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Pumps - Theory, Practice and Maintenance

  M01 – Pumps - Theory, Practice and Maintenance Defining pumping systems
  • Most important characteristics of a pumping system
  • Types of pumps
  • Positive Displacement family tree
  • Basic difference between Centrifugal and PD pumps
  • Rotary pumps
  • Market applications and Selection of Pumps
    • Applications of PD pumps
    • General guidelines for pump selection
    • Pump characteristics v/s market applications
    • Application – High Viscosity, Low and variable viscosity
    • Application – Low shear pumping, Solids handling capability
    • Application – Multi-phase flow
    • Process Condition – High pressure
    • Process Condition – Low flow, Efficiency
    • Process Condition- Combination of high pressure / low flow and efficiency
    • Process Condition - Flow control
    • Environmental system requirements
  • Centrifugal Pump
    • Basics
    • Types (Construction based)
    • Construction of an impeller
    • Types of impellers
    • Seal chamber and stuffing box
    • Defining Suction Head
    • Capacity, Input horsepower, output horsepower, Efficiency
  • Pump Fundamentals
    • Pressure
    • Head v/s Pressure
    • Effect of specific gravity on Head
    • Kinetic energy
    • Design of volutes and flow patterns
    • Specific gravity and pump performance
    • Effect of fluid velocity
    • Gauge height correction
    • What is TDH and TH
  • Pump Performance parameters
    • Head-Flow characteristics
    • Power-Flow characteristics
    • Pump Efficiency
    • Efficiency v/s Flow
    • Net Positive Suction Head (NPSH) and its Characteristics
  • NPSH and Cavitation
    • Cavitation process
    • Cavitation damage
  • Preferred operating range of a centrifugal pump
    • Allowable operating range
  • Pump characteristic curves
    • Effect of RPM
    • System curves
      • System Head
      • Energy requirements to lift the fluid
      • Power required to lift the fluid
      • Static Head
      • Dynamic Head
      • Sources of Friction
      • Parameters influencing frictional losses
      • Standard Pipe Head Loss Tables
      • Calculating frictional losses
      • Frictional loss coefficients
      • Pipe lengths and associated Heads
      • Types of System Curves
        • System Curve – No control valve
        • System Curve – With control valve
  • Parallel pumps
    • Parallel pumping system
    • Parallel pumping system – Low friction
    • Parallel pumping – Mismatched pumps
  • Series pumping
  • Pump vibration
  • New generation pump example
  • How pumps get damaged – 10 Ways
  • Monitoring and Predicting Centrifugal Pump performance
    • If the pump does not deliver enough water
    • If the pump does not deliver enough pressure
    • If the pump does not prime properly
    • If the pump is drawing too much amperage
    • Monitoring Wet end of the pump
      • Monitoring Stuffing box and Seal area
      • Monitoring Bearing case
  • Predicting pump performance
  • Preventive maintenance
    • Preventing bearing and seal failures
    • Good maintenance practices for seals and bearings
    • Recommended daily preventive maintenance checks for centrifugal pumps and drives
    • Recommended monthly and 6 monthly preventive maintenance checks for centrifugal pumps and drives
    • Recommended yearly preventive maintenance checks for centrifugal pumps and drives
  • Trouble shooting of centrifugal pumps
    • The pump is hooked up to the piping and it is running
    • The pump is still hooked up to the piping, but it is not running
    • The pump has been taken into the workshop, but has not yet been disassembled and you will be present at the disassembly
    • The pump has been disassembled. You were not present, but the parts are available for your inspection
    • Troubleshooting four possibilities of rub or wear marks
    • Centrifugal pumps – Troubleshooting guide
  • Trouble shooting of Reciprocating Pumps
    • Pump storage tips
  • Alignments Techniques
    • What is coupling alignment?
    • Types of coupling
    • Co-linearity
    • Types of Misalignment
      • Offset, or Parallel
      • Angular
    • Measurement Conventions
    • Pre-alignment Steps
    • Alignment Tolerances
    • Thermal Growth Targets
    • Not correcting for soft foot
    • Not roughing in
    • Usage of shims
    • Not controlling backlash or unwanted movement
    • Incorrect sequence of moves
    • 4 steps of alignment
      • Angular misalignment in the Vertical Plane
      • Parallel Offset in the Vertical Plane
      • Angular misalignment in the Horizontal Plane
      • Parallel Offset in the Horizontal Plane
    • Things to watch if alignment still does not happen
    • A few helpful tips
  • Pump mounting
    • Foundations
      • Housekeeping pads
      • Inertia bases
    • Base plate selection
    • Foundation preparation
    • Base plate installation
    • Grouting
    • Pump and Motor Installation
    • Pipe Installation
    • Pipe strain
  • How to start a pump
    • Pump rotation
    • Motor Solo
    • Couplings
    • Other Startup Considerations
    • Pump Start up
    • Final Vibration Acceptance
  • Checklist


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