Practical Pump & Compressors Technology – Maintenance & Diagnostics

Practical Pump & Compressors Technology – Maintenance & Diagnostics

OBJECTIVES

• Maximize the efficiency, reliability, and longevity of all types of compressors, pumps, and bearings
• Size and select out of the various types of dynamic and positive displacement compressors, and 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 compressors, pumps, and bearings by applying advanced fault detection techniques
• Select bearings and lubrication, compressor and pump sealing arrangements, meet commissioning requirements, conduct vibration and used oil analyses, troubleshoot, provide predictive and preventive maintenance, enhance reliability, and reduce cost
• Determine the maintenance required to minimize compressor and pump downtime and operating cost and maximize their efficiency, reliability, and longevity
• Gain a thorough understanding of compressor and pump characteristics and compressor surge and surge prevention systems
• Understand all the causes of failures in compressors and pumps
• Determine all the design features that improve the efficiency and reliability of all compressors and pumps
• Design different types of compressor and pumping systems
• Gain a thorough understanding of the various types of sealing arrangements used in compressors and pumps

WHO SHOULD ATTEND

• Engineers of all disciplines
• Managers
• Technicians
• Maintenance personnel
• Other technical individuals

COURSE OUTLINE

Gas Laws, Compressor Types and Applications

• Perfect and Imperfect Gases
• Compressor Polytropic Efficiency and Power Requirements
• Compressor Volumetric Flow Rate and Volumetric Efficiency
• Rotary and Reciprocating Compressors
• Dynamic Compressors (Centrifugal and Axial)
• Compressor Performance Measurement
• Receivers, Compressor Control, and Compressor Unloading Systems
• Preventive Maintenance and Housekeeping

Positive Displacement Compressors

• Performance of Positive Displacement Compressors
• Reciprocating Compressors
• Reciprocating Compressors Troubleshooting and Maintenance
• Diaphragm Compressors
• Rotary Screw Compressors and Filter Separators
• Straight Lobe Compressors
• Recent Developments in Liquid/Gas Separation Technology

Dynamic Compressors

• Dynamic Compressor Technology
• Centrifugal and Axial Compressors
• Simplifies Equations for Determining the Performance of Dynamic Compressors
• Centrifugal Compressors – Components, Performance Characteristics, Balancing, Surge Prevention Systems and Testing
• Choking, and Anti-Choking Systems
• Compressor Auxiliaries, Off-Design Performance, Stall, and Surge

Dynamic Compressors Performance, Compressor Seals, and Compressor System Calculations

• Dynamic Compressors Performance
• Surge Limit, Stonewall, Prevention of Surge, Anti-Surge Control Systems
• Compressor Seal Systems
• Gas Seals, Liquid Seals, Liquid Bushing Seals, Contact Seals, Restricted Bushing Seals, Seal Liquid leakage System
• Dry Seals, Advanced Sealing Mechanisms, and Magnetic Bearings
• Compressor System Calculations
• Sizing of Compressor System Components, Sizing of Gas Receiver

Bearings, Lubrication, Vibration Analysis and Predictive Maintenance

• Bearings, Types of Bearings, Thrust Bearings
• Lubrication, Viscosity of Lubricants, Non-Newtonian Fluids, and Greases
• Used Oil Analysis
• Vibration Analysis and Predictive Maintenance
• Vibration Causes, Resonant Frequency, Vibration in Predictive Maintenance, Diagnostics
• Diagnostic Testing

Pump Categories, and Centrifugal Pumps

• Pump Categories: Dynamic (Centrifugal) and Positive Displacement (Reciprocating and Rotary)
• 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

• 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

Positive Displacement 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

Troubleshooting of Pumps

• Pump Maintenance, Inspection, Overhaul, Diagnoses of Pump Troubles
• Troubleshooting of Centrifugal Pumps
• Troubleshooting of Rotary Pumps
• Troubleshooting of Reciprocating Pumps
• Water Hammer
• Bearings
• Used Oil Analysis
• Smart Instrumentation

 Pump Selection Pump Selection

• Pumping System Calculations
• Workshop: Design and selection of Different Pumping Systems for the Oil and Gas Industry, and the Power Generation Industry
• Vibration Analysis and Predictive Maintenance
• Control Valve Selection, Cavitations, and Noise
• Actuators, Positioners, and Accessories
• Diagnostics of Pumping Systems
• Pump Drivers
• Motors
• Variable-Frequency Drive