CENTRIFUGAL PUMPS:- PROBLEM IDENTIFICATION AND PROBLEM SOLVING FOR INDUSTRIES

INTRODUCTION FOR CENTRIFUGAL PUMPS:- PROBLEM IDENTIFICATION AND PROBLEM SOLVING FOR INDUSTRIES

It can rightly be claimed that no machine and very few tools have had as long a history in the service of man as the pump, or have filled as broad a need in his life. Every process which underlies our modern civilization involves the transfer of liquids from one level of pressure or static energy to another. Pumps have played an essential role in our life ever since the dawn of civilization. Worldwide developments in pump theory, design and applications have continued to emerge, and these have begun to effect the outlook of pump engineers and users. Pumps have continued to grow in size, speed and energy level, revealing new problems that are being addressed by innovative materials, mechanical and hydraulic design approaches. Environmental pressures have increased, and these can and are being responded to by the creative attention of pump engineers and users. After all, the engineer is trained to solve problems, employing techniques that reflect knowledge of
physical phenomena in the world around us.

Pumps have their fair share of engineering problems in industry.

The said problems could be classified into:-

• Problems which could be identified and solved immediately, with little or no financial implications or loss in production and a drop in quality levels;
• Problems which could be identified and cannot be solved immediately, with little
  or no knowledge of its implications;
• Problems which recur frequently and cannot be solved permanently etc;

Some of the reasons for these are due to:-

• Incompetent staff;
• A vast variety of equipment;
• Many moving (sliding, reciprocating, rotating) components etc.

This course is industry designed, to provide a broad understanding of the improvement methodology, concepts, and process. The methodology is presented with case studies and examples drawn from service, business process and manufacturing applications. The integration of manufacturing and maintenance is also addressed. With a heavy practice orientation, as much as a third of your time will be spent working through interactive practical exercises and assessments. This course is designed as an introduction to concepts and methodology.

COURSE OBJECTIVES

This training program is designed to provide an understanding of engineering related problems related to industry globally and a clear sense of what is required to effectively  structure, establish measurements and solve problems. Participants will learn the goals and deliverables behind the solutions. Methodology as well as the most commonly used tools within each phase will be discussed. Participants will also learn how to support a problem solving initiative within their organization.

LEARNING OUTCOMES

On successful completion of this course, the participant should be able to:-

• Understand the benefits and implications of pump engineering problem solving programs, and relate the concepts to the overall business mission and objectives.
• Think about his/her organization as a collection of processes, with inputs that determine the output.
• Recognize the engineering problem solving model used to improve processes.
• Recognize the organizational factors that are necessary groundwork for a successful engineering problem solving program.
• Integrate the engineering problem solving program effort with other process improvement initiatives.
• Learn the various types of centrifugal pumps, their functions and terminologies used;
• Understand the design methodologies for centrifugal pumps;
• Understand the various maintenance methods for centrifugal pumps; and
• Understand the application of centrifugal pumps in various industries.

METHODOLOGY

• The latest educational methods and strategies will be utilized.
• The course is designed to maximize delegate participation.
• Questions and answers are encouraged throughout and at the daily wrap-up sessions. This gives participants the opportunity to discuss with others and the presenter their specific problems and appropriate solutions.
• The course shall be conducted through lectures, case studies, group discussions and exercises to reinforce participant’s learning.

MEASUREMENT TOOLS

Quiz, exercises and a test at the end of second day.

WHO SHOULD ATTEND
Facilities engineers, maintenance engineers, design engineers and any one who would like to widen their knowledge on the theory of pumps.

PAST PARTICIPANTS
Universiti Teknologi Malaysia, Penang Port Sdn.Bhd. Cement Industries of Malaysia Berhad, Politeknik Mukah (Sarawak), Petlin Malaysia Sdn Bhd

COURSE CONTENT

DAY 1 

Specifications, installation and operation

• • Introduction
    • • Introduction
      • Definition of head and related calculations
      • Definition of capacity and related calculations, flow velocity
      • Piping design:- Parts 1, 2, 3 and 4

• •  Net Positive Suction Head and Specific Speed
    • • Types of pumps
      • Calculation of NPSH
      • Suggested remedies for NPSH, and cavitation.

• •  Pump and System Characteristic Curves
    • • Various types of system curves
      • Information required to plot system curve
      • The various types of pump curves for the various types of pumps.

Motor sizing and application

• • Power, Efficiency and Electrical Requirements
    • • Power requirements
      • Motor selection
      • Power consumption and energy savings
      • Types of motors
      • Torque and power factor
  • Variable Speed Systems
    • • Reasons for using variable speed systems
      • Energy savings under constant and fluctuating flow demand.

DAY 2

Maintenance & Troubleshooting

• • Affinity Laws
    • The relationship between pump speed, flow, power, head and impeller diameter
    • Analysis of the pump composite performance curve

• • Pump Installation, Alignment and Field Testing Methods
    • Rim and face alignment using the dial indicatior and laser methods
    • Alignment procedures and equipment set-up
    • Determination of total head from gauge readings
    • Flow measurements using volumetric methods
    • Venturimeter, orifices pitot tube and weirs.

• • Pump  Operations And Maintenance
    • • Pump performance and temperature monitoring
      • Lubricant analysis
      • Air entertainment
      • Impeller Clearance
      • Installation
      • Cleanliness
      • Replacement and Inspection of Bearings

• • Vibration Analysis
    • • Vibration Level Characteristics
      • Vibration Analysers
      • Frequency
      • Amplitude and Phase

• • Safety And Pump Plant Renovation
    • • Safety apparel and procedures
      • Purpose of plant renovation
      • Improvements, Survey Plan and Implementation
      • Summary of survey results and overall assessment.