Practical Pump & Valve Technology

Accreditations

Introduction

This two week seminar will introduce delegates to the different types of pumps and valves and their associated terminology. Centrifugal and positive-displacement pumps, packing, mechanical seals and sealing systems, bearings and couplings will all be discussed.

Understanding the function of each valve type will have an important reflection on the process quality, equipment and plant reliability, and the economics of the whole activity. Different application needs to select the appropriate valve type for a particular flow characteristic. Operation of the valve affects the system and the process. Understanding the problems associated with valves is essential for diagnosis and troubleshooting and the needed maintenance for the particular type of valves.

The application of the different types of pumps and valves will be discussed along with their suitability for different operational duties. Operation, troubleshooting and maintenance will be dealt with in depth.

The seminar is split into two modules:

MODULE I - Practical Pump Technology

MODULE II - Practical Valve Technology: Selection, Operation, Maintenance and Troubleshooting

Each module is structured and can be taken as a stand-alone course; however, delegates will maximise their benefits by taking Module 1 and 2 back-to-back as a two-week seminar.

Objectives

By the end of this seminar delegates will be able to:

• Have an understanding of the different types of pumps.
• Be able to operate pumps as close as possible to the design efficiency.
• Will be able to monitor pump efficiency, availability and reliability.
• Have learnt about selection, operation and maintenance strategies.
• Be able to troubleshoot pump problems.
• Have an understanding of different parameters affecting the operation of valves
• Have an ability to select the right valve for the particular application
• Have an ability to perform the necessary calculation for valve sizing
• Have anunderstanding of the problems associated with valves like flashing, slamming and water hammer
• Have an ability to perform troubleshooting of systems involving valves
• Have an ability to decide on the right maintenance plan concerning different types of valves

Training Methodology

The seminar will be conducted along workshop principles with formal lectures, case studies and interactive worked examples. Relevant case studies will be provided to illustrate the application of each tool in an operations environment. Questions, comments and personal experience from every participant will have a chance to be heard and discussed. Each learning point will be re-enforced with practical exercises. There will be ample opportunities for discussion and sharing experiences.

Organisational Impact

On completion of this seminar the delegate will be able to critically analyse the methodologies employed within the organisation and instigate improvements where required. Deep understanding of different types of valves would have a great impact on the plant reliability, operation stability and overall running cost reduction. Selection of the right valve for the appropriate application does have important impact on the processes quality.

Personal Impact

Safety and relief valves play a vital rule for the safety concerning equipment and personnel. Pumps are ubiquitous in any industrial setting and the operation and maintenance must be understood. Technical knowledge is key to effective control and peer respect within any maintenance organisation; when this is achieved personal satisfaction follows.

This seminar will give the delegate the required level of technical knowledge and skill to achieve that personal satisfaction.

The knowledge gained in this seminar will:

• Enable the delegate to optimise the operation and maintenance of different types of pumps.
• Give the delegate confidence to carry out failure analyses on pumps thereby avoiding repetitive failures.
• Allow tighter control of maintenance budgets by the avoidance of unplanned equipment failures in service.

Competencies Emphasized

This seminar aims to enable participants to develop the following competencies:

• Understanding of pump operating and maintenance techniques.
• Ability to put in place measures to quantify equipment condition.
• Interface with pump equipment providers.
• Identify and specify new and replacement pumps.
• Deepen the understanding of the function of different types of valves
• Understanding the characteristics of valves
• Ability to carry out the selection and sizing process
• Understand the problems and phenomenon associated with valves operation
• Ability to carryout troubleshooting of valves and systems that valves are connected to

Who Should Attend?

This seminar is directed towards Supervisors, Team Leaders and Professionals in Maintenance, Engineering and Production. The seminar will also benefit anyone who wishes to update themselves on pump technology, judge the suitability of different types of pumps for their needs, and learn how to operate and maintain them for the benefit of their organisations. Maintenance, Operation, and People in R and D department are recommended to attend this course.

 SEMINAR OUTLINE 

Module I

Practical Pump Technology

DAY 1

Introduction

• Introduction
• Pump Types and Terminology
• Net Positive Suction Head (NPSH)
• Pump Performance (Centrifugal and Positive Displacement)
• Cavitation
• Hydraulic Pulsations and Pipe Vibration

DAY 2

Positive Displacement Pumps

• Reciprocating Pumps
• Reciprocating Pump Valves
• Rotary Pumps – scroll and gear types
• Special Application Pumps – metering pumps, diaphragm pumps
• Failure Mechanisms – identification and monitoring

DAY 3

Centrifugal Pumps

• Centrifugal Pump Theory
• Matching Pumps with Drivers
• Pump Wear Rings and Balance Lines
• Multi-Stage Pumps
• Performance Analysis
• Failure Mechanisms – identification and monitoring

DAY 4

Seals and Bearings

• Conventional Packing Glands
• Mechanical Seals
• Seal Failure Mechanisms
• Maintenance and Repair of Mechanical Seals
• Bearings – failure modes and how to extend life

DAY 5

Reliability

• Couplings
• Alignment
• Planned Maintenance - Predictive and Preventive
• Reliability Programmes

Module II

Practical Valve Technology:
Selection, Operation, Maintenance and Troubleshooting

DAY 6

Basics of the Valve Technology

Valves Technology

• Types of Valves
• Valves characteristics
• Sealing performance
• Leakage Criterion
• Leakage Classifications
• Sealing Mechanisms
• Valve stem seals
• Flow characteristics
• Flow through valves
• Valve flow characteristics
• Linear & equal %

DAY 7

Manual versus Automatic Valves

Manual Valves

• Functions of manual valves
• Methods of regulation
• Valve Types:
• Stopping/starting valves
• Control valves
• Valve end connections
• Valves rating
• Valves seating
• Types of manual valves
• Gate Valves
• Plug Valves
• Ball Valves
• Butterfly Valves
• Pinch Valves
• Diaphragm Valves

Check Valves

• Applications
• Types of Check Valves
• Lift check valves
• Swing check valves
• Tilting-disc check valves
• Diaphragm check valves
• Check Valves Operation
• Selection of Check Valves

DAY 8

Relif and Safety Valves: Function and Operation

Relief and Safety Valves

• Relief Valves Types
• Pressure-relieving devices
• Automatically operated valves
• Direct-acting & piloted pressure relief valves
• Modulating, full-lift, and ordinary pressure relief valves
• Valve Loading
• Safety Valves
• Operation of Direct-acting pressure relief valves
• Blowdown
• Relief valves problems

Rupture Valves

• Applications of Rupture Discs
• Rupture discs vs. Pressure relief valves
• Rupture discs in gases and liquid service
• Temperature and bursting pressure relationship
• Pressure tolerances
• Design and performance of ductile metal rupture discs
• Types of Rupture discs:
• Prebulged rupture discs
• Reverse buckling discs
• Vent panels
• Graphite rupture discs
• Double disc assemblies
• Rupture disc and pressure relief valve combinations
• Selection of rupture discs
• Operation of Rupture Discs

DAY 9

Valves Troubleshooting

Valves Problems, and Troubleshooting

• High Pressure Drop
• Pressure Recovery Characteristics
• Cavitation in Valves
• Incipient and choked cavitation
• Flow curve cavitation index
• Cavitation-elimination devices
• Flashing versus Cavitation
• Flow Choking
• High Velocities
• Water Hammer
• What causes water hammer?
• Water Hammer Calculations
• Solutions for water hammer
• Surge Protection
• Check valve slamming
• Noise problems
• Clean air standards
• Life loading
• Packing for fugitive-emission control
• Troubleshooting the Control Valves

Control Valves & Actuators

• Control Valves Types
• Linear Valve Features
• Rotary Valve Features
• Control Valve Flow Characteristics
• Quick Opening Characteristics
• Linear & Equal %
• Actuation systems
• Types of actuators
• Pneumatic Piston Actuator
• Electric motors
• Electrohydraulic Actuators
• Actuator Performance
• Valve Positioner
• Operation of Positioners
• Positioner calibration

DAY 10

Valve Sizing and Selection

• Valve-sizing criteria for manual valves
• Valve-sizing criteria for check valves
• Valve-sizing criteria for throttling valves
• Incipient and advanced cavitation
• Terminal pressure drop ratio
• Percent of Flashing
• Pressure Recovery Coefficient
• Valve Sizing & Selection Procedure
• Selecting a valve type
• Different valves characteristics
• Examples

Accreditations

 

The Practical Pump Technology and The Practical Valve Technology: Selection, Operation, Maintenance and Troubleshooting are fully endorsed courses under the API Training Certification (American Petroleum Institute). API certified programmes have undergone strict audit against predetermined standards set by API. These courses represent standards for best practices and is industry specific. Certificate No. TPCP-0140 Certificate No. TPCP-0136

GLOMACS is registered with the National Association of State Boards of Accountancy (NASBA) as a sponsor of continuing professional education on the National Registry of CPE Sponsors. State boards of accountancy have final authority on the acceptance of individual courses for CPE credit. Complaints regarding registered sponsors may be addressed to the National Registry of CPE Sponsors, 150 Fourth Avenue North, Suite 700, Nashville, TN, 37219-2417. Web site: www.nasba.org