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Pumps and Compressors, Performance Evaluation, Preventive Maintenance and Troubleshooting

Introduction

Pumps and Compressors, Performance Evaluation, Preventive Maintenance and Troubleshooting

Course Objectives

• Comprehensive understanding of pump and compressor operations, performance, preventative maintenance and troubleshooting.
• Necessary experience and confidence to handle any challenge related to pumps and compressors.
• Experience to closely examine existing machinery employing pumps and compressors to check for maintenance or damage control.
• Required foresight to predict damages that could pose a serious threat soon and make changes to ensure that business is not impacted.
• Adequate confidence and knowledge to train other professionals on pumps and compressors.
• Ability to contribute to organizational development through reduced costs and better equipment.
• Knowledge and awareness of international standards and protocols to be followed.
• Overall skill set and capabilities to manage responsibilities related to pump and compressor operations.
• Practical ability to evaluate centrifugal and reciprocating compressor field performance using standardized methods, performance maps, and real-time monitoring software.
• Expertise in performing predictive and preventive maintenance using vibration analysis, temperature and energy monitoring, and systematic inspection techniques to minimize downtime and increase equipment reliability.
• Skills to optimize system efficiency, analyze causes of performance losses, and make data-driven recommendations using mechanical and operating parameters such as flow, head, pressure, and efficiency.
• Knowledge of fault-finding techniques for diagnosing common pump and compressor failures and applying root cause analysis to resolve operational issues.
• Proficiency in maintaining accurate performance records, tracking maintenance activities, and using historical data for reliability improvement and asset management programs.

Who Should Attend?

• Engineers and other staff members working on pumps and compressors
• Vendors of pumps and compressors
• Managers overseeing operations involving pumps and compressors
• Senior members of an organization responsible for making critical decisions in the organization
• Compliance officials and quality checkers responsible for ensuring all operations comply with international guidelines
• Safety inspectors responsible for ensuring employee safety
• Finance advisors providing the required expert opinion for purchases related to machinery
• Any other professional who would like to know more about pumps and compressors

Course Outline

Module 1 – Components of a Pump or Compressor Station

• Scrubber or inlet separator to remove liquids
• Filter to remove contaminants
• Gas coolers
• Heater and cooler
• Fuel gas system
• Station flow measurement
• Auxiliary power unit
• Compressed air system
• Power gas system
• High voltage electrical system
• Security system
• Building heating system
• Control and instrumentation systems for automated operation
• Emergency shutdown systems and safety interlocks
• Vibration monitoring and condition assessment equipment
• Lubrication and seal oil systems for reliability enhancement

Module 2 – Factors Playing a Role in Determining Pump and Compressor Stations

• Size and configuration of drivers and compressors or pumps
• Climatic conditions
• Location relative to support resources
• Regulatory, environmental and safety requirements
• Proximity to inhabited areas
• Process fluid properties and composition requirements
• Operating pressure and temperature ranges
• Redundancy and backup system requirements for critical applications
• Environmental noise and emission compliance standards

Module 3 – Factors Influencing Selection of Pump or Compressor Unit

• Performance ratings and load cycles
• Installation requirements and constraints
• Configuration options
• Type of energy source
• Maintenance support resources
• Life cycle costs
• Noise and exhaust emission requirements
• Efficiency characteristics and energy consumption analysis
• Variable speed drive capabilities for load matching
• Materials of construction for corrosive or high-temperature applications
• Control system integration and automation compatibility

Module 4 – Types of Compressors

• Positive displacement
  • Reciprocating compressors
  • Ionic liquid piston compressor
  • Rotary screw compressors
  • Rotary vane compressors
  • Rolling piston
  • Scroll compressors
  • Diaphragm compressors
• Dynamic
  • Air bubble compressor
  • Centrifugal compressors
  • Diagonal or mixed-flow compressors
  • Axial compressors
• Hermetically sealed, open or semi-hermetic
• Variable Refrigerant Flow (VRF) systems with advanced controls
• Magnetic bearing centrifugal compressors for oil-free operation
• Multi-stage compression systems for high-pressure applications
• Turbo compressors with advanced aerodynamic design

Module 5 – Parameters Assessed for Centrifugal Compressor Performance

• Flows
• Efficiencies
• Heads
• Speeds
• Polytropic and isentropic efficiency calculations
• Surge margin and operating range analysis
• Gas composition effects on performance characteristics
• Power consumption and energy efficiency ratios

Module 6 – Parameters to be Monitored for Compressor Maintenance

• Motor temperature
• Vibration
• Motor current
• Bearing temperature and lubrication oil condition
• Pressure and temperature across compression stages
• Seal condition and leakage monitoring
• Performance degradation trending and analysis

Module 7 – Air Compressor Troubleshooting Aspects

• Compressor not operating
• Excessive noise during operation
• Knock – same cycle as RPM
• Knock while compressor is loading
• Milky oil in oil reservoir
• Excessive oil consumption
• Oil in discharge air
• Compressor vibration
• Air blowing out of inlet
• Insufficient pressure at point of use
• Excessive belt wear
• Excessive discharge air temperature
• Repeated fuse blows
• Sudden stop of the compressor
• Root cause analysis using pressure-volume (P-V) diagrams
• Valve timing and performance evaluation
• Intercooler and aftercooler performance issues
• Control system malfunctions and sensor failures

Module 8 – Types of Pumps

• Getter-ion or sputter-ion pumps
• Cryopumps
• Sorption pumps
• Non-evaporable getter pumps
• Turbomolecular pumps
• Centrifugal pumps with various impeller designs
• Positive displacement pumps including gear and screw types
• Magnetic drive pumps for hazardous fluid handling
• Multi-stage pumps for high-head applications

Module 9 – Steps of Setting-Up a Centrifugal Pump

• Open valves in auxiliary sealing, cooling, flushing and bypass lines
• Open suction valve
• Close discharge valve
• Prime or vent, as necessary
• Energize the driver
• Open discharge valve
• Pre-startup inspection checklist and system verification
• Alignment and coupling checks before operation
• Baseline performance measurement and documentation
• Control system configuration and safety interlock testing

Module 10 – Key Performance Parameters of a Centrifugal Pump

• Head
• Friction head
• Velocity head
• Pressure head
• Net Positive Suction Head (NPSH) requirements and available NPSH
• Hydraulic and mechanical efficiency calculations
• Best Efficiency Point (BEP) determination and operation
• Specific speed and pump selection criteria

Module 11 – Parameters to be Regularly Monitored for Centrifugal Pump Maintenance

• Suction pressure
• Discharge pressure
• Flow
• Pump speed
• Pump efficiency
• Power
• Seal chamber pressure and temperature monitoring
• Vibration analysis and bearing condition assessment
• Motor current signature analysis for fault detection
• Performance curve monitoring and degradation tracking

Module 12 – Pump Troubleshooting Aspects

• Little or no discharge
• Loss of suction
• Motor overheating and shutdown
• Pump leak at the shaft
• Excessive noise or vibration of the pump
• Lack of pump prime
• Lack of pump pressure
• Pump not starting
• Cavitation detection and mitigation strategies
• Impeller damage assessment and repair techniques
• System curve analysis and operating point optimization
• Predictive maintenance using condition monitoring technologies
• Energy efficiency optimization and performance recovery methods
• Advanced diagnostic techniques including thermal imaging and acoustic monitoring