Pumping Machinery Consulting and Training

 

 

 

Course Description:

 

 "CENTRIFUGAL AND POSITIVE DISPLACEMENT  PUMPS: Theory, Applications and Hands-On"

by

 

Dr. Lev Nelik, P.E., APICS

Cell 770-310-0866

DrPump@PumpingMachinery.com

www.PumpingMachinery.com

 

 

            

 

 

You receive 1.8 Continuing Education Units (CEU) and qualify for 15 Professional Development Hours needed to fulfill Professional Engineers’ continuing education requirements in many states.

 

Note: Open School class in Atlanta starts 8 am thru 4 pm, both days. For on-site classes, the starting and ending times are determined as best fits the hosting company (typically 7:00 am thru 3:30 pm).

 

Level I (BASICS) Course Description and Audience

(for Advanced, Level II, scroll further below)

 

This 2-day action-oriented course is prepared for maintenance personnel, engineers, equipment reliability leaders, plant operators, purchasing and facility management who are involved with pumps, and want to get a better understanding of pump designs, application-related differences between the pump types, as well as obtain a practical and unique hands-on reassembly experience to supplement the theory. The course provides an opportunity to review, refresh and enhance the attendants' pump knowledge, and to learn the latest pump technologies to help solve their specific problems. It also provides an opportunity to interact, learn from the instructor and from each other, and to implement the troubleshooting techniques at the facilities immediately following the training.

                    

The course will introduce participants to the different types of pumps and their associated terminology. Centrifugal and Positive-Displacement pumps, packing, mechanical seals and sealing systems, bearings and couplings will all be discussed. The application of the different types of pumps will be discussed along with their suitability for different operational duties. Pump operation, troubleshooting and maintenance will be dealt with in depth. Pump to motor alignment, effect of piping loads and energy savings through efficiency improvement and identification of the regime of operation to avoid problems present practical and immediate opportunities for implementation at the plant level. Actual testing of live pumps is conducted by the attendees in class, and the obtained performance curves are plotted.

 

The course will also benefit anyone who wishes to update themselves on pump technology, judge the suitability of different types of pumps for their needs, and learn how to operate and maintain them for the benefit of their organizations.

A hands-on part of the course is a unique opportunity to "get hands dirty" and to see, firsthand, the internals of the equipment, which they otherwise might have only seen on drawings, specs and books. Conversely, plant mechanics and maintenance people will get an opportunity to put the theory, the "why’s and what’s", behind their practical knowledge. Every attendee thus will walk away with something new, specific and helpful for their personal development as well as immediate benefits to their companies.

 

Objectives

At the end of this course participants will:

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Be familiar with different pump classes and types

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Be able to operate pumps as close as possible to the design efficiency

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Will be able to monitor pump efficiency, availability and reliability

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Have learnt about selection, operation and maintenance strategies

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Be able to evaluate and implement energy savings and determine best operating zones

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Be able to troubleshoot pump problems

 

Prerequisites

The attendees should have some basic knowledge of machinery, such as pumps, or mixers, motors, turbines, etc. Dress casual, prepare to work with tools, although no heavy lifting. Bring a calculator.

 

Special Features

In additional to theory and hands-on reassembly work, the participants will be testing pumps, obtain and plot H-Q curves using a single centrifugal seal-less mag-drive pump, and then two pumps operating in parallel.

 

Assessment Measures

A self-check List-of-Learning is provided. By answering a 1-page questioner at the beginning of the course and comparing with same at the end of the course, each participant will be able to do a self-evaluation summary of his or her accomplishments during the course.

 

Key Benefits

The knowledge gained in this course will:
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Enable the attendees to optimize the operation and maintenance of different types of pumps

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Give the attendees confidence to carry out failure analyses on pumps thereby avoiding repetitive failures

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Allow tighter control of maintenance budgets by the avoidance of unplanned equipment failures in service

 

Training Methodology

The course will be conducted along workshop principles with formal lectures, case studies and interactive hands-on work. Relevant case studies will be provided to illustrate the application of each tool in an operations environment. Each learning point will be opportunities for discussion and sharing experiences.

 

Organizational Impact

On completion of this course the attendee will be able to critically analyze the methodologies employed within the

Organization and instigate improvements where required.

 

Personal Impact

Technical knowledge is key to effective control and peer respect within any maintenance organization; when this is achieved personal satisfaction follows. This course will give the attendee the required level of technical knowledge and skill to achieve that personal satisfaction and professional growth.

 

Competencies

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Understanding of pump operating and maintenance techniques

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Ability to put in place measures to quantify equipment condition

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Interface with pump equipment providers

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Identify and specify new and replacement pumps

 

Fees

(see web updates): includes 300-pages set of Course Notes. Class size is limited, early registration is recommended. With questions, registrations and directions please call or email at address above.

 

Changes, Cancellations, Refund

Our facilities' arrangements and pre-planning, events reservations, transportations of course materials, printing of books, and similar logistics require us to make long term advanced planning of training seminars. This make it difficult to allow refunds. In the event you can not attend the training, our policy allows the following options:

a. You can send a qualified substitute(s)

b. If no substitute is available, for special circumstances (death in a family, inclement weather, work strikes, or an agreed upon special arrangements),  we can allow one free switch-over to any training within the next (12) months

c. You can apply the registration fee toward the training to be scheduled for a group, on-site, at your facility, within the next (24) months

 

Course Content (Level I: Basics, 2 days)

 

Introduction

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Pump Types and Terminology

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Classification of Pumps. Differences and similarities. Photographs and cross-sectional views. List of Manufacturers.

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Pump Performance (Centrifugal and Positive Displacement)

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Net Positive Suction Head (NPSH), cavitation, recirculation, suction specific speed

 

Centrifugal Pumps

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Centrifugal Pump Theory

o Pump performance curves: head-capacity, power, efficiency

o System curve: static versus friction components

o Affinity laws

o Operating point control: valve throttling versus speed controller

o Parallel operation

o Example: "How Much Money Did a Maintenance Department Save His Plant?"  Efficiency and power are compared and annual energy cost savings are calculated for pumps of various horsepower levels.

o Overview of major specs: HI, ANSI, API, PIP, ISO

o Sealing methods: packings, mechanical seals, and seal-less designs

o Viscosity correction exercise. Constructing complete new H-Q, power and efficiency curves for a given viscosity, from the original curve on water

o Case History - Double Suction Cooling Water pump troubleshooting

o Reassembly of a single stage end suction centrifugal pump

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Pump Wear Rings

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Single-Stage and Multi-Stage Pumps

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Failure Mechanisms – identification and monitoring

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Participants test two pumps in parallel, and construct a pump curve.

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Field Troubleshooting, Specialty Designs, and Performance Modification Techniques. Impeller redesign; volute modifications; sound tests to determine recirculation on-set.

 

Positive Displacement Pumps

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Performance characteristics: flow-pressure curve, power, efficiency

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Viscosity effects. Theoretical flow, actual flow, and slip

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Quick rule-of-thumb estimating of a through-flow capability of a gear pump based on a single gear main dimensions

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Minimum required suction pressure, based on speed, viscosity and geometry. Cavitation in gear pumps

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Lubrication: hydrodynamic versus boundary (PV values)

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Hands-On Exercise: reassembly of a gear pump. Changing of worn bushings, gears, shafts and seals

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Overview of other types of rotary pumps
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Internal Gear pumps

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Multiple Screw pumps

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Progressing Cavity pumps

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Metering pumps

 

Seals and Bearings

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Conventional Packing Glands

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Mechanical Seals

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Seal Failure Mechanisms

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Maintenance and Repair of Mechanical Seals

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Bearings – failure modes and how to extend life

 

Reliability

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Couplings

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Alignment: Piping and Baseplates

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Planned Maintenance - Predictive and Preventive

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Reliability Program

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Field Troubleshooting, Specialty Designs, and Performance Modification Techniques

Application Criteria and Specific Parameters

o Pump Type choices -  via Specific Speed (Ns) used as a selection criterion

o Flow-Pressure envelope

o Viscosity

o Chemistry and materials of construction

o Abrasiveness

o Temperature

o Self-Priming

o Driver

Course Content (Level II: Advanced, 3 days)

Day 1

8:00 – 8:30: Introductions

8:30 - 10:00: Hands-on exercise (roll up your sleeves!)

   *  disassembly and reassembly of a centrifugal pump including:

   *  mechanical seals proper setting: component design versus cartridge (do you (still) remember how to set the spring tension?)

   *  setting proper impeller front clearances and the energy/efficiency penalty on incorrect clearances ("how much?")

   *  bearings and lubrication: oil, grease, forced lubrication, oil mist - which is best, most practical, ("it depends") ?

10:00 – 12:00: Detailed example of a hydraulic system - friction losses, elevation head, pipe size variations - class exercise

12:00 – 13:00: lunch

13:00 - 15:30: Live Performance Test of a centrifugal pump - one pump versus two pumps in parallel (will the flow double?)

  * generate actual pump curve and review operation of two pumps in parallel

  * Flow - Head - Power - Efficiency

 

Day 2

8:00 – 10:00: Suction Side performance -  live testing:

*  NPSHR versus NPSHA evaluation

*  minimum submergence (cavitation versus air entrainment) - which is more problematic or damaging?

10:00 – 12:00: Vibration analysis presentation using a multi-channel analyzer live demo

*  3-channel analyzer shows live Acceleration (g), Velocity (V) and Displacement (D), in both time trace and frequency FFT live signatures

*  data acquisition hardware, software, 3 accelerometers (probes), and a PC computer - complete system presentation for immediate live data acquisition and analysis applications

12:00 – 13:00: lunch 

13:00 - 14:00: Pump Types and Fundamentals Overview (how much did you forget?)

  *  "Discharge Side": Performance (flow - head - power - efficiency)

  *  "Suction Side": cavitation, NPSHA/NPSHR, recirculation, damage minimization efforts

  * Specs:

      **  HI

      **  ANSI and ISO

      **  API-610

      **  PIP

14:00 – 15:30: PREMS-2A (Pumps Reliability and Efficiency/Energy Monitoring System setup and operation

  *   on-line continuous monitoring of pump performance (actual live versus expected (OEM) curves, and vibrations/temperatures monitoring including spectral analysis FFT

  *   hardware, software, probes (transducers, ultrasonic flow meter, CT transformers for power, accelerometers, and local/direct display versus internet connection options)

  *  Hands-on efficiency testing of a centrifugal pump (to compare versus PREMS automated test at Day 1)

 

Day 3

 8:00 – 10:00: hands-on exercise: field balancing of rotors (finding location and magnitude of the unbalance, and applying trial weights method to compensate and balance)

 10:00 – 12:00: Pump Operating Point (POP) and Best Efficiency Point (BEP) - why are they not the same?

  *  efficiency prediction computer program

  * Affinity Laws

 12:00 – 13:00: lunch

 13:00 – 14:00: Performance modification methods - class exercises (actual example)

  *  Affinity Laws (impeller trim, VFD speed change, customized impeller redesign (within the same casing)

  *  Pumps Reliability and troubleshooting aspects

 14:00 – 15:30: Positive Displacement Pumps 

 15:30 – 15:45: Q&A and Adjourn

 

Course Instructor

Dr. Nelik has 30+ years experience with pumps and pumping equipment. He is a Registered Professional Engineer, who has published over fifty documents on pumps and related equipment worldwide, including a "Pumps" section for the Encyclopedia of Chemical Technology (John Wiley), a section for the Handbook of Fluids Dynamics (CRC Press), and a book "Centrifugal and Rotary Pumps: Fundamentals with Applications", by the CRC Press. He is a President of Pumping Machinery, LLC company, specializing in pump consulting, training, and equipment troubleshooting. His experience in engineering, manufacturing, and field troubleshooting includes: Ingersoll-Rand (Engineering), Goulds Pumps (Technology), Roper Pump (Vice President of Engineering, and Repair/Overhaul) and Liquiflo Equipment.

 

Dr. Nelik is an Editor of Pump Magazine, an Advisory Board Member of Water and Wastes Digest, Editorial Advisory Board Member of Pumps & Systems magazine, and a former Associate Technical Editor of the Journal of Fluids Engineering. He is a Full Member of the ASME, and a Certified ASPICS. He is a graduate of Lehigh University with Ph.D. in Mechanical Engineering and a Masters in Manufacturing Systems. He teaches pump training courses in the US and worldwide, and consults on pumps operations and troubleshooting, engineering aspects of centrifugal and positive displacement pumps, maintenance methods to improve reliability, improve energy savings, and optimize pump-to-system operation.