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RE05
Industrial
Equipment :
Compressors, Pumps,
Motors & Variable-Speed Drive : Selection Sizing, Applications, Operation,
Diagnostic Testing, Troubleshooting & Maintenance
Introduction
The seminar will introduce delegates to the different types of pumps, motors and
drives and their associated terminology. Centrifugal and positive-displacement
pumps and compressors, packing, mechanical seals and sealing systems, bearings
and couplings will all be discussed.
The application of the different types of pumps and compressors will be
discussed along with their suitability for different operational duties. Pump
operation, troubleshooting and maintenance will be dealt with in depth.
Who should attend?
This seminar is directed towards Supervisors, Team Leaders and Managers in
Maintenance , Engineering and Production . It is suitable for who expects to
become involved at any stage in project applications and applicable maintenance
technologies. The seminar will also benefit anyone those wishes to update
themselves on pump and compressor technology, judge the suitability of different
types of pumps and compressors for their needs, and learn how to operate and
maintain them for the benefit of their organisations.
Objectives
At the end of this seminar participants will have:
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Have an
understanding of the different types of pumps and compressors.
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Be able to
operate pumps and compressors as close as possible to the design efficiency.
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Will be
able to monitor pump and compressor efficiency, availability and reliability.
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Have learnt
about selection, operation and maintenance strategies.
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Be able to
troubleshoot pump and compressor problems.
Key Benefits
The knowledge gained in this seminar will:
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Enable the
delegate to develop a proactive maintenance reg ime within the organisation.
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Allow
tighter control of maintenance budgets by the avoidance of unplanned equipment
failures in service.
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Enable the
delegate to optimise the operation and maintenance of different types of pumps
and compressors.
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Give the
delegate confidence to carry out failure analyses on pumps and compressors
thereby avoiding repetitive failures.
Training Methodology
The seminar will be conducted along workshop principles with formal lectures,
case studies and interactive worked examples. Relevant case studies will be
provided to illustrate the application of each tool in an operations
environment. Each learning point will be re-enforced with practical exercises.
There will be ample opportunities for discussion and sharing experiences.
Organisational Impact
Predictive maintenance of rotating plant is vital to the budgetary success of
the operations organisation. On completion of this seminar the delegate will be
able to critically analyse the methodologies employed within the organisation
and instigate improvements where required.
Personal Impact
Technical knowledge is key to effective control and peer respect within any
maintenance organisation; when this is achieved personal satisfaction follows.
This seminar will give the delegate the required level of technical knowledge
and skill to achieve that personal satisfaction.
Competencies
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Understanding of pump and compressor 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 and compressor equipment providers.
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Identify
and specify new and replacement pumps and compressors.
Course Outline
Day
1
Compressors
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Compressor
types: positive displacement (reciprocating and rotary), and dynamic
(centrifugal and rotary), compressor operation, gas laws
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Compressor
performance measurement, inlet conditions, compressor performance, energy
available for recovery
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Positive
displacement compressors, reciprocating compressors, reciprocating
compressors, diaphragm compressors.
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Rotary
compressors, rotary screw compressor, lobe type air compressor, sliding vane
compressors, liquid ring compressors
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Dynamic
compressors, centrifugal compressors, axial compressors
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Air
receivers, compressor control, compressor unloading system
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Intercoolers and aftercoolers, filters and air intake screens
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Preventive
maintenance.
Centrifugal & Axial Compressors
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Principle
of operation of centrifugal and axial flow compressors, characteristics of
centrifugal and axial flow compressor
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Surging,
choking, bleed valves, variable stator vanes, inlet guide vanes
Compressor Systems Calculations
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Affinity
Laws for centrifugal compressors
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Calculations of air leaks from compressed-air systems, annual cost of air
leakage
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Centrifugal
compressor power requirement
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Compressor
selection, calculations of air system requirements
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Characteristics of reciprocating compressors and blowers
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Selection
of air distribution system, water cooling requirements for compressors
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Sizing of
compressor system components, sizing of air receiver
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Calculations of receiver pump-up time
Day 2
Pumps
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Pump
definition, pump categories: dynamic and displacement reciprocating & rotary
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Centrifugal
pumps: theory of operation of a centrifugal pump, casings and diffusers,
radial thrust, hydrostatic pressure tests
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Impeller,
axial thrust, axial thrust in multistage pumps, hydraulic balancing devices,
balancing drums, balancing disks
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Centrifugal
pumps general performance characteristics, cavitation, net positive suction
head and requirements
Bearings & Lubrication
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Types of
bearings, ball and roller bearings, stresses during rolling contacts
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Statistical
nature of bearing life, materials and finish, sizes of bearings, types of
rolling bearings, thrust bearings
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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
Positive Displacement Pumps
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Reciprocating pumps, piston pumps, plunger pumps, rotary pumps, screw pumps,
lobe pump
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Cam
pumps, vane pumps, metering pumps
Pump Selection
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Engineering
of system requirements, fluid type, system head curves, alternate modes of
operation, margins, wear, future system changes
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Selection
of pump and driver, pump characteristics, code requirements, fluid
characteristics, pump materials, driver type
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Pump
specification, specification types, data sheet, codes and standards, bidding
documents, technical specification, commercial terms, special considerations,
performance testing, pump drivers
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Special
control requirements, drawing and data requirements form, quality assurance
and quality control, bidding and negotiation
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Public and
private sector, bid list, evaluation of bids, cost, efficiency, economic life,
spare parts, guarantee/warranty, simple bid evaluation
Day 3
Mechanical Seals
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Basic
components, temperature control, seal lubrication/leakage, typical single
inside pusher seal
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Maintenance
recommended on centrifugal pumps, recommended pump maintenance
Vibration Analysis & Predictive Maintenance
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Vibration
instrumentation, velocity transducer, acceleration transducer, transducer
selection, time domain, frequency domain, machinery example, vibration
analysis
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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
Day 4
Maintenance Of Motors
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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
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Starting of
induction motors and associated techniques
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Speed
control methods of induction motors
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Characteristics of motors, enclosures and cooling methods, application data,
design characteristics, insulation of AC motors
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Failures in
three-phase stator windings, predictive maintenance, motor troubleshooting,
diagnostic testing for motors
Variable Speed Drives
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Basic
principles of AC Variable-Speed Drives (VSD's), constant torque reg ion,
constant power (extended speed) reg ion, four quadrant operation
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Power
semiconductors, diode, thyristor (SCR), IGBT, MOSFET, GTO and others
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Inverters,
Voltage-source and Current-source, Pulse Width Modulated (PWM) inverters
Day 5
Variable Speed Drives
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Two-level
pulse width modulated inverter, DC link energy and capacitor sizing,
regeneration or dynamic slowdown, dynamic breaking, reg eneration
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PWM
waveforms and analysis, effects of PWM on motor bearings and insulation and
life expectancy, Volts/Hertz control, start up and operation, dynamics, PWM
rectifier inverter systems
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Switching
transients, harmonics and power factor, failures, common failure modes, fault
current limit, device explosion rating, device application, thyristor failures
and testing, identification of failed Thyristor and Diode, testing of
Thyristor and Diode
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AC drive
applications issues, Line power factor, Effect of AC input on drive operation,
IGBT switching transients, insulation voltage stress, motor winding voltage
distribution, Radiated and Conducted Electromagnetic Interferences (EMI),
cable terminating (matching) impedance, inverter output filter, EMI filtering
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Cabling
details for AC drives, cable details, motor, cable, and power system
grounding, motor bearing currents, motor shaft grounding brush, reduction of
stator to rotor capacitance value, motor cable wiring practices
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Summary of
application rules for AC drives and selection criteria
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Maintenance, common failure modes, motor application guidelines
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Control
systems, low performance and open loop operation, medium performance and
closed loop operation, high performance and closed loop operation, current
feedback control, speed control, sensorless drives, evaluation and comparison.
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Industry
standards and case studies.
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