Course details

Overview ?

INTRODUCTION

This programme provides a comprehensive understanding of the various types of reciprocating, rotary, and dynamic compressors and pumps. This includes trunk piston, sliding crosshead piston, diaphragm, rotary screw, straight lobe, sliding vane, liquid ring, centrifugal, and axial compressors as well as piston pumps, plunger pumps, rotary pumps, screw pumps, two- and three-lobe pumps, cam pumps, vane pumps, bellows-type metering pumps, diaphragm pumps, canned motor pumps, and centrifugal pumps. Bearings are also covered thoroughly. The characteristics, selection criteria, sizing calculations, sealing arrangements, common problems, repair techniques, as well as the preventive and predictive maintenance of these compressors and pumps are covered in detail.

This programme is a MUST for those who use this equipment. It covers how compressors, pumps, and bearings operate and provides the guidelines and rules that must be followed for their successful application.

This programme provides the following for all types of compressors, pumps, and bearings:

Basic Design
Specification
Selection Criteria
Sizing Calculations
Sealing Arrangements
Common Operational Problems
All Diagnostics, Troubleshooting, and Maintenance Required for this Equipment Including Vibration Analysis, and Used Oil Analysis
Compressor and Pump Drivers

PROGRAMME OBJECTIVES

Maximize the efficiency, reliability, and longevity of all types of compressors, pumps, and bearings
Size and select out of the various types of dynamic and positive displacement compressors, and pumps using the performance characteristics and the selection criteria that you learn in this programme
Carry out diagnostic testing and inspection of critical components with the knowledge of common failure modes of compressors, pumps, and bearings by applying advanced fault detection techniques
Select bearings and lubrication, compressor and pump sealing arrangements, meet commissioning requirements, conduct vibration and used oil analyses, troubleshoot, provide predictive and preventive maintenance, enhance reliability, and reduce cost
Determine the maintenance required to minimize compressor and pump downtime and operating cost and maximize their efficiency, reliability, and longevity
Gain a thorough understanding of compressor and pump characteristics and compressor surge and surge prevention systems
Understand all the causes of failures in compressors and pumps
Determine all the design features that improve the efficiency and reliability of all compressors and pumps
Design different types of compressor and pumping systems
Gain a thorough understanding of the various types of sealing arrangements used in compressors and pumps

TRAINING METHODOLOGY

The instructor relies on a highly interactive training method to enhance the learning process. This method ensures that all the delegates gain a complete understanding of all the topics covered. The training environment is highly stimulating, challenging, and effective. The participants will learn by case studies. They will be able to apply all the concepts to their own organization.

PROGRAMME SUMMARY

This programme provides indepth understanding of the operation, selection, sizing, applications, sealing arrangements, troubleshooting, and maintenance of all types of compressors, pumps, and bearings. All the methods used to enhance the performance, reliability, troubleshooting, and maintenance of this equipment are discussed in detail. This programme includes also detailed coverage of mechanical seals, compressor and pump drivers, compressor surge, choking, surge prevention systems, and anti-choking systems. Dry seals and magnetic bearings are also covered in detail in this programme.

PROGRAMME OUTLINE

DAY 1 - Gas Laws, Compressor Types and Applications

Perfect and Imperfect Gases
Compressor Polytropic Efficiency and Power Requirements
Compressor Volumetric Flow Rate and Volumetric Efficiency
Rotary and Reciprocating Compressors
Dynamic Compressors (Centrifugal and Axial)
Compressor Performance Measurement
Receivers, Compressor Control, and Compressor Unloading Systems
Preventive Maintenance and Housekeeping

DAY 2 - Positive Displacement Compressors

Performance of Positive Displacement Compressors
Reciprocating Compressors
Reciprocating Compressors Troubleshooting and Maintenance
Diaphragm Compressors
Rotary Screw Compressors and Filter Separators
Straight Lobe Compressors
Recent Developments in Liquid/Gas Separation Technology

DAY 3 - Dynamic Compressors

Dynamic Compressor Technology
Centrifugal and Axial Compressors
Simplifies Equations for Determining the Performance of Dynamic Compressors
Centrifugal Compressors – Components, Performance Characteristics, Balancing, Surge Prevention Systems and Testing
Choking, and Anti-Choking Systems
Compressor Auxiliaries, Off-Design Performance, Stall, and Surge

DAY 4 - Dynamic Compressors Performance, Compressor Seals, and Compressor System Calculations

Dynamic Compressors Performance
Surge Limit, Stonewall, Prevention of Surge, Anti-Surge Control Systems
Compressor Seal Systems
Gas Seals, Liquid Seals, Liquid Bushing Seals, Contact Seals, Restricted Bushing Seals, Seal Liquid leakage System
Dry Seals, Advanced Sealing Mechanisms, and Magnetic Bearings
Compressor System Calculations
Sizing of Compressor System Components, Sizing of Gas Receiver
Workshop – Case Studies: Design and Selection of Different Compressor Systems for the Oil and Gas industry, and the Power Generation Industry

DAY 5 - Bearings, Lubrication, Vibration Analysis and Predictive Maintenance

Bearings, Types of Bearings, Thrust Bearings
Lubrication, Viscosity of Lubricants, Non-Newtonian Fluids, and Greases
Used Oil Analysis
Vibration Analysis and Predictive Maintenance
Vibration Causes, Resonant Frequency, Vibration in Predictive Maintenance, Diagnostics
Diagnostic Testing

DAY 6 - Pump Categories, and Centrifugal Pumps

Pump Categories: Dynamic (Centrifugal) and Positive Displacement (Reciprocating and Rotary)
Centrifugal Pumps: Operation, Casings and Diffusers, Hydrostatic Pressure Tests, Impellers, Hydraulic Balancing Devices, Mechanical Seals, Minimum Flow Requirement, Performance Characteristics, Cavitation, and Net positive Suction Head

DAY 7 - Centrifugal Pump Mechanical seals

Centrifugal Pump Mechanical Seals, Components, Temperature Control, Seal Lubrication/Leakage, Applications, Types of Mechanical Seals, Common Failure Modes of Seals, Seal Refurbishment
Maintenance Recommended for Centrifugal Pumps
Vibration Analysis and Predictive Maintenance

DAY 8 - Positive Displacement Pumps

Reciprocating Pumps, Piston Pumps, Plunger Pumps, Rotary Pumps, Screw Pumps, Two- and Three-Lobe Pumps
Cam Pumps, Vane Pumps, Bellows-Type Metering Pumps
Diaphragm Pumps
Canned Motor Pumps, Seal-less Pump Motors

DAY 9 - Troubleshooting of Pumps

Pump Maintenance, Inspection, Overhaul, Diagnoses of Pump Troubles
Troubleshooting of Centrifugal Pumps
Troubleshooting of Rotary Pumps
Troubleshooting of Reciprocating Pumps
Water Hammer
Bearings
Used Oil Analysis
Smart Instrumentation

DAY 10 - Pump SelectionPump Selection

Pumping System Calculations
Workshop: Design and selection of Different Pumping Systems for the Oil and Gas Industry, and the Power Generation Industry
Vibration Analysis and Predictive Maintenance
Control Valve Selection, Cavitation, and Noise
Actuators, Positioners, and Accessories
Diagnostics of Pumping Systems
Pump Drivers
Motors
Variable-Frequency Drives