Practical Pumps Technology: Selection, Application, Operation, Troubleshooting & Maintenance

This course will provide a comprehensive understanding of the various types of reciprocating, rotary, and centrifugal pumps including piston pumps, plunger pumps, rotary pumps, screw pumps, two- and three-lobe pumps, cam pumps, vane pumps, bellows-type metering pumps, diaphragm pumps, canned motor pumps, and centrifugal pumps. It will also focus on maximizing the efficiency, reliability, and longevity of this equipment by providing an understanding of the characteristics, selection criteria, common problems and repair techniques, preventive and predictive maintenance.

This course is a MUST for anyone who is involved in the selection, applications, or maintenance of reciprocating, rotary, and centrifugal pumps because it covers how this equipment operates, the latest maintenance techniques, and provides guidelines and rules that ensure the successful operation of this equipment. In addition, this seminar will cover in detail the basic design, operating characteristics, specification, selection criteria, advanced fault detection techniques, critical components and all preventive and predictive maintenance methods in order to increase reliability of the equipment and reduce the operation and maintenance cost. Also, the following information will be provided for all reciprocating, rotary, and centrifugal pumps:

• Basic Design
• Specification
• Selection Criteria
• Sizing Calculations
• Enclosures and Sealing Arrangements
• Codes and Standards
• Common Operational Problems
• All Diagnostics, Troubleshooting, Testing, and Maintenance

Course Objectives

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

• Gain a thorough understanding of the operating characteristics of reciprocating, rotary, and centrifugal pumps
• Learn in detail all the diagnostic techniques and inspections required of critical components of reciprocating, rotary, and centrifugal pumps
• Understand thoroughly all the tests required for the various types of reciprocating, rotary, and centrifugal pumps
• Determine all the maintenance and troubleshooting activities required to minimize the downtime and operating cost of reciprocating, rotary, and centrifugal pumps
• Gain a detailed understanding of the various methods used to repair and refurbish reciprocating, rotary, and centrifugal pumps
• Learn the various methods used to maximize the efficiency, reliability, and longevity of reciprocating, rotary, and centrifugal pumps
• Gain a detailed understanding of all the calculations and sizing techniques used for reciprocating, rotary, and centrifugal pumps
• Understand all the design features that improve the efficiency and reliability of reciprocating, rotary, and centrifugal pumps
• Learn how to select reciprocating, rotary, and centrifugal pumps by using the performance characteristics and selection criteria that you will learn in this seminar
• Learn about the various types of enclosures and sealing arrangements used for reciprocating, rotary, and centrifugal pumps
• Understand all the commissioning requirements for reciprocating, rotary, and centrifugal pumps
• Learn all the codes and standards applicable for reciprocating, rotary, and centrifugal pumps
• Understand the causes and modes of failure of reciprocating, rotary, and centrifugal pumps
• Learn all the requirements for designing different types of reciprocating, rotary, and centrifugal pumping systems

Course Outline

Day 1

Pumps

• Pump Terminology
• Nomenclature and Definitions
• Pump Types

Centrifugal Pumps

Centrifugal Pump Theory

• Operating Characteristics
• Centrifugal Pump Operation
• Cavitation and NPSH
• Elements of Minimum Continuous Safe Flow (MCSF)
• How to Calculate MCSF
• Types of Centrifugal Pumps

Centrifugal Pump Specification and Selection

Selecting a Pump Vendor

• Industry Standards
• API vs. ANSI Standards
• Driver Size Selection
• Variable Speed Drive Selection
• Pump Design Audit/Review

Day 2

Centrifugal Pump Maintenance and Repair Parts of Centrifugal Pumps

• Bearing Basics
• Balancing Criteria
• Installation and Startup

Troubleshooting Centrifugal Pumps

• Inspecting Centrifugal Pump Components for Wear
• Centrifugal Pump Overhaul
• Case Studies

Positive Displacement Pumps:

Reciprocating Pumps

• NPSH Requirement for Reciprocating Pumps · Rotary Pump Theory and Operation
• PD Pumps in the Operating System
• How to Select Progressing Cavity Pumps

Day 3

Special Purpose PD Pumps

Fluid Metering System Design and Options

• PD Metering Pumps, Plunger Pumps, Diaphragm Pumps, Rotary Metering Pumps
• Controlling Pulsation and Surge

Pump Categories, Centrifugal Pumps, and Mechanical Seals

• Pump Categories: Dynamic (Centrifugal) and Positive Displacement (Reciprocating and Rotary)
• Centrifugal Pumps: Operation, Casings and Diffusers, Hydrostatic Pressure Tests, Impellers, Hydraulic Balancing Devices, Mechanical Seals, Minimum Flow Requirement, Performance
• Characteristics, Cavitation, and Net positive Suction Head
• Centrifugal Pump Mechanical Seals, Components, Temperature Control, Seal Lubrication/Leakage, Applications, Types of Mechanical Seals, Common Failure Modes of Seals, Seal Refurbishment
• Maintenance Recommended for Centrifugal Pumps
• Vibration Analysis and Predictive Maintenance

Day 4

Positive Displacement Pumps, Troubleshooting, Maintenance, and Selection of Pumps

• Reciprocating Pumps, Piston Pumps, Plunger Pumps, Rotary Pumps, Screw Pumps, Two- and Three-Lobe Pumps
• Cam Pumps, Vane Pumps, Bellows-Type Metering Pumps
• Diaphragm Pumps
• Canned Motor Pumps, Seal-less Pump Motors
• Pump Maintenance, Inspection, Overhaul, Diagnoses of Pump Troubles
• Troubleshooting of Centrifugal Pumps
• Troubleshooting of Rotary Pumps

Day 5

• Troubleshooting of Reciprocating Pumps
• Water Hammer
• Smart Instrumentation
• Pump Selection
• Pumping System Calculations
• Workshop: Design and selection of Different Pumping Systems for the Oil and Gas Industry, and the Power Generation Industry
• Vibration Analysis and Predictive Maintenance
• Diagnostics of Pumping Systems
• Pump Drivers

## Course Methodology

A variety of methodologies will be used during the course that includes:

• (30%) Based on Case Studies
• (30%) Techniques
• (30%) Role Play
• (10%) Concepts
• Pre-test and Post-test
• Variety of Learning Methods
• Lectures
• Case Studies and Self Questionaires
• Group Work
• Discussion
• Presentation