Preventive Maintenance and Troubleshooting of Pumps and Compressors

Introduction

Efficient Pumps and Compressor Operations are paramount to overall effective plant objectives ensuring minimum downtimes. The variety of this machinery brings certain complexities when identifying problems and conducting the specific maintenance requirements. This course is designed to assist engineers and technicians in identifying the various pumps and compressors they will be expected to handle. It was detailing the how-to conduct scheduled maintenance and how to replace parts and troubleshooting methods based on manufacturers and practical experience.

Objectives

By the end of the course, participants will be able to:

• Provide skills and practical knowledge on pumps and compressors, predictive maintenance in diagnostics.
• Identify the pumps and compressor in general service and the various maintenance methods plus the number of practical fault-finding techniques available
• Identify the main problems associated with wear and tear and minimizing downtimes along with lubrication requirements.

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations.

Who Should Attend?

This course is intended for engineers and technicians involved with maintenance programs and are responsible for day-to-day servicing and operational efficiency. Also, plant and maintenance engineers, process engineers and maintenance managers. It may also be invaluable to supervisors who are involved in pumps and compressor maintenance schedules.

Course Outline

Day 1:

• Pumps: Types, functions, design and operation
• Operating Characteristics
• Positive Displacement, Centrifugal and Vertical pumps
• Common applications of various types of pumps
• Pump operations practical assessments
• Hydraulic Balance: Bearing types, Impellers configuration
• Lubrication: Oil & Greases
• Hydraulic Disturbance of pumps due to casing configuration and systems
• Review hydraulics of flow; velocity, pressure head, velocity head, head loss

Day 2:

• Transfer of energy; power, energy, electrical systems, brake & water
• Horsepower, efficiency, energy costs pack and capillary columns
• Installing: Conditions, leveling techniques, piping systems
• Troubleshooting and fault finding and correct procedures
• Pump selection fault diagnosis etc.
• Loss of capacity identification
• Tools and Instruments: Type and Care, Usage
• Alignment: vibration, Frequencies and Alignment problems
• Predictive maintenance: Problem, Identification, Scheduling Maintenance
• Programs, Failures and Analysis
• Lubrication Requirements

Day 3:

• Predictive maintenance: Methods, Prevention programs Motors; operation, maintenance, troubleshooting, single phasing
• Bearings; types, removal, installation, lubrication, troubleshooting
• Couplings; types, installation, alignment, vibration
• Blowers; types, operation & maintenance, troubleshooting
• Mechanical Seals; types, Selection
• Replacing Seals: Techniques and methods, packed glands, selection, replacement etc.
• Mechanical Checks: Procedures and Controlled
• Overhauls and Repairs: Preparing, inspecting and assembling components
• Replacement: Broken, Defective or Worn Components

Day 4:

• Compressors: Identification and Functions
• Centrifugal, Axial, Reciprocation, Helical, Screw
• Applications, Usage and Limitations
• Design & Technical: Compressor rotors, impellers, Casings
• Seals Diaphragms, Nozzles, Gland Systems
• Balancing
• Bearings
• Alignment Techniques and Support: Dial Indicator Methods, Laser Optic Cold Alignment, On Stream, Hot Alignment Verification Techniques
• Compressor Parameters: Thermodynamics, Capacity, Power, Efficiencies
• Selection of Centrifugal Process compressors: Calculation methods, Characteristic Curves, Stability
• Selection of Centrifugal Process Compressors: Calculation methods, Volumetric Efficiency, Multi-staging, Frame loads, Characteristic Curves

Day 5:

• Basic Troubleshooting: Failures, Defects, Design Problems
• Selection of Screw Compressors: Advantages & Disadvantages
• Predictive and Preventative Maintenance Techniques
• Overall Troubleshooting and maintenance techniques
• Maintenance skills: Development and Implementing, Manuals and Information sources
• Maintaining Records: Maintenance, Repairs and Decisions