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Sulzer Pump, Hydrodynamic Couplings and Bergmann Mechanical Seals Training

Introduction

Sulzer Pump, Hydrodynamic Couplings and Bergmann Mechanical Seals Training

Objectives

Upon the successful completion of this course, participants will be able to:-

• • Know the basics principal of pump operations
  • Learn the different types of pumps
  • Understand the pump construction
  • Learn how the performance curve of the pump is measured
  • Use the similarity laws to calculate the pump performance at a different speed and rotor size
  • Highlight the importance of the related international standards of pumps
  • Familiarize with different auxiliary systems for pumps (oil system and protection system)
  • Understand the basics of sealing systems (mechanical seals and packing) as well as the different types of bearings and its applications
  • Learn the maintenance procedure of pumps
  • Learn the common causes of pump failures (e.g. cavitation and vibrations)
  • Familiarize the attendees with different types of Bergman Mechanical Seals
  • Understand the mechanical design of Bergmann Mechanical Seals
  • Learn the principles of operation of Bergmann Mechanical Seals
  • Learn the maintenance procedure Bergmann Mechanical Seals
  • Learn the failure analysis and troubleshooting of Bergmann Mechanical Seals
  • Familiarize the attendees with different types of bearings and their associated problems
  • Casing, wear rings and impeller types and their usage will be discussed.
  • Know the basics principal of Voith operations
  • Learn the Design principles of Voith couplings
  • Understand what is the Fluid drive
  • Understand the hydrodynamic principle of Voith couplings
  • Understand the Voith couplings construction
  • Fields of Application of Voith couplings
  • Learn how is variable speed fluid coupling operates

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 training course is recommended for anyone involved in the selection, inspection, maintenance, and troubleshooting of pumps. This includes:

• Mechanical Maintenance Engineers
• Operation Engineers
• Mechanical Maintenance Supervisors
• Mechanical Maintenance Technicians
• Plant Field Operators, Supervisors and Section Heads

Course Outline

Day 1: Introduction and Pumping Fundamentals

• Introduction
• Hydraulics - A Few Basics
• Vapor Pressure
• Pumping process concept
• Operating Parameters
• Head
• Flow
• RPM
• Power
• Efficiency
• Pump Net Positive Suction Head (NPSH)

Pumping Methods

• Centrifugal action
• Displacement action
• Rotary displacement pumps
• Pump Classification
• Pump Types and Terminology
• Pump Classification
• Centrifugal Pump Basics
• Principle of Operation
• Understanding of pumping theory
• Classify characteristics of pumps
• Mixed Flow Pumps
• Axial Flow Pumps
• Low-pressure & High-pressure pumps
• Pumping vertically & pumping horizontally
• Single-suction & Double-suction pumps
• Single-stage, Double-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

Day 2: Sulzer Pumps Performance Curves

• Head-Capacity curve
• Power-Capacity curve
• Efficiency-Capacity curve
• NPSH-Capacity curve
• Limits of operation
• Characteristics curves for different types of pumps
• How to obtain these curves experimentally
• How to calculate these characteristic curves

Sulzer 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 Auxiliary System

• Pump Bearings
• Antifriction bearings
• Journal bearings
• Range of applications of both types of bearings
• Different methods of Bearings Lubrications
• Lube-oil systems
• Failure modes and how to extend the life of the bearings.

Sulzer Pump Maintenance

• Maintenance and Inspections
• Proper Preventive Maintenance Schedule
• A maintenance schedule includes these types of inspections:
• Routine maintenance
• Routine inspections
• Three-month inspections
• Bearing Maintenance
• Bearing lubrication schedule
• Lubricating-oil requirements
• Oil volumes
• Acceptable oil for lubricating bearings
• Shaft Seal Maintenance
• Mechanical-seal maintenance
• Packed Stuffing-Box Maintenance
• Accepted leakage rate
• Adjustment of gland
• Tightening of packing

Sulzer Pump Overhauling

• Disassembly/dismantling Procedure
• Lockout and Tag out
• Tools required
• Drain the pump
• Remove the coupling
• Remove the back pull-out assembly
• Remove the coupling hub
• Impeller removal
• Seal-chamber cover removal
• Remove the dynamic seal
• Power-end disassembly
• Disassemble the bearing frame
• Pre-assembly inspections
• Replacement guidelines
• Shaft and sleeve replacement guidelines
• Surface inspection locations
• C-face adapter inspection
• Seal chamber and stuffing box cover inspection
• Bearings inspection
• Condition of bearings
• Checklist
• Bearing-housing inspection
• Checklist
• Bearing fits and tolerances

Reassembly

• Assemble the rotating element and the bearing frame
• Assemble the frame
• Install the impeller
• Post-assembly checks
• Bolt torque values
• Parts dismantle, refurbishment, inspection.
• Wear limit measurement & assembly.
• Shaft-end play measurements
• Adjusting wear ring clearance
• Measuring shaft run out
• Measuring bearing radial clearance
• Measuring impeller clearance

Day 3: Sealing Methods

• Overview (Packing and Mechanical Seals)
• Soft packing
• Difference between packing and mechanical seal
• Packing material
• Cooling methods for packing
• Packing installation procedure

Bergmann Mechanical Seals

Basic Seal Designs – Mechanical Seal Classifications

• Pusher seal / Non – pusher seal
• Balanced and unbalanced seals
• Single seal and double seals
• Inside and outside seals
• Separate seals & cartridge seals
• Special seal designs
• API seal arrangement

Seal Component Materials

• Seal faces material
• Gaskets materials
• Springs
• Materials
• Hardware materials
• Types of Bergmann Mechanical Seal
• Mechanical Seal Arrangement
• Applications of Bergmann Mechanical Seals
• Construction of Bergmann Mechanical Seals
• Materials of Bergmann Mechanical Seals Components
• Temperature Control of Bergmann Mechanical Seals
• Sealing and Flushing Fluids
• Mechanical seal plans according to API 682

Day 4: Installation of Bergmann Mechanical Seals

• Pre-installation checks (equipment checkpoints)
• Seal installation & seal setting in horizontal pumps
• Seal installation & seal setting in vertical pumps
• Selection of Bergmann Mechanical Seals
• Failure Causes of Bergmann Mechanical Seals
• Maintenance and Repair of Bergmann Mechanical Seals
• Mechanical seal repair and seal faces inspection (optical inspection system)
• Troubleshooting of Bergmann Mechanical Seals

Introduction of Coupling Fundamentals

• Operating principles of hydrodynamic
• Power transmission

Hydrodynamic Principles

• Fluidic connections
• Similarity laws for hydrodynamic power transmitters
• Geometric similarity
• The similarity of flow velocities
• The similarity of hydrodynamic power transmitters
• Interaction of several flow machines
• Primary characteristic curves
• Secondary characteristic curves
• Determining characteristic curves

 Day 5: Hydrodynamic Voith couplings

• Characteristic curves
• Fluid couplings in drive systems
• Electric motor, multi-motor drives
• Diesel engine
• Dependence on rotation direction and direction of action
• Structure of the coupling designs
• Constant-fill couplings
• Variable-speed couplings
• Clutch couplings
• Hydrodynamic features, advantages and benefits