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