
  • Classroom discussions
  • Case study

 

COURSE CONTENTS

MODULE 1 : INTRODUCTION TO PUMPS AND PUMPING SYSTEMS

  • What are pumps?
  • Duty, function and types of pump applications
  • Installation of pumping systems, associated fittings and effecting factors
  • Pump family and their working principle
  • Hydrokinetic pumps and components – centrifugal, axial and mixed flow
  • Positive displacement pumps and components – gear, lobe, screw, vane and piston
  • Metering and vacuum pumps, special types and duty of pumps

 

MODULE 2 : COMPONENTS OF CENTRIFUGAL PUMPS AND THEIR TECHNOLOGY

  • Type and effect of casings: volute and vortex
  • Impeller: types and constructions
  • Split casing, double suction pump
  • Multistage pumps – vertical and horizontal installation
  • Submersible pumps – applications and advantages
  • Seal and packing: types, arrangement and installation
  • Bearing and lubrication strategies
  • Wear rings and leakage joints
  • The effect of balancing devices (piston and disc)
  • Installation of shaft, sleeve and eye ring

 

MODULE 3 : CENTRIFUGAL PUMPS: PERFORMANCE AND TESTING

  • Testing requirements (factory and on-site) and procedures
  • Pump curves – Head (H), Efficiency (η), BHP, NPSH vs Flowrate (Q)
  • Reading pump performance and charts
  • Testing and determination of Net Positive Suction Head (NPSH)
  • Requirement of NPSHR and NPSHA for cavitation

 

MODULE 4 : CAVITATION, AIR AND VAPOUR LOCK

  • Cavitation in pump and relation to suction head
  • Effects of cavitation to the pump performance
  • Effect of NPSHR and NPSHA to pump cavitation
  • Guidelines in prediction and prevention of pump cavitation
  • Cavitation damage and pump failures
  • Air pocket and vapour lock and their related problems
  • Procedures in releasing vapour and air locks

 

MODULE 5 : BEST PRACTICE IN PUMP COMMISSIONING, START-UP AND OPERATION

  • Preparation for commissioning
  • Start-up approach and procedures for several types of pump installations
  • Requirement and procedure for pump priming and venting
  • Observation and monitoring of pump operation
  • Normal and emergency shutdown practices
  • Minimum flow requirements

 

MODULE 6 : PUMP AND PIPING SYSTEMS: MAINTENANCE AND TROUBLESHOOTING

  • Pump maintenance: breakdown, predictive, preventive and TPM
  • Best practice and guidelines in pump installation
  • Suction system and its effects
  • Cavitation in pump and cavitation damage
  • Air pocket and vapour lock, and procedures to release vapour and air locks
  • Bearing and lubrication
  • Pump failure and repair

 

MODULE 7 : PLANT VISIT AND EQUIPMENT INSPECTION (For In-house program only)

  • Plant visit and inspection
  • Discussion on operational aspect of pumps
  • Revision on maintenance practices and scheduling