Pumps - Application, Operations, Maintenance & Troubleshooting

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PUMPS – APPLICATION, OPERATION,

MAINTENANCE AND TROUBLESHOOTING

COURSE OUTLINE:

This training course will introduce participants 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 course Addresses factors that prevent pumps from achieving their optimum
performance and life. Starting with an initial understanding of fluids and applications, the
course also details specifications, design and correct pump type, selection, operating,
troubleshooting and care of pumping machinery.

Also included, is the understanding of pump hydraulics, sealing and bearing lubrication.
Participant s can address problem solving and troubleshooting methods and will be
given the opportunity to discuss their own pumping problems in training sessions.

OBJECTIVES:

At the end of this course, participants should be better able to:

 Explain and understand pump terminology


 Identify the various types of pumps
 Understand pump characteristics and interpret pump curves
 Understand Pump Types and Classification
 Understand Criteria for Pump Selection
 Perform a number of simple pump calculations
 Confidently test and commission pump sets
 Explain how Pumps are Constructed
 Detail how to Install, Test and Commission Pump Systems
 Explain how to start up a New Pump or one after Strip Down for Maintenance
 Develop the skills to match pumps to process specification.
 Understand the requirements for trouble-free bearing and mechanical seal
operation.
 Reduce pumping costs by keeping pumps operating at maximum efficiency with
minimum maintenance.
 Effectively troubleshoot pumping problems by using a logical approach.

Training Methodology

The course will be conducted along workshop principles with formal lectures, case
studies and interactive hands-on work. Relevant case studies will be provided to
illustrate the application of each tool in an operations environment. Audio Visual Aids
will be demonstrated on Pump Assembly, Dismantling & Troubleshooting.
COURSE MODULES:

1. Welcome & Pre- Test

2. Pumps – Introduction, Classification & Performance

Pump Types and Terminology


Classification of Pumps. Differences and similarities. Photographs and cross-sectional
views. List of Manufacturers.
Centrifugal Pump Classification
API 610 Types & Features – Overhung , Between Bearing, Vertical Suspended
Rotary & Reciprocating Pumps Classification
Pump Performance (Centrifugal and Positive Displacement)
Net Positive Suction Head (NPSH), Cavitation, recirculation, suction specific speed
Pump Affinity Laws – Effect of Changes in Pump Speed and Impeller Diameter
Pump performance curves: head-capacity, power, efficiency
System curve: static versus friction components
Operating point control: valve throttling versus speed controller

3. Pumping & Fluids Impact

Impact of
 Density
 Viscosity
 Temperature
 Corrosivity
 Erosion

4. Pumping & Impact of Piping System

Effects on pumping
 Head
 Velocity
 Resistance
 Forces
 Expansion, contraction, vibration
 Environment

5. Pump Drives

 Close coupled
 Direct driven
 Belt driven
 Variable speed drives
 Canned
 Couplings
 Power sources
 Alignment

6. Mechanical 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

7. Pump Reliability

Couplings
Alignment: Piping and Baseplates
Planned Maintenance - Predictive and Preventive
Reliability Program
Field Troubleshooting, Specialty Designs, and Performance Modification Techniques

8. Pumping Controls & Installation

Pump controls and instruments


 Safety controls
 Volume controls

Pump installation issues


 Foundations and bases
 Pipe connections
 Vibration and force isolation
 Environmental protection

9. Pump Commissioning and Performance

Testing and commissioning


Condition monitoring
Optimising performance
Inspection
Performance measurements

10. Pump Maintenance

Pump Breakdown and removal


Single Stage Pump dismantling and repair
Preparation for re-assembly
Pump Assembly
Vertical and multistage pump repairs
11. Practical Exercises on Maintenance and Troubleshooting

12. Open Discussion & Examination

Course Instructor: Mr. Md. Kamaluddin Ahmed

Mr. Kamal is Pipeline & Pumps Specialist with expertise in Design, Construction,
Operations & Maintenance Engineering with over Twenty years of petrochemical
experience in maintenance, operation, detailed and conceptual engineering, quality
assurance/control and commissioning. Mr. Kamal obtained his Bachelors in Mechanical
engineering Technology from the Osmania University, India. He is a Professional
Member of American Society of Mechanical Engineers.

Mr. Kamal has been responsible for engineering, maintenance, and technical support
for various operating facilities. His responsibilities have included equipment & pipelines
troubleshooting and repair, equipment reliability, failure investigations, predictive
maintenance programs, site engineering and equipment installation / commissioning.

Mr. Kamal has also been the lead machinery specialist and mechanical engineer as a
consulting engineer, supporting de-bottleneck projects and grass roots facilities. Mr.
Kamal has worked in many industries including the oil sands, refineries, chemical
plants, as well as the pharmaceutical industry.

He teaches Pipeline & pumping training courses in India and worldwide including KSA,
UAE, Qatar, Sudan , Malaysia, Vietnam and consults on pumps operations and
troubleshooting, engineering aspects of centrifugal and positive displacement pumps,
maintenance methods to improve reliability, improve energy savings, and optimize
pump-to-system operation.

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