Pumps Operation, Maintenance and Trouble Shooting

Pump Introduction

• Hydraulics – A Few Basics
• Vapor Pressure
• Pump Classification

Day Two

Basics of Centrifugal Pump

• Centrifugal Pump Basics
• Principle of Operation,
• Pump Classifications
• Mixed Flow Pumps
• Axial Flow Pumps
• Low-pressure & High-pressure pumps
• Single-suction & Double-suction pumps
• Single-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
• Pump Bearings
• Antifriction bearings
• Journal bearings
• Range of applications
• Lubrication of bearings

• 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

Day Four

Trouble Shooting & Maintenance of Pumps

Pump Troubleshooting

• Pump Installation, Startup and Operation Guidelines
• Pump Inspection and Performance Control
• Pump Maintenance Based on Daily Observations of Pump Operation,
• Diagnoses of Pump Troubles and Records of Inspections and Repairs
• Control of Lubrication System
• Mechanical Seals, Bearings and Couplings
• Vibration Control and Analysis
• Cavitation in pumps
• Net Positive Suction Head
  • Available against required NPSH
  • Symptoms of cavitation
  • Effects of Cavitations
  • Avoidance of cavitation
• Water Hammer Problems and Troubleshooting
• General Troubleshooting Checklist
• Shaft deflection
  • Critical speed and shaft deflection
  • Parameters affecting shaft deflection
  • Effects of shaft deflection on Mechanical seals and Bearings

Day Five

Failure or Deviation Symptoms

• Pump does not deliver
• Insufficient capacity delivered
• Insufficient discharge pressure developed
• Pump loses prime after starting
• Pump requires excessive power
• Stuffing box / mechanical seal leak excessively
• Packing / mechanical seal has short life
• Pump vibrates or noisy
• Bearing have short life
• Pump overheats and seizes