The seminar aims to familiarize participants with centrifugal pumps, packing, mechanical seals, sealing systems, bearings, and couplings. It will cover the implications and applicability of operating centrifugal pumps under different operating conditions. The seminar will also discuss the various applications of pumps and their suitability for different operational duties.

In-depth discussions will be conducted on pump operation, troubleshooting, and maintenance, providing participants with comprehensive knowledge in these areas. Additionally, the seminar will address the selection, operation, and maintenance of different types of prime movers. This will enable participants to understand the interaction between the driver (prime mover) and the driven unit (pump).

By the end of the seminar, participants will have a solid understanding of centrifugal pumps and their components, as well as the importance of proper operation, troubleshooting, and maintenance. They will also gain insights into the selection and management of prime movers, facilitating a holistic understanding of the driver-pump system.

Course Objectives:

By virtue of dynamic participation in this seminar it is to be expected that delegates will make a substantial, positive impact on the operational and maintenance regimes within their home organization.

At the end of this seminar participants will have:

· 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 organization.

· 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 utilize 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 organizations.

Course Outlines:

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

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