ICTD International Centre for Training and Development

Pumps & Compressors: Predictive Maintenance in Diagnostics

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About the course

Efficient Pumps and Compressor operations are paramount to overall effective plant objectives ensuring minimum down times. The variety of this machinery brings certain complexities when identifying problems and conducting the specific maintenance requirements.

This course is designed to assist engineers and technicians in identifying the various pumps and compressors they will be expected handle. It will detail the how to conduct scheduled maintenance and how to replace parts and troubleshooting methods based on manufacturers and practical experiences.

Course Objectives

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

  • Provide skills and practical knowledge on pumps and compressors, predictive maintenance in diagnostics
  • Identify the pumps and compressor in general service and the various maintenance methods plus the number of practical fault finding techniques available
  • Identify the main problems associated with wear and tear and minimizing down times along with lubrication requirements

## Course Outline

Day 1

  • Pumps: Types, functions, design and operation
  • Operating Characteristics
  • Positive Displacement, Centrifugal and Vertical pumps
  • Common applications of various types of pumps
  • Pump operations practical assessments
  • Hydraulic Balance: Bearing types, Impellers configuration
  • Lubrication: Oils & Greases
  • Hydraulic Disturbance of Pumps due to casing configuration and systems
  • Review hydraulics of flow; velocity, pressure head, velocity head, head loss.

Day 2

  • Transfer of energy; power, energy, electrical systems, brake & water

Horsepower, efficiency, energy costs pack and capillary columns.

  • Installing: Conditions, Leveling techniques, Piping systems
  • Trouble Shooting and Fault Finding and correct procedures
  • Pump Selection Fault Diagnosis Etc.
  • Loss of Capacity identification
  • Tools and Instruments: Type and Care, Usage
  • Alignment: Vibration, Frequencies and Alignment problems
  • Predictive Maintenance: Problem Identification, Scheduling Maintenance

Programs, Failures and Analysis

  • Lubrication Requirements

Day 3

  • Preventative Maintenance: Methods, Prevention programs Motors; operation, maintenance, troubleshooting, single phasing.
  • Bearings; types, removal, installation, lubrication, troubleshooting.
  • Couplings; types, installation, alignment, vibration.
  • Blowers; types, operation and maintenance, troubleshooting
  • Mechanical Seals: Types, Selection
  • Replacing Seals: Techniques and methods, Packed Glands, Selection, Replacement etc.
  • Mechanical Checks: Procedures and Controlled
  • Overhauls and Repairs: Preparing, Inspecting and Assembling Components
  • Replacement: Broken, Defective or Worn Components

Day 4

  • Compressors: Identification and Functions
  • Centrifugal, Axial, Reciprocating, Helical, Screw
  • Applications, Usage and Limitations
  • Design and Technical: Compressor rotors, Impellers, Casings,
  • Seals Diaphragms, Nozzles, Gland Systems
  • Balancing
  • Bearings
  • Alignment Techniques and Support: Dial Indicator Methods, Laser Optic Cold Alignment, On stream, Hot Alignment Verification Techniques
  • Compressor Parameters: Thermodynamics, Capacity, Power, Efficiencies
  • Selection of Centrifugal Process Compressors: Calculation methods, Characteristic Curves, Stability
  • Selection of Centrifugal Process Compressors: Calculation Methods, Volumetric Efficiency, Multi-staging, Frame Loads, Characteristic Curves

Day 5

  • Basic Trouble Shooting: Failures, Defects, Design Problems
  • Selection of Screw Compressors: Advantages and Disadvantages
  • Predictive and Preventative Maintenance Techniques
  • Overall Troubleshooting and maintenance techniques
  • Maintenance skills: Development and Implementing, Manuals and Information sources
  • Maintaining Records: Maintenance, Repairs and Decisions
  • Case studies and Group Exercises
  • Group discussions
  • Course Review & Evaluation
  • Course Summary

## 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

Who should attend

This course is intended for engineers and technicians involved with maintenance programs and are responsible for day-to-day servicing and operational efficiency. Also plant and maintenance engineers, process engineers and maintenance managers. May also be invaluable to supervisors who are involved in pumps and compressor maintenance schedules

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