Pump and Valve Operation, Control, Maintenance & Troubleshooting

Pump and Valve Operation, Control, Maintenance & Troubleshooting

OBJECTIVES

• Have an understanding of the different types of pumps and valves and their features and function
• 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 apply safe start-up and shutdown operation of pumps and valves and interpret data analysis  and calculations
• Have the ability to operate, control, maintain and troubleshoot pumps and valves
• Have the ability to decide on the right maintenance plan concerning different types of valves

COURSE OUTLINE

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
  • Failure Mechanisms – identification and monitoring
• Centrifugal Pumps
  • Centrifugal Pump Theory
  • Pump Components
  • Matching Pumps with Drivers
  • Performance Analysis
  • Failure Mechanisms – identification and monitoring

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

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

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