Course Outline

Course Outline

Operation, Maintenance & Troubleshooting of Pumps, Compressors & Turbines

Ref No. Dates Venue Fee (US$)  
ME 002 23 - 27 Jun 2019 Dubai 4500 Register
ME 002 01 - 05 Dec 2019 Dubai 4500 Register

Operation, Maintenance & Troubleshooting of Pumps, Compressors & Turbines

Introduction

Oil and Gas process plants require specialized equipment to provide the energy to transfer large quantities of the liquids and gases through piping and pipelines designed for those purposes. This transfer occurs from the oil and gas fields through refining and processing plants, and onwards to the storage and sales points. The equipment used for to transfer the fluids are termed Rotating Equipment. These equipment are used extensively and provides an increase in pressure for both liquid and gas streams to enable the passage of fluids to the required destination.

This PROCLAD Academy training course will introduce delegates to different types of Operation, Maintenance & Troubleshooting of Pumps, Compressors & Turbines and associated equipment, such as bearings, seals, filters, separators, etc. The focus in the training course will be on the start-up and operation of these equipment and their optimal diagnostics and troubleshooting techniques. The training course will also cover efficient and trouble-free operation of pumps, compressors and turbines, along with their ability to control the main operational parameters and will include emphasis on physical principles and clear technical reasoning. 

The key features of PROCLAD Academy’s Operation, Maintenance & Troubleshooting of Pumps, Compressors & Turbines training course are:

  • Principles of pump, compressor and turbine start up and operation
  • Best practices for maintenance and repair
  • Measurement and control of performance of these machines
  • Inspection and diagnosing the root cause of problems
  • Troubleshooting techniques for operational problems of pumps, compressors and turbines
Learning Objectives

Attendance to PROCLAD Academy’s Operation, Maintenance & Troubleshooting of Pumps, Compressors & Turbines training course will enable the participants to:

  • Understand different types of pumps, compressors and turbines
  • Operate pumps, compressors and turbines close to the design efficiency
  • Monitor pump compressor and turbine reliability and availability and cost effectiveness
  • Select the best operation and maintenance strategy
  • Troubleshoot pump, compressor and turbine problems
Target Audience

PROCLAD Academy’s Operation, Maintenance & Troubleshooting of Pumps, Compressors & Turbines training course is designed to benefit all levels of Technical Personnel in the oil and gas industry as well as in chemical and process industries but will greatly benefit:

  • Technical Personnel in charge of production
  • Maintenance and Operation Engineers
  • Supervisors
  • Operators
  • Engineering Managers
Training Methodology

PROCLAD Academy’s Operation, Maintenance & Troubleshooting of Pumps, Compressors & Turbines training course will utilize a variety of proven learning techniques to ensure maximum understanding, comprehension and retention of the information presented. This includes lecture with active delegate participation including discussions, real life problems, case studies and relevant videos.

Through an active participation in the group work and class discussions, the delegates will get a lot of opportunity to increase their experience and knowledge of techniques available for equipment troubleshooting.

Course Outline

Introduction

  • Hydraulics – A Few Basics
  • Vapor Pressure
  • Pump Classification 

Centrifugal Pump Basics

  • Principle of Operation,
  • Pump Classifications
  • Mixed Flow Pumps
  • Axial Flow Pumps
  • Low-pressure & High-pressure pumps
  • Single-suction & Double-suction pumps
  • Single-stage and Multi-stage pumps
  • Volute & Diffuser pumps
  • Closed impeller, open, impeller or Semi-open impeller
  • Casing Construction (Radially Split, Axially Split, Double Casing)
  • Impeller Shrouds (Open, Partially Open, Closed)
  • Shaft Position (Horizontal, Vertical)
  • Wear Ring Running Clearances
  • Pump Bearings
  • Antifriction bearings
  • Journal bearings
  • Range of applications
  • Lubrication of bearings

Pumps Operation Procedures

  • Operating conditions
  • Pump curve against piping system curve
  • System curve calculation
  • NPSH available and required
  • Suction system configurations
  • NPSH measurement
  • Normal operating range
  • Best operating condition
  • The minimum flow rate limit
  • The maximum capacity limit
  • Off-design operation
  • Operation difficulties

Pump Troubleshooting

  • Pump Installation, Startup and Operation Guidelines
  • Pump Inspection and Performance Control
  • Pump Maintenance Based on Daily Observations of Pump Operation,
  • Diagnoses of Pump Troubles and Records of Inspections and Repairs
  • Control of Lubrication System
  • Mechanical Seals, Bearings and Couplings
  • Vibration Control and Analysis 

Cavitation in pumps

  • Net Positive Suction Head
  • Available against required NPSH
  • Symptoms of cavitation
  • Effects of Cavitations
  • Avoidance of cavitation
  • Water Hammer Problems and Troubleshooting
  • General Troubleshooting Checklist
  • Shaft deflection
  • Critical speed and shaft deflection.
  • Parameters affecting shaft deflection
  • Effects of shaft deflection on Mechanical seals and Bearings

Failure or deviation symptoms

  • Pump does not deliver
  • Insufficient capacity delivered
  • Insufficient discharge pressure developed
  • Pump loses prime after starting
  • Pump requires excessive power
  • Stuffing box / mechanical seal leak excessively
  • Packing / mechanical seal has short life
  • Pump vibrates or noisy
  • Bearing have short life
  • Pump overheats and seizes
  • First Law of Thermodynamics
  • Second Law of Thermodynamics
  • Compressor Types and Applications
  • Introduction to the compressor types
  • How a centrifugal compressor works
  • How a positive displacement compressor works
  • Different between dynamic and positive displacement compressor
  • How screw compressor works
  • How lobe compressors works
  • Principle of operation of:
    • centrifugal compressors
    • single-stage (low ratio)
    • multi-stage horizontally split compressors
    • multi-stage (barrel) centrifugal compressors
    • multi-stage integral gear centrifugal compressors
  • Principle of operation of axial flow compressors, characteristics of axial flow compressor
  • Centrifugal Compressor Configurations and Components
  • Casing Configuration
  • Horizontally Split Compressor Casings
  • Vertically Split Compressor Casings
  • Axially vs. Radially Split
  • Compressor Impellers
  • Impeller Geometry
  • Impeller Arrangements on Compressor Shafts
  • Impeller Thrust
  • Balance piston
  • Diffusers
  • Diaphragms
  • Compressor Bearings
  • Radial Bearings
  • Thrust Bearings
  • Compressor seals (Labyrinths, carbon rings, liquid films and dry gas seals)
  • Dry Gas Seals and Support Systems:
  • Comparison of Dry Gas Versus Wet Sealing Systems
  • Principles of Dry Gas Seals and Construction Features

Centrifugal Compressor Control

  • Performance Characteristics
  • The performance curves
  • Limits of operating speed: First and second critical speed
  • Effect of speed variation
  • Effect of inlet conditions
  • Effect of gas molecular weight
  • Performance of different types of compressors
  • Limits of flow rates: Surge line and stonewall line

Surge and Surge Control

  • Off-design Operation
  • Vibration control system
  • Alarm and trip system

Centrifugal Compressor Operation

  • Compressor start-up and shut down
  • Speed limits.
  • Required speed calculations
  • System Resistance
  • Inlet conditions Effects
  • Parallel and series operation

Centrifugal Compressor Troubleshooting

  • Guidelines for trouble-free centrifugal compressor operation
  • Examples from recent failure incidents attributed to design defects, processing and manufacturing deficiencies, assembly errors, off-design or unintended service conditions, maintenance deficiencies, etc.
  • Liquid Entrainment
  • Compressor fouling
  • Cleaning Centrifugal Compressors
  • Compressor off-design performance, low rotational speeds, high rotational speeds
  • Performance degradation
  • Excessive vibration

Steam Turbines

  • Operating Principles & Mechanical Design
  • Impulse Turbines
  • Reaction Turbines
  • Application Ranges
  • Configurations
  • Application Constraints

Turbine Components

  • Turbine Rotors
  • Blading
  • Diaphragms
  • Nozzles
  • Steam Chests
  • Glands and Gland Systems
  • Bearings
  • Seals
  • Rotor Dynamics
  • Governing Systems
  • Lube Oil Management

Operation of Steam Turbines

  • Commissioning
  • Startup
  • Run-In and Shut-down
  • Surveillance and Health Monitoring
  • Performance Measurement
  • Monitoring and Tracking
  • Steam Turbine Washing
  • Steam Turbine Inspection