Centrifugal Pump Selection, Construction, Operation, Maintenance, Repair & Troubleshooting
Pumps are machines which serve to lift, to transfer or in general to move liquids (of different density and viscosity). Their action is characterized by the increase in pressure or speed of the propelled fluid. For liquids being propelled, they serve to transform mechanical energy supplied by a motor (electric or combustion motor, or steam turbine) into hydraulic energy (mainly pressure). The increase in pressure of the propelled fluid usually serves to:
- Lift the fluid.
- Increase flow speed.
- Overcome back pressure.
- Overcome pressure drops.
Pumps may be classified based on the applications they serve, the materials from which they are constructed, the liquids they handle, and even their orientation in space.
A comprehensive way to arrange pumps into categories is to place them into two major groups, which may be divided into subcategories:
- Centrifugal pumps
- Positive displacement pumps
- Reciprocating pumps
- Rotary pumps
Upon the successful completion of the course, participants will be able to:
- Understand the principles of centrifugal pumps design.
- Understand the specification and classification of centrifugal Pumps.
- Understanding pump construction and technology: API and ISO specifications.
- Understanding centrifugal pump performance, efficiency and power.
- Understanding pumps piping systems.
- Describe centrifugal pump internal forces and mechanical criteria.
- Explain (understanding & familiar) the centrifugal pump priming, start up, operation and maintenance.
- Updated with the last technique for pump survey and online condition monitoring system for pumps.
- Understanding Main causes of centrifugal pump damage & pump reconditioning.
Explain the operation and maintenance problems for each type of mechanical seals pump coupling.
- Explain in detail the required inspection and repair for the pump components.
- Know thorough understanding about construction of centrifugal Pumps and improves their capabilities and skills in operating and maintaining them in their plants.
- Know detailed description of advanced treatment of the detection, location and diagnosis of faults in Pumps. Several practical Case studies and examples from the field are used throughout the course to emphasize key points and to underline the relevance and applicability of the topics being addressed.
Operation and maintenance staff: Engineers, Supervisors and Technicians
This interactive training course includes the following training methodologies as a percentage of total tuition hours:
- Lectures
- Workshops, work presentations
- Group Work in case study & Practical Exercises.
- Videos and general discussions
- Pre Test and Post Test
Course Outline
Introduction of pump and compressors.
- Centrifugal compressors and PD Compressors.
- Centrifugal pumps and Positive displacement pumps
- Positive displacement pumps strengths and concerns
- Centrifugal pumps strengths and concerns.
- Power efficiency comparison PD vs centrifugal
Pump basic
- Introduction- basic concepts and theory.
- Function of pumps.
- Pump classifications, code and standards.
- Pump operating parameters- Head, Flow, rpm, Power, Efficiency.
- Pump Types and Terminology.
Centrifugal pump theory.
- Classification of Centrifugal Pumps.
- Arrangements of Centrifugal Pumps.
- Centrifugal pumps components.
- Types of Impellers.
Centrifugal pump theory. (Continued)
- Types of Casings.
- Pump performance curve.
- Pump specific speed and horse power
- Theory of pressure increase in impeller.
- Pump thrust balance and axial force.
- Pump affinity lows.
- Pump Operation Procedure.
NPSH and Cavitation Phenomena
- Introduction.
- Concept of Pump Cavitation.
- Viscosity impellor shape and cavitation.
- General Symptoms of Cavitation
- Effects of Cavitation on Pumps and its parts.
- How to avoid cavitation?
- Case Studies
Selection of centrifugal pump and pumping system.
- Pump performance curve important points.
- System performance curves
- Piping design equations.
- Energy loss in piping network.
- Combination of pump system.
- Pump selection criteria.
- Common pump sizing issues.
- Oversized pumps and high flow noise.
Centrifugal pump construction and components.
- Pump coupling types, selection and applications.
- Pump bearings types, selection and applications.
- Pump lubrication system.
- Bearing housing temperatures and motor intensity.
- Bearing and lubrications.
- Function of bearings.
- Sliding surface bearings.
Centrifugal pump operation and optimizations.
- Shaft sealing.
- Seal chambers (stuffing boxes).
- Compression packings.
- Mechanical seal types, selection and applications.
- Throttling C.V and bypass lines
- Hydraulic load on the impeller.
- Simultaneous load on pump shaft.
- Head and flow impact on pump reliability.
- Coupling and balancing and ring clearances.
- Stability.
- Frication face heating.
- Start-up.
- Priming.
Monitoring pump performance.
- Centrifugal pump priming.
- Simple harmonic motion .
- Complex vibration.
- Energy and power considerations.
- Mechanical structures.
- Natural frequencies.
- Resonance.
- Frequency analysis.
- Machine diagnosis
Troubleshooting and maintenance.
- Pumps troubleshooting and main causes of failures.
- Machinery maintenance practices.
- Maintenance program goals.
- Historical review.
- Components of maintenance program.
- Case studies.
Simplified overview of the classes of maintenance.
- Case studies.
- Reliability centered maintenance.
- RCM principles
- Types of RCM.
- RCM analysis.
- Group discussions.
- Course summary and evaluation.
- Case Studies
- Course Summary
- Examples and Solutions.