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RE04
Design & Operating Conditions of Centrifugal Pumps & Prime movers
Introduction
The seminar will
introduce delegates to centrifugal pumps, packing, mechanical seals and sealing
systems, bearings and couplings. The implication and applicability of operating
centrifugal pumps under varying operating regimes will all be discussed. The
application of pumps will be discussed along with their suitability for
different operational duties. Pump operation, troubleshooting and maintenance
will be dealt with in depth.
The selection,
operation and maintenance of the several different types of prime movers will
also be discussed so that the delegates understand the interaction between the
driver and driven units.
Objectives
By virtue of
dynamic participation in this seminar it is to be expected that delegates will
make a substantial, positive impact on the operational and maintenance regimes
within their home organisation. At the end of this seminar participants will
have:
The knowledge to select the appropriate pump and driver for any
given application
The ability to ensure correct operation of centrifugal pumps and
an understanding of the implications of incorrect operation.
An understanding of a range of equipment failures and their
implications to the operational organisation.
The ability to design a maintenance plan for the upkeep and
maintenance inspections of static and rotating plant.
A practical approach to developing an action plan to utilise
these technologies in their own areas of responsibility, fitting them into the
overall maintenance strategy, and measuring benefits
Course
Outline
Day 1
Pumps
Centrifugal pumps: theory of operation of a centrifugal pump,
casings and diffusers, radial thrust, hydrostatic pressure tests
Impeller, axial thrust, axial thrust in multistage pumps,
hydraulic balancing devices, balancing drums, balancing disks
Centrifugal pumps general performance characteristics,
cavitation, net positive suction head and requirements
Pump Selection
Engineering of system requirements, fluid type, system head
curves, alternate modes of operation, margins, wear, future system changes
Selection of pump and driver, pump characteristics, code
requirements, fluid characteristics, pump materials, driver type
Pump specification, specification types, data sheet, codes and
standards, bidding documents, technical specification, commercial terms, special
considerations, performance testing.
Day 2
Mechanical
Seals
Basic components, temperature control, seal lubrication/leakage,
typical single inside pusher seal
Maintenance recommended on centrifugal pumps, recommended pump
maintenance
Operational requirements and limitations
Bearings &
Lubrication
Types of bearings, ball and roller bearings, stresses during
rolling contacts
Bearing life, materials and finish, sizes of bearings, types of
rolling bearings, thrust bearings and how they are affected operationally.
Used oil Analysis: proper lube oil sampling technique, test
description and significance, visual and sensory inspections, chemical and
physical tests, water content, viscosity, emission spectrographic analysis,
infrared analysis, total base number (TBN), total acid number (TAN), particle
count, summary
Day 3
Vibration
Analysis & Predictive Maintenance
Vibration instrumentation, velocity transducer, acceleration
transducer, transducer selection, time domain, frequency domain, machinery
example, vibration analysis
Vibration causes, forcing frequency causes, unbalance,
misalignment, mechanical looseness, bearing defects, gear defects, oil whirl,
blade or vane problems, electric motor defects, uneven loading, drive-shaft
torsion
Electric Motor
Drives
Introduction to AC induction motors and their construction, rotor
slip and principles of operation, equivalent circuit, torque-speed
characteristics, motoring and regenerative region of operation
Starting of induction motors and associated techniques
Speed control methods of induction motors
Characteristics of motors, enclosures and cooling methods,
application data, design characteristics, insulation of AC motors
Failures in three-phase stator windings, predictive maintenance,
motor troubleshooting, diagnostic testing for motors
Variable Speed
Drives
Basic principles of AC Variable-Speed Drives (VSD's), constant
torque region, constant power (extended speed) region, four quadrant operation
Power semiconductors, diode, thyristor (SCR), IGBT, MOSFET, GTO
and others
Inverters, Voltage-source and Current-source, Pulse Width
Modulated (PWM) inverters
Day 4
Turbine Prime
Movers
Turbine Characteristics including Speed, Specific consumption and
Efficiency
Steam Conditions. Influence of inlet steam state and exhaust
steam
Control Systems. Speed governors, pressure & temperature control
systems
Safety devices – Overspeed & Overpressure
Construction
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Casings
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Diaphragms
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Stator
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Blades
Bearings & Seals
Rotor, journal and thrust bearings, Internal and shaft seals,
Coupling
Rotor Dynamics
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Balance
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Critical speeds
Associated Systems
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Lubrication system
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Seal systems
Typical mechanical incidents
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