Pumps and Pumping Systems Optimization

Pumps of various designs and applications are encountered nowadays throughout petrochemical and process industries as well as in power generation and environmental engineering. Pumping systems have to provide efficient transport of various liquids, sometimes complex and difficult two-phase fluids. Although there has been great progress in pump design in recent years, there are still many issues related to the mechanical and hydraulic problems to be considered that are associated with efficient operation of the whole pumping system. There is always need for optimization of the pumping system in operation with the goal of reducing the overall costs of production.

This intensive Pumps & Pumping Systems Optimization training course will provide an overview of important technical aspects of pumps and pumping systems as encountered in industrial applications. Of special interest will be centrifugal pumps as well as other types of positive displacement pumps. This course will also concentrate on the thorough understanding of technical principles of fluid flow in pumping systems as a prerequisite for successful pump operation. The focus will be on the elimination of potential problems as well as on pump inspection and condition monitoring. The training course will include several real-life case studies that will be solved in the form of workshops in order to illustrate the methods of efficient operation and maintenance of pumping systems.

Audience

This course is designed for:

Mechanical & Process engineers who are working in petrochemical and process industry
Technologists in Power Generation, Water Supply & Environmental Engineering
Technical personnel who deal with piping and flow control systems
Operators & Maintenance personnel
Technical personnel in charge of inspection of pumping system

Course objectives

The course objectives are:

Make the adequate selection of various types of pumps based on the application
Optimize the efficiency of operation of pumping systems
Analyze the problems in operation related to seals, bearings and flow control
Use the root cause analysis in detecting problems of pumping system & piping
Apply the best practices for maintenance, problem solving & troubleshooting

Course contents

Day-1

Pretest
Overview of Pumps and Pump Design Elements
Overview of Centrifugal Pumps Based on Design and Application
Reciprocating and rotary positive displacement pumps
Main elements of centrifugal pump construction
Critical Pump Elements: Seals & Bearings
Pumps for special applications
Workshop: Examples and Problem Solutions
Workshop: Examples and solutions

Day-2

Centrifugal Pump Q-H Characteristics
Pump Characteristic Curve (Q-H) and selection of BEP
Calculation of Net Positive Suction Head (NPSH)
Cavitation Prevention and Suction Piping Design
Parallel & Series of Pumps in Operation
Pump Capacity Control Methods: Throttling, Speed Variation, etc.
Workshop: Examples and Problem Solutions

Day-3

Pumping System Layout and Hydraulic Calculations
Principles of Piping Layout & Safety Requirements
Calculation of Friction Losses & Pressure Drop in piping systems
Pipe sizing based on Pumping Power requirements
Piping Load estimates: Stresses and Thermal movements
Pipe Vibrations and Support Systems Selection
Workshop: Examples and Problem Solutions

Day-4

Pumping System Optimization
Pumping System Efficiency Analysis
Reasons for Inefficiency of Pumping Systems
Steps in Successful Pumping System Optimization
Pump Inspection, Control & Performance Testing
Condition Monitoring and Vibration Analysis
Workshop: Examples and Problem Solutions

Day-5

Pump Installation, Maintenance & Troubleshooting
Installation, Commissioning and Start-Up of Pumping Systems
Importance of Proper Pump Alignment
Root Cause Analysis of Typical Pump Problems in Operation
Optimization of Maintenance Procedure of Pumping Systems
Troubleshooting of Problems in Operation
Summary & Conclusions
Posttest

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