During the course, participants will be introduced to various categories of pumps, motors, and drives, along with the corresponding terminology. The curriculum will cover topics such as centrifugal and positive displacement pumps and compressors, packing, mechanical seals, sealing systems, bearings, and couplings. Detailed discussions will be held on the application of different pump and compressor types, considering their suitability for various operational responsibilities. Additionally, the course will provide in-depth coverage of pump operation, troubleshooting techniques, and maintenance practices.

Course Objectives:

Upon successful completion of this course, the delegates will be able to:

Understand the different types of pumps and compressors
Operate pumps and compressors as close as possible to the design efficiency
Monitor pump and compressor efficiency, availability and reliability
Learn about selection, operation and maintenance strategies
Troubleshoot pump and compressor problems

The knowledge gained in this course will:

Enable the delegate to develop a proactive maintenance regime within the organization.
Allow tighter control of maintenance budgets by the avoidance of unplanned equipment failures in service.
Enable the delegate to optimize the operation and maintenance of different types of pumps and compressors.
Give the delegate confidence to carry out failure analyses on pumps and compressors thereby avoiding repetitive failures.

Who Should Attend?

This course is directed towards Supervisors, Team Leaders and Professionals in Maintenance, Engineering and Production. It is suitable for who expects to become involved at any stage in project applications and applicable maintenance technologies. The course will also benefit anyone those wishes to update themselves on pump and compressor technology, judge the suitability of different types of pumps and compressors for their needs, and learn how to operate and maintain them for the benefit of their organizations.

Course Outlines:

Compressors

Compressor types: positive displacement (reciprocating and rotary), and dynamic (centrifugal and rotary), compressor operation, gas laws
Compressor performance measurement, inlet conditions, compressor performance, the energy available for recovery
Positive displacement compressors, reciprocating compressors, reciprocating compressors, diaphragm compressors.
Rotary compressors, rotary screw compressor, lobe type air compressor, sliding vane compressors, liquid ring compressors
Dynamic compressors, centrifugal compressors, axial compressors
Air receivers, compressor control, compressor unloading system
Intercoolers and aftercoolers, filters and air intake screens

Centrifugal & Axial Compressors

Principle of operation of centrifugal and axial flow compressors, characteristics of centrifugal and axial flow compressor
Surging, choking, bleed valves, variable stator vanes, inlet guide vanes

Compressor Systems Calculations

Affinity Laws for centrifugal compressors
Calculations of air leaks from compressed-air systems, the annual cost of air leakage
Centrifugal compressor power requirement
Compressor selection, calculations of air system requirements
Characteristics of reciprocating compressors and blowers
Selection of air distribution system, water cooling requirements for compressors
Sizing of compressor system components, sizing of air receiver
Calculations of receiver pump-up time

Pumps

Pump definition, pump categories: dynamic and displacement reciprocating & rotary
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

Bearings & Lubrication

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

Statistical nature of bearing life, materials and finish, sizes of bearings, types of rolling bearings, thrust bearings
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

Positive Displacement Pumps

Reciprocating pumps, piston pumps, plunger pumps, rotary pumps, screw pumps, lobe pump
Cam pumps, vane pumps, metering pumps

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, datasheet, codes and standards, bidding documents, technical specification, commercial terms, special considerations, performance testing, pump drivers
Special control requirements, drawing and data requirements form, quality assurance and quality control, bidding and negotiation
The public and private sector, bid list, evaluation of bids, cost, efficiency, economic life, spare parts, guarantee/warranty, simple bid evaluation.

Mechanical Seals

Basic components, temperature control, seal lubrication/leakage, typical single inside pusher seal
Maintenance recommended on centrifugal pumps, recommended pump maintenance

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

Maintenance of Motors

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

Filters