Rotating Equipment Fundamental and Performance Monitoring
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Rotating Equipment Fundamental and Performance Monitoring Course
Introduction:
Delegates will learn about the many kinds of pumps, motors, and drives as well as the terminology related to them during the session.There will be discussions on packing, mechanical seals and sealing systems, couplings, centrifugal and positive-displacement pumps and compressors, bearings, and couplings.
Course Objectives:
At the end of this seminar participants will have:
· Have an understanding of the different types of pumps and compressors.
· Be able to operate pumps and compressors as close as possible to the design efficiency.
· Will be able to monitor pump and compressor performance, efficiency, availability and reliability.
· Have learnt about selection, operation and maintenance strategies.
· Be able to troubleshoot pump and compressor problems.
· 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 seminar is directed towards Supervisors, Team Leaders and Managers in Maintenance, Engineering and Production. The seminar will also benefit anyone who expects to become involved at any stage in project applications and applicable maintenance technologies. The seminar will also benefit anyone who 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, 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 after coolers, filters and air intake screens
Centrifugal And 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, annual cost of air leakage
- Centrifugal compressor power requirement
- Compressor selection, calculations of air system requirements
- Sizing of compressor system components, sizing of air receiver
- Calculations of receiver pump-up time
Pumps
- Pump definition, pump categories: dynamic and displacement 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, pump drivers
- Special control requirements, drawing and data requirements form, quality assurance and quality control, bidding and negotiation
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
Mechanical Seals
- Basic components, temperature control, seal lubrication/leakage, typical single inside pusher seal
- Maintenance recommended on centrifugal pumps, recommended pump maintenance
- Vibration Analysis And 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