PE999.Compressors and Pumps: Selection, Applications, Operation, Troubleshooting, and Maintenance

Compressors and Pumps: Selection, Applications, Operation, Troubleshooting, and Maintenance

17 – 21 October 2016, Kuala Lumpur

Course Director: Ronald Frend

Ron is a registered engineer, and has over forty five years of engineering, consulting and management experience. He rose to a senior management position in Shell International (Middle East) before opening an engineering consultancy in England.

www.petroEDGEasia.net

Compressors and Pumps: Selection, Applications, Operation, Troubleshooting, and Maintenance 17 – 21 October 2016| Kuala Lumpur

Train Your Whole Team At A Convenient Time And Location Through In-House Training. Call us at +65 6741 9927 to enquire or email your query to [email protected]. Visit us at www.petroedgeasia.net for more information.


Introduction Maximum efficiency, reliability, and longevity of compressors, pumps, and bearings are of great concern to many industries. These objectives can only be achieved by understanding the characteristics, selection criteria, sizing calculations, sealing arrangements, common problems, repair techniques, as well as their preventive and predictive maintenance. This course is a MUST for those who use this equipment. It covers how compressors and pumps operate and provides the guidelines and rules that must be followed for their successful application. Their basic design, specification and selection criteria, sizing calculations as well as all maintenance issues including vibration analysis, and used oil analysis are discussed in detail. Objectives

To provide an understanding of the various types of compressors, pumps, and bearings so participants can operate, maintain and troubleshoot compressors and pumps for their applications.

To achieve reduced capital, operating and maintenance costs along with increase in efficiency. Upon participating in this course, delegates will be able to:

Carry out troubleshooting of critical components with the knowledge of common failure modes of compressors and pumps by applying advanced fault detection techniques.

Identify bearings and lubrication, pump and compressor sealing arrangements, meet commissioning requirements, conduct vibration measurement and used oil analysis.

Determine the maintenance required to minimize compressor and downtime, pump operating cost and maximize their efficiency, reliability, and useful life.

Gain an understanding of compressor surge and surge prevention systems.

Understand the causes of failures in compressors and pumps.

Determine all the features that improve the efficiency and reliability of compressors and pumps.

Identify different types of compressor and pumping systems.

Gain an understanding of the various types of sealing arrangements used in compressors and pumps. Who Should Attend? Process engineers, plant engineers, project managers, maintenance managers, water treatment plant managers, facility managers and technicians. The course will be of great interest to chemical process industries, oil and gas industries, manufacturing plants, power generation plants and others industries and organizations that must use compressors and pumps. Your Expert Course Director: Ronald Frend

Ron is a registered engineer, and has over forty five years of engineering, consulting and management experience. He

rose to a senior management position in Shell International (Middle East) before opening an engineering consultancy in

England. Ron was assigned to Petroleum Development (Oman) as a mechanical engineer in 1983. Ron’s first job was to

initiate a project to evaluate and replace as necessary the floors on all floating and fixed roof storage tanks in North

Oman. The project was then expanded to cover all stationary equipment inspections and repairs so that within two

years all statutory and maintenance inspections on tanks, pressure vessels, relief valves, pig traps and headers and

pipelines were scheduled for inspection and scheduled targets were being achieved. During this time Ron controlled

several contractors and was directly involved in financial and quality control. In 1986 Ron was moved within the section to be in control of

equipment monitoring and analysis support. Ron initiated the installation of computerised analysis systems for the optimal utilisation of

maintenance resources. In 1987 PDO initiated a “Zero Cost” approach to maintenance budgeting in which every aspect of maintenance and

engineering had to be justified instead of (as before) extrapolating previous years costs. The core component of this budgeting exercise was

the condition assessment expertise coupled with maintenance engineers’ direct knowledge of the equipment. This created a 17% reduction

in the overall maintenance budget while production increased by over 15%. In 1988 Ron was promoted to Head of Surface Support. His

responsibilities included the planning and direct control of all above ground maintenance support in the North Oman concession area

(24,000 square kilometers). Ron used his experience and expertise of maintenance, reliability and engineering to formulate a practical

methodology for effective control of maintenance activities.

Ron’s training approach is respected and appreciated throughout the petrochemical, manufacturing and services industries. Ron has

pioneered the use of Potential Failure Analysis (PFA) – a technique in which all possible modes of failure are examined before a failure

occurs. This allows the engineers to put in place monitoring mechanisms to give advance warning of impending failures. PFA is

complementary to FMEA & FMECA and ultimately RBI and RCM to enable the effective application of reliability and maintenance

engineering.

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5 Day Program Outline Day 1 Pumps

Pump types & categories: dynamic and displacement (reciprocating & rotary).

Centrifugal Pumps

Centrifugal pumps: basic theory of operation, casings and diffusers, radial thrust, hydrostatic pressure tests.

Impeller, axial thrust, axial thrust in multistage pumps, hydraulic balancing devices, balancing drums, balancing disks.

Mechanical seals, bearings, couplings, bedplates, minimum flow requirement.

Centrifugal pumps general performance characteristics, cavitation, net positive suction head.

Centrifugal Pump Mechanical Seals

Seal types and arrangements API 682

Basic components, temperature control, seal lubrication/leakage

API standard flush plans – selection & operation Positive Displacement Pumps

Reciprocating pumps, piston pumps, plunger pumps, rotary pumps, screw pumps, two-and three-lobe pumps.

Cam pumps, vane pumps, bellows-type metering pumps.

Applications & selection Troubleshooting of Pumps

Pump maintenance, daily observations of pump operation, diagnosis of pump troubles.

Troubleshooting of centrifugal pumps

Troubleshooting of rotary pumps

Troubleshooting of reciprocating pumps

Troubleshooting of steam pumps

Vibration diagnostics, analysis symptoms, impeller unbalance, hydraulic unbalance.

Water Hammer

Introduction, nomenclature, basic assumptions, effects of water hammer in high and low-head pumping systems.

Magnitude of the pulse, possible causes of water hammer

Mitigating measures to water hammer, applications of water hammer

Day 2 Pump Identification

Identification of system requirements, fluid type, piping, alternate modes of operation, margins, wear, future system changes.

Selection of pump and driver, pump characteristics, fluid characteristics, pump materials, driver type.

Troubleshooting Pumping Systems

Identify performance of pumps installed in series and in parallel, selection of pump driver speed, affinity laws for centrifugal pumps.

Explanation of pump specific speed and suction specific speed.

Determine total head, friction losses in the piping system, power requirement of the pump.

Pump selection procedure, select category and type of pump, evaluate the selected pump.

Day 3 Basics of Gas Laws and Compression Principles

Introduction, symbols, compressor operation, compressor thermodynamics.

Ideal or perfect gas laws

Enthalpy & Entropy

Compressor power requirement, compressibility correction, multiple staging.

Compressor volumetric flow rate, cylinder clearance and volumetric efficiency, cylinder clearance and compression efficiency

Compressor Types and Applications

Introduction, positive displacement compressors.

Rotary compressors, rotary lobe compressors, rotary vane compressors, rotary screw compressors, rotary liquid ring compressors.

Reciprocating compressors.

Dynamic compressors, centrifugal compressors, principle of operation of centrifugal compressors, centrifugal single-stage (low ratio) compressors, centrifugal single stage integral gear compressors, centrifugal multi-stage horizontally split compressors, centrifugal multi-stage with side loads compressors, centrifugal multi-stage (barrel) compressors, centrifugal multi-stage integral gear compressors.

Axial flow compressors, axial horizontally-split compressors. Compressors

Compressor types: positive displacement (reciprocating and rotary), and dynamic (centrifugal and rotary), compressor operation.

Compressor performance measurement, inlet conditions, compressor performance, energy available for recovery.

Positive displacement compressors, reciprocating compressors, diaphragm compressors, bellows compressors.

Rotary compressors, rotary screw compressor, lobe type air compressor, sliding vane compressors, liquid ring compressors.

Dynamic compressors, centrifugal compressors, axial compressors

Air receivers, compressor control, compressor unloading system.

Intercoolers and aftercoolers, filters and air intake screens

Preventive maintenance and housekeeping Performance of Positive Displacement Compressors

Compressor performance, positive displacement compressors.

Reciprocating compressor rating, reciprocating compressor sizing.

Capacity control, clearance pockets, compressor performance.

Reciprocating compressors, compressor valves.

Reciprocating compressor leakage, screw compressor leakage. Reciprocating Compressors

Introduction, crankshaft design, bearings and lubrication systems.

Connecting rods, crossheads, frames and cylinders, compressor cooling.

Pistons, piston and rider rings, valves, piston rods, packings.

Cylinder lubrication, distance pieces








Reciprocating Air Compressors Troubleshooting and Maintenance

Introduction, location, foundation, air filters and suction lines.

Air-receiver location and capacity, starting a new compressor.

Lubrication, non-lubricated cylinders, valves, piston rings.

Intercoolers and aftercoolers, cleaning, packing.

API 688 for dynamic pulsation damping using acoustic analysis Day 4 Rotary Screw Compressors and Filter Separators

Twin-screw machines, compressor operation, applications of rotary screw

compressors.

Dry and liquid injected compressors, operating principles.

Power calculation, temperature rise, capacity control, mechanical construction.

Industry experience, maintenance history, performance summary.

Oil-flooded single-screw compressors.

Selection of modern reverse-flow filter separators, conventional filter-separators and self cleaning coalescers, removal efficiencies, filter quality.

Selection of the most suitable gas filtration equipment, evaluation of the proposed filtration configuration, life-cycle-cost calculations, conclusions.

Coke fuel, Introduction, Properties and Usage, Other coking processes.

Liquid/Gas Separation Technology

Introduction

Removal mechanisms

Liquid/gas separation o Gravity separators o Centrifugal separators o Mist eliminators o Filter vane separators o Liquid/gas coalescers. o Selection of liquid/gas separation equipment

Formation of fine aerosols.

Troubleshoot liquid carryover into compressors Centrifugal Compressors – Components, Performance Characteristics, Balancing, Surge Prevention Systems and Testing

Introduction

Casing Configuration

Construction features o Diaphragms o Interstage seals o Balance piston seals o Impeller Thrust

Performance Characteristics o Slope of the centrifugal compressor head curve o Stonewall o Surge o Off-design Operation

Rotor Dynamics

Rotor Balancing

Surge Prevention Systems

Surge Identification

Liquid Entrainment

Instrumentation

Cleaning Centrifugal Compressors Day 5 Compressor Auxiliaries, Off-Design Performance, Stall, and Surge

Introduction

Compressor auxiliaries

Compressor off-design performance, low rotational speeds, high rotational speeds.

Performance degradation. Compressor Seal Systems

Introduction, the supply systems, the seal housing system, the atmospheric draining system, the seal leakage system, the drainer, the vent system, the degassing tank, the supply system, the seal housing system.

Gas seals, liquid seals, liquid bushing seals, contacts seals, restricted bushing seals, seal supply systems, flow through the gas side contact seal, flow through the atmospheric side bushing seal, flow through the seal chamber, seal liquid leakage system.

Dry Seals, Advanced Sealing Mechanisms and Magnetic Bearings

Introduction, background, dry seals, operating principles, operating experience, problems and solutions, upgrade developments of dry seals, prevention of dry gas seal failures by gas conditioning, need for training, minimizing the risk of sealing problems.

Magnetic bearings, operating principles, operating experience and benefits, problems and solutions, development efforts, thrust-reducing seals, integrated designs.

Develop maintenance plan for pumps & compressors

Identify maintenance tasks for pumps & compressors

Determine maintenance interval for pumps & compressors

Discuss a typical centrifugal compressor overhaul

Identify condition monitoring locations

Take vibration readings

Understand typical vibration symptoms.








EARLY BIRD NORMAL TEAM DISCOUNTS

Kuala Lumpur, Malaysia 17 – 21 October 2016

SGD 4,899 SGD 5,099

petroEDGE recognises the value of learning in teams. Group bookings at the same time from the same company receive the following: 3 or more at 5% off 5 or more at 7% off 8 of more at 10% All other promotions including early bird are exclusive of the group discount.

DELEGATE DETAILS Delegate 1

Please note - Indicate if you have already registered by Phone +Fax +Email +Web - If you have not received an acknowledgement before the training

course, please call us to confirm your booking. - Photocopy this form to register multiple delegates.

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Compressors and Pumps: Selection, Applications, Operation, Troubleshooting, & Maintenance

R E G I S T R A T I O N F O R M






Engineering

PE999.Compressors and Pumps: Selection, Applications, Operation, Troubleshooting, and Maintenance