PUMPS OPERATION, MAINTENANCE & TROUBLESHOOTING

Transcription

1 Training Title PUMPS OPERATION, MAINTENANCE & TROUBLESHOOTING Training Duration 5 days Training Venue and Date Pumps Operation, Maintenance & Troubleshooting Nov $3,750 In any of the 5 star hotels. The exact venue will be informed once finalized. Abu Dhabi, UAE Training Fees 3,750 US$ per participant for Public Training includes Materials/Handouts, tea/coffee breaks, refreshments & Buffet Lunch. Training Certificate Define Management Consultants Certificate of course completion will be issued to all attendees. WHO SHOULD ATTEND The course is designed for plant safety specialists, maintenance engineers and technicians, maintenance planners, system engineers and operators in the power generation, oil, chemical, paper and other processing industries involved in pumps selection, specification, procurement, inspection, troubleshooting or repair. Mechanical and operation engineers and senior technicians who are responsible for specifying, selecting, operating, and troubleshooting and maintaining pumps. DESCRIPTION Pumps Troubleshooting means to find the root cause behind the problems or failures of the pump. Troubleshooting is a complete exercise involves number of activities that need to be practiced carefully and accurately for the troubleshooting to be successful. A good monitoring system, enough instrumentations, adequate data recording system, expert edition process of the accumulated data, right technique and analysis, need to be available. Of course troubleshooter must be deeply understand and familiar with the machine he is troubleshooting, the design, operation, oil systems, flushing systems, bearings, balancing systems, type of mechanical seals, and the application. The course will discuss all aspects concerning pumps, familiar the participant with the details of pumps, different designs, application, operation, maintenance and potential problems and their possible root causes, and methods of eliminating or reducing the failure causes, methods analysis to find out the root causes of failures, and methods of curing such problems. A successful troubleshooting method increase the uptime of

2 machines, increase the profitability of the plant, and assure more safety for machines and personnel and minimize the cost of maintenance. TRAINING OBJECTIVES: Deep understanding of the pumps different designs for different applications Familiarize the participants with different auxiliary systems for pumps, oil system, mechanical seals, flushing systems, balancing systems and alike Learn the performance, limit of operations and common causes of failures of pumps Learn methods of failure analysis, like oil analysis, vibration measurements, etc Learn the principles and elements of troubleshooting methodology Learn the appropriate strategy of maintenance Exercise the troubleshooting on real cases COURSE METHODOLOGY A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions, and motivate everybody find the right answers. The delegates will also be encouraged to raise their own questions and to share in the development of the right answers using their own analysis and experiences. Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course. OUTLINE :- Day One 1. Pumps: Performance, Control and Operation Manufacturer Characteristic Curves How to obtain pump performance curves experimentally How to calculate pump performance curves operated at different speed How to calculate pump performance curves for different impeller size How to correct pump characteristics for fluid viscosity Effect of suction conditions on pump characteristics Positive displacement pumps Metering Feature Limits of Operation ISO and ASME characteristic curves Preferred range of operation Allowable range of Operation Pump cavitation, NPSHR Pumps minimum flow rate limit Pumps Controls Pump and System interaction

3 Variation of operating conditions Protective controls Capacity control Modification by speed variation Modification by valve positioning Day Two 2. Pumps: Selection, Standards, and Specifications Pumps Standards: ANSI, HI, API, ASME, ISO standards How standards differ Standards tolerances Pumps Application Boiler Feed Pumps Pump capacity, suction conditions, and discharge pressure Condensate Pumps Extremely low NPSHA Water works Ground and surface water sources Petroleum refinery service pumps (API-610) Production, transportation and refining, high degree of standardization Chemical pumps The widest variety of pumping problems, corrosive and corrosiveabrasive liquids Paper stock and process pumps Similar to chemical pumps, non-clogging impellers Sewage and waste water Submersible pumps Food and beverage sanitary pumps Cleanliness and Contamination problems and Dispensing Air conditioning and refrigeration pumps Sodium chloride and calcium chloride brines The piping system to serve System Head curve How to calculate friction loss Suction system configurations, NPSHA How to calculate NPSHA Pumps ratings Head, Capacity and Power Manufacturer Data

4 How to read through the manufacturer catalogues Manufacturer Selector Chart Specifications and inquiries Preparing pump inquiries Inquiries for specific services Water works services Chemical services Petroleum services Day Three 3. Pumps: Design, Materials and Seals Types of Pumps Positive displacement pumps Rotary Pumps Dispensing Pumps Metering Feature Centrifugal pumps Axial flow pumps Multistage pumps Special design pumps Vertical pumps Seal-less magnetic drive pumps Submersible wastewater pumps Multi-phase pumps Pumps fittings Standard fitted pump All bronze, all iron, acid-resisting and salt water pumps Material Selection, ph value, and galvanic corrosion Mechanical seal selection Single seals Double seals Cartridge seals Dry gas seals Seal flush and circulation plans Day Four 4. Pumps: Failure Analysis, Troubleshooting and Maintenance The six sigma problem solving method DMAIC (Development, Measurement, Analysis, Improvement, and Control Phases) Pump condition monitoring Vibration Analysis

5 Vibration severity charts The head-flow Method Shut-off Head Method Thermodynamic Method Balance Flow Measurement Reasons for Failures Mechanical Mechanical seal Shaft deflection Lubrication system Balancing system Operational Reduced NPSH Low flow operation Cavitation Parallel flow operation Maintenance Strategies Preventive Maintenance Predictive Maintenance Proactive Maintenance Day Five 5. Case Studies a. system resistance reduction b. system resistance increase c. pump internal wear d. pump internal leakage e. pump foundation deterioration f. cavitation effect g. erosion and corrosion effect h. wearing ring problem 6. Delegates case studies Each group supposes to bring with them their own cases in order to analyze them and come up with the root cause behind the failure. The case should be supported with the necessary documents: the pump catalogue, the piping system, the type of service, the description of the problem, and the measurement carried out..

6 TRAINING INSTRUCTOR PROF. TAHA ALDOSS Prof. Taha Khalil Aldoss Senior Associate Consultant with number of Training and Consultation companies, specializing in Pumps, Compressors, Heat Exchangers, Piping systems and Valves. Professor Aldoss graduated from Case Western Reserve University, USA. He worked in Jordan Petroleum Refinery for a number of years as a maintenance and workshop engineer. As a consultant, he has worked for many industrial projects. He is teaching engineering courses for more than 25 years and delivers technical courses in pumps, compressors, piping systems, A/C and heating systems for engineers and technicians. Professor Aldoss has worked in the following positions: - Dean, Amman College for Engineering Technology, Al-Balqa Applied University - Chairman, Mechanical Engineering Department, Jordan University of Science and Technology - Assistant Dean of Engineering Department, Jordan University of Science and Technology - Maintenance and Workshop Engineer, Jordan Petroleum Refinery. Professor Aldoss has been awarded a number of prizes for his distinguished publications and research work. His awards include the Shoman prize and the Fulbright Fellowship. He has more than 60 publications in international refereed journals and international conferences. He also holds three patents. Industrial Experience: Jordan Refinery: Prof. Taha worked in Jordan Refinery for four years, during these years he worked as a maintenance engineer and an area engineer. He participated during that in many shutdowns and maintenance tasks of different process units like Topping and FFC units. Work included all maintenance tasks of the column lining and repairs plus all shutdown works for the heat exchangers, pumps, compressors, furnaces and boilers. Overhaul for the steam turbines, pumps, compressors and blowers were also among those tasks.

7 During the period as the manager of the workshop the tasks were of different types including all types of machining, repairs, valve testing, fabrication, welding and testing of different welded piping spools. Preparation of weldments for WPS tests plus that for welder certification were also among the works the workshop was doing. That included destructive and x-rays testing, preheating, and post heat treatment of welded parts. The Third Refinery Expansion: He also participated in the third large expansion of the refinery. A project worth of 20 million US$ in 1977, were new and larger refining units were installed with all types of piping erection, a hydrogen unit were among the new installations. The project involved reviewing the design, the specifications of the machinery and equipments. Follow up the work with the contractor. Observe all tests of the welding work and the hydrostatic leakage tests. And later the comotioning of the machinery. Jordan University (JUST) Heating System: Evaluation Project. Recently Dr. Taha was involved with the mechanical installations of the King Abdallah University Hospital in at Jordan University of Science and Technology. Heating system with all involvements, like Boilers, and heating piping systems, design review and installation follow up were among the tasks. Dr. Taha also lead a team concerning the evaluation of a big steel in steel heating piping system which was leaking due to the failure of the leak detection system. The project is a worth of more than 10 million US $. A thorough review of the system were executed, many tests and examinations were performed. The task took more than one year of continuous work examining a very large piping system, of 25" of the inside pipe that is installed in 50" casing pipe. The system has no expansion loops nor expansion bellows, and is of pre-stressed type operated at high pressure (40 bar) and high temperature (150 o C). The pipe was buried at more than 10 m below the grade. The team concluded after a lot of measurements, excavations and examinations, that much of the pipe were exposed to corrosion without being detected by the leak detection system, and that the pipe is in a situation were its repair is not economically visible. The report was delivered to the university to decide on that. JUST Heating System: Alternative System After taken other technical opinions, the University decided on replacing the whole system with a new one. The university forms a team under Dr. Taha leadership to prepare a study for new alternative heating system for the whole university. Number of proposals were prepared, trying to use most of the old system good subsystems, like the boilers, water treatment units,

8 main pumps, and of course the portion of the piping distribution system inside the buildings. The issue concentrated on the main lines, from the boiler service room up to the pumps distributing rooms at the buildings, a length of 2000 m piping. JUST Heating System: Follow up team The university approved the proposed solution, and tendered it for design and execution. The team under the leadership of Prof. Taha assigned the task of reviewing the design, and after that to follow up the execution. The Project cost two million dollars and took two years to finish. The system running since then successfully with least problems. Prof. Taha also involved in the projects initiated by the Trade and Economy Ministry, the Department of Measurements and Specification concerning establishment of a National Standards and Specification for more than 15 years. Ties with Industrial Firms and Companies: Prof. Taha established very good ties with number of establishments and petrochemical plants in the Gulf region, especially through delivering short courses and workshops in number of engineering topics. Among those companies are: ADMA-OPCO, Abu Dhabi, UAE ADCO, Onshore and off shore, Abu-Dhabi, UAE Dubai Port, Dubai, UAE ADGAS, Abu Dhabi, UAE GASCO, Abu Dhabi, UAE TAKREER, Ruwais, UAE BANAGAS, Manama, Al-Bahrain Yanpet Petrochemical Company, Yanbu-Saudi-Arabia Saudi Electric Company, AlRiyad, Saudi Arabia Cement Company, Jeddah, Saudi Arabia Potash Company, Amman, Jordan Jordan Refinery, Amman, Jordan Industrial Courses and Workshops: Topics of the short courses and workshops covering the following topics: Turbomachines: Pumps, Compressors, Fans: Operation, Construction, Control, Troubleshooting and Maintenance. Flowmeters & Flow measurements: Operation, Calibration, Data Analysis, Selection Heat Transfer Equipments: (Heat Exchangers & HVAC Systems): Construction, Designs, Operation, Control, Troubleshooting and Maintenance, Specification and Purchasing, Codes and standards.

9 Piping systems: Design, Material, Welding, Installation, Fittings, Expansion Loops and Expansion Joints, Testing and maintenance, Codes and Standards Hydraulic and Pneumatic Systems and Control Valves: Design, Applications, Selection and Specifications, Operation, and Control Failure analysis and Maintenance Strategies: Function/equipment critical analysis, FMEA, RSA, Maintenance RBM.