Pumps,Compressors and Valves Maintenance

Introduction

This course will be introducing the different types of pumps and valves and their associated terminology. In addition to, the different methods of inspection of the main component and the accessories of the pumps and valves will be explained in detail. The different applications of pumps and valves and the troubleshooting of each of them and the method of treatments will be dealt with in-depth. This training program aims at providing the participants with the fundamental concepts of the different pumps and valves used in various industrial purposes. Participants will have in-depth knowledge of improving performance, design methodology, equipment selection, proper operation, inspection, maintenance and troubleshooting through the presentation of actual case studies.

Objectives

The programme assumes familiarity with the design and construction of pumps and compressors. From this starting point, it adopts an analytical approach to understanding the failure of all types of pumps and compressors.

From a component-by-component perspective, the programme investigates the root causes of failure and relates these to operating conditions and process parameters. Design, installation, lubrication and wear-related failure mechanisms are identified and a detailed understanding of the troubleshooting and diagnostic methods needed to detect and identify these are developed. 

The programme provides participants with the knowledge needed to be effective in the inspection, monitoring and diagnostics of pumps and compressors, with emphasis placed upon the importance of a combined condition monitoring and strip-down inspection approach to maintenance.

Training Methodology

The training methodology is interactive with group exercises and is suitable for all employees involved in functions management. The pace and level of the training workshop is customized to the understanding of the delegates. Ongoing back-up and support is available after the training on request to the supplier, and the training course is also available for in-house presentation as well as for “Competency Transfer’’.

Who Should Attend?

This course is directed towards Engineering, Supervisors, Technician working in operation, inspection and maintenance of pumps and valves

Course Outline

Day 1

• Introduction to pumps
• Pump applications
• Pump classification
• Positive displacement pumps
• Reciprocating pumps, operation, inspection & maintenance
• Piston pump.
• Plunger pump
• Diaphragm pump, single diaphragm and double diaphragm
• Rotary pumps, operation, inspection & maintenance.
• External gear pump.
•  Internal gear pump.
• Vane pump.
• Screw pump, single rotor and multi rotor
• Lobe pump.
• Axial piston pump.
• Radial piston pump.
• Flexible pump.

Day 2

• Different types of dynamic pumps: Axial flow pump, Radial flow pump, Mixed flow pump.
•  Classification of radial pumps (Centrifugal pumps)
•  Centrifugal pump theory
•  Pump performance: Operating point of pumps, Parallel and series pump operation, Pump selection example.
•  Pump selection and sizing.
•  Design features: Impeller types, open type, semi open and closed impeller, Wearing rings, Stuffing boxes,, Bearing types, Couplings, Axial thrust and different method to avoid (Balance hole- Balance drum-Balance disk- outlet vane), Radial force, causes and avoided.
• Multi stage centrifugal pumps, design and construction.
•  Pump controls
• Vibration monitoring

Day 3

• Causes and precaution about cavitation phenomena in pumps.
• Net positive suction head (NPSH) calculations.
• Causes and precaution about water hammer phenomena in pumps.
• Pump testing
• Pump installation, operation and maintenance.
• Conventional packing glands and mechanical seals, troubleshooting
• seal failures, maintenance and repair of mechanical seals
• Different types of submersible pumps.
• Different types of fire pumps, Standard NFPA 2002.
• Precaution about operation of pumps.
• Troubleshooting and maintenance of different types of pumps.
• Preventive and predictive maintenance of pumps.
• Inspection Checklist for Pumps.
• Case studies in condition monitoring of pumps
• Video tape about assembly & disassembly of centrifugal pumps and troubleshooting.
• CD about pump selections, Patterson pump, Grundfos pump and another.
• CD video about animation of each type of pumps
• CD video about different types of hydraulic pumps
• CD video about reasons of cavitation and water hammer in pumps.

Day 4 

• Functions of Valves: Starting and stopping flow, Regulating or throttling flow, Preventing back flow, Regulating pressure, Reliving pressure.
•  Selection of Valves.
•  Different Types of Valves, operation, inspection & maintenance
• Gate valve: The gate valve closure, The rising stem gate valve, The non rising stem gate valve
• Globe valve: Functions of globe valve, Advantages of a globe valve, -Globe valve installation, Two-way globe valve
• Angle valve: Function of globe and angle valve, Function of angle valve, the advantage of the angle valve.
• Plug Valve
•  Ball Valve
• Butterfly Valve: Types of butterfly valves, Advantage and disadvantage of the butterfly valve, Application fields of the butterfly valve.
• Needle Valve.
• Check Valve.
• Relief Valve.
• Non-Return Valve.
• Diaphragm Valve.
• Pinch Valve.
• Control Valve.
• Directional Control Valves
•  Advantage & Disadvantage of Each Valves.

Day 5

• Different Types of Check Valves operation, inspection & maintenance:
• Swing check valve.
• Lift check valve.
• Spring check valve.
• Horizontal lift check valve.
• Stop the check valve.
• Vertical lift check valve.
• Ball checks valves.
• Piston check valves.
• Tilting disc check valves.
• Foot valves.
•  Introduction to Control Valves
•  Valve and Actuator Types
•  Control valves           
•  Globe valves
• Single-port valve bodies
• Balanced-plug cage-style valve bodies
• High capacity, cage-guided valve bodies
• Port-guided single-port valve bodies
• Double-ported valve bodies
• Three-way valve bodies
• Rotary valves
• Butterfly valve bodies
• V-notch ball control valve bodies
• Eccentric-disk control valve bodies Eccentric-plug control valve bodies
•  Control valve end connections: Screwed pipe threads, Bolted gaskets flanges, Welding end connections,
• Valve Body Bonnets: Extension bonnets, Bellows seal bonnets, Control valve packing
•  Actuators:
• Diaphragm actuators
• Piston actuators
• Electro-hydraulic actuators
• Manual actuators
• Rack and pinion actuators
•  Electric actuators
• Control Valve Accessories: Petitioners, Limit switches, Solenoid valve manifold, Supply pressure regulator.
•  Materials selection guide and limitation of using valves.
•  Selection of proper valve
• Comparison between the Valves.
• Valve maintenance and inspection.
• Troubleshooting of Valves
• High-Pressure Drop
• Cavitation in Valves, incipient and choked cavitation, flow curve cavitation index, cavitation-elimination devices
• Flashing versus Cavitation, flow choking, high velocities.
•  Water Hammer, What causes water hammer? Solutions for water hammer
• Surge Protection
•  Check valve slamming
• Noise problems
•  Clean air standards
•  Packing for fugitive-emission control
•  Troubleshooting the control valves
• Connection, Piping, Stuffing Box & Fittings.
•  Inspection Checklist for valves.
• CD about Rapture Disk, Safety & Relief Valves.