Predictive Maintenance and Troubleshooting of Pumps & Compressors

Reg Number TPCP-0088

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INTRODUCTION

Pumps and compressors are generally critical machines in any production process, and hence it is vital that maintenance is most effective for these units. This programme aims to provide delegates with a comprehensive understanding of how to use a combined predictive and preventive maintenance approach to achieve maximum reliability and greatest understanding of any deterioration that may occur.

WHO SHOULD ATTEND?

• Engineers, supervisory and technical staff involved in the monitoring, predictive maintenance and diagnostics of pumps and compressors

PROGRAMME OBJECTIVES

The programme assumes familiarity with the design and construction of pumps and compressors. From this starting point it adopts an analytical approach to understanding the failure of all types of pumps and compressors.

From a component-by-component perspective, the programme investigates the root causes of failure, and relates these to operating conditions and process parameters. Design, installation, lubrication and wear related failure mechanisms are identified and a detailed understanding of the troubleshooting and diagnostic methods needed to detect and identify these is developed.

The programme provides participants with the knowledge needed to be effective in the inspection, monitoring and diagnostics of pumps and compressors, with emphasis placed upon the importance of a combined condition monitoring and strip-down inspection approach to maintenance.

TRAINING METHODOLOGY

The programme is delivered in a combination of lecture style and computer-based training. In addition, a significant amount of time is set aside for small working group activity when addressing case study problems. Extensive use is made of case study material to underline the key aspects of the course and to give the delegates exposure to current best practice.

PROGRAMME OUTLINE

DAY 1

• Friction, lubrication and wear mechanisms
• Adhesive wear, abrasive wear, fatigue and fretting
• Machinery life cycles
• Mechanical issues, balancing and alignment
• Statistical reliability analysis

• Reliability models
• Root cause of, symptoms and detection mechanisms for imbalance
• Root cause of, symptoms and detection mechanisms for looseness
• Root cause of, symptoms and detection mechanisms for misalignment
• Root cause of, symptoms and detection mechanisms for gear problems
• Root cause of, symptoms and detection mechanisms for bearing problems
• Cavitation, causes and prevention

• Anti-friction bearings: types, lifetime, mounting, applications, related problems
• Plain and pad bearings, thrust bearings: operation, maintenance, incidents
• Mechanical seals, types, operation, related problems
• Other seals for positive displacement pumps and reciprocating compressors
• Performing a balance

• Vibration monitoring
• Overall and spectral measurements
• Vibration limits
• Introduction to spectrum analysis
• Lubricant monitoring
• Shape, size, amount, chemical composition of debris
• Analytical techniques

• The role of condition monitoring in pump and compressor maintenance Diagnostic methods
• Capabilities and limitations of condition monitoring, and the need for a combined approach
• The importance of plant inspection
• Measurement devices, and what to monitor and where

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