Pump and Valve Operation Techniques, Control, Maintenance and Troubleshooting

Pump and Valve Operation Techniques, Control, Maintenance and Troubleshooting

Date/Time: Date(s) - 20/12/2022 - 22/12/2022( 8:00 am - 5:00 pm )
Location: Malaysia, Kuala Lumpur


Overview

Pumps and valves are at the heart of most industrial processes, and the second most common machine in the world. Because they are so common, pumps and valves are often overlooked as a potential source of improved productivity, or a cause of excess costs if not operated properly. Plant managers, maintenance engineers and production supervisors should adhere to best practices and understand the operational do’s and don’ts for employing pumps and valves properly in manufacturing and industrial applications. This training provides an overview of how to operate pumps and valves properly and the performance parameters that need to be monitored in a preventive or predictive monitoring program. It also describes continuous monitoring systems, with several case studies on how they can be applied to improve system performance and reduce maintenance costs.

Objectives

  • Understanding of the different types of pumps and their associated terminology
  • Understanding of Centrifugal and positive displacement pumps, packing, mechanical seals and sealing systems, bearings and couplings
  • Understanding of different parameters affecting the operation of valves
  • Ability to select the right valve for the particular application and to perform the necessary calculation for valve sizing
  • Ability to perform troubleshooting of systems involving valves
  • Ability to decide on the right maintenance plan concerning different types of valves

Who Should Attend?

  • Facility / Utility Engineers
  • Operation Personnel
  • Maintenance and Troubleshooting Personnel
  • High Pressure Pumps Operators
  • Supervisors & Technicians
  • Team Leaders

Outlines

Pumping Systems

  • Introduction
    • Pump Types and Terminology
    • Pump Performance (Centrifugal and Positive Displacement)
  • Understanding Head
    • Types of Head: Friction, Pressure, Static & Velocity
    • Friction in Valves, Piping & Fittings
    • Calculating Actual Head in a System
  • Cavitation in Pumps and Valves
    • Net Positive Suction Head (NPSH)
    • Vapour and Gas Cavitation
    • Flashing vs. Cavitation

Pump Types

  • Positive Displacement Pumps
    • Reciprocating Pumps
    • Reciprocating Pump Valves
    • Rotary Pumps – scroll and gear types
    • Failure Mechanisms – identification and monitoring
  • Centrifugal Pumps
    • Centrifugal Pump Theory
    • Pump Components
    • Matching Pumps with Drivers
    • Performance Analysis
    • Failure Mechanisms – identification and monitoring

Achieving Pump Reliability

  • Sealing Systems
    • Conventional Packing Glands, Mechanical Seals & Flush Plans
    • Seal Failure Mechanisms
    • Maintenance and Repair of Mechanical Seals
  • Bearings – failure modes and how to extend life
    • Lubrication
    • Plain Bearings
    • Anti-Friction Bearings
  • Couplings & Alignment
    • Couplings
    • Alignment & Balancing
    • Foundations & Bedplates

Valves Technology

  • Types of Valves (globe, gate, ball, plug, check)
  • Flow Characteristics
    • Flow through Valves
    • Valve Flow Characteristics
    • Linear, Quick Opening & Equal %
  • Valve Sizing
    • Calculating the Correct Cv Value
    • Selecting Valve Size Using Valve Coefficient
    • Calculations for Correct Valve Selection
  • Sealing Performance
    • Leakage Classifications
    • Sealing Mechanisms
    • Valve Stem Seals

Control Valves

  • Functions of valves
  • Methods of regulation
  • Control Valve Types
  • Valve end connections
  • Valves seating
  • Valve Control

Relief and Safety Valves: Function and Operation

  • Relief Valves Types
  • Relief Valve Parts
  • Direct Acting and Pilot Control
  • Applications
  • Relief valves problems
  • Applications of Rupture Discs

Valves Troubleshooting & Maintenance

  • High Pressure Drop
    • Pressure Recovery Characteristics
    • Flow Choking
    • High Velocities
  • Water Hammer
    • What causes water hammer?
    • Solutions for Water Hammer
  • Troubleshooting the Control & Isolation Valves
    • Review of Common Faults
    • Developing a Preventive Maintenance Plan

Training Methodology

  • Case Studies.
  • Individual and group discussions and exercises.
  • Intensive training by using templates, diagrams, and charts.
  • Planning activities and presentations.
  • Self-assessments.
  • Action plan.

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