Design & Operating Conditions of Centrifugal Pumps & Prime Movers (VSD & FSM)

INTRODUCTION:

The seminar will introduce delegates to centrifugal pumps, packing, mechanical seals and sealing systems, bearings and couplings. The implication and applicability of operating centrifugal pumps under varying operating regimes will all be discussed. The application of pumps will be discussed along with their suitability for different operational duties. Pump operation, troubleshooting and maintenance will be dealt with in depth.

The selection, operation and maintenance of the several different types of prime movers will also be discussed so that the delegates understand the interaction between the driver and driven units.

OBJECTIVES:

YOU WILL LEARN

• The knowledge to select the appropriate pump and driver for any given application
• The ability to ensure correct operation of centrifugal pumps and an understanding of the implications of incorrect operation.
• An understanding of a range of equipment failures and their implications to the operational organisation.
• The ability to design a maintenance plan for the upkeep and maintenance inspections of static and rotating plant.
• A practical approach to developing an action plan to utilise these technologies in their own areas of responsibility, fitting them into the overall maintenance strategy, and measuring benefits

WHO SHOULD ATTEND:

This seminar is directed towards Supervisors, Team Leaders and Managers in Maintenance, Engineering and Production.

The seminar will also benefit anyone who wishes to update themselves on Maintenance Engineering Technologies, judge the suitability of these technologies for their needs, and learn how to implement them for the benefit of their organisations.

COURSE OUTLINE :

• Pumps

– Centrifugal pumps: theory of operation of a centrifugal pump, casings and diffusers, radial thrust, hydrostatic pressure tests

– Impeller, axial thrust, axial thrust in multistage pumps, hydraulic balancing devices, balancing drums, balancing disks

– Centrifugal pumps general performance characteristics, cavitation, net positive suction head and requirements

• Pump Selection

– Engineering of system requirements, fluid type, system head curves, alternate modes of operation, margins, wear, future system changes

– Selection of pump and driver, pump characteristics, code requirements, fluid characteristics, pump materials, driver type

– Pump specification, specification types, data sheet, codes and standards, bidding documents, technical specification, commercial terms, special considerations, performance testing.

• Mechanical Seals

– Basic components, temperature control, seal lubrication/leakage, typical single inside pusher seal

– Maintenance recommended on centrifugal pumps, recommended pump maintenance

– Operational requirements and limitations

• Bearings & Lubrication

– Types of bearings, ball and roller bearings, stresses during rolling contacts

– Bearing life, materials and finish, sizes of bearings, types of rolling bearings, thrust bearings and how they are affected operationally.

– Used oil Analysis: proper lube oil sampling technique, test description and significance, visual and sensory inspections, chemical and physical tests, water content, viscosity, emission spectrographic analysis, infrared analysis, total base number (TBN), total acid number (TAN), particle count, summary

• Vibration Analysis & Predictive Maintenance

– Vibration instrumentation, velocity transducer, acceleration transducer, transducer selection, time domain, frequency domain, machinery example, vibration analysis

– Vibration causes, forcing frequency causes, unbalance, misalignment, mechanical looseness, bearing defects, gear defects, oil whirl, blade or vane problems, electric motor defects, uneven loading, drive-shaft torsion

• Electric Motor Drives

– Introduction to AC induction motors and their construction, rotor slip and principles of operation, equivalent circuit, torque-speed characteristics, motoring and regenerative region of operation

– Starting of induction motors and associated techniques

– Speed control methods of induction motors

– Characteristics of motors, enclosures and cooling methods, application data, design characteristics, insulation of AC motors

– Failures in three-phase stator windings, predictive maintenance, motor troubleshooting, diagnostic testing for motors

• Variable Speed Drives

– Basic principles of AC Variable-Speed Drives (VSD’s), constant torque region, constant power (extended speed) region, four quadrant operation

– Power semiconductors, diode, thyristor (SCR), IGBT, MOSFET, GTO and others

– Inverters, Voltage-source and Current-source, Pulse Width Modulated (PWM) inverters

• Turbine Prime Movers

– Turbine Characteristics including Speed, Specific consumption and Efficiency

– Steam Conditions. Influence of inlet steam state and exhaust steam

– Control Systems. Speed governors, pressure & temperature control systems

– Safety devices – Overspeed & Overpressure

– Construction

• Casings
• Diaphragms
• Stator
• Blades

– Bearings & Seals

– Rotor, journal and thrust bearings, Internal and shaft seals, coupling

– Rotor Dynamics

• Balance
• Critical speeds

– Associated Systems

• Lubrication system
• Seal systems

– Typical mechanical incidents