PUMPS SERIES

M ASTERING C ENTRIFUGAL P UMPS

C ENTRIFUGAL P UMPS : D ESIGN , S ELECTION , A PPLICATIONS A ND P ERFORMANCE A NALYSIS
13-14 MAY 2013 22-23 JULY 2013 MILLENNIUM HOTEL SIRIH JAKARTA HOLIDAY INN JOHANNESBURG - ROSEBANK

C ENTRIFUGAL P UMPS : O PERATIONS , M AINTENANCE & T ROUBLESHOOTING

15-16 MAY 2013 24-25 JULY 2013 MILLENNIUM HOTEL SIRIH JAKARTA HOLIDAY INN JOHANNESBURG - ROSEBANK
Himadri Sen is a veteran with more than 35 years experience in centrifugal pump on both process and mechanical side. He started his career in 1974 with Mather & Platt Limited, one of the pioneers and largest organization in the design & manufacture of centrifugal pumps and pumping systems. He handled diverse assignments in Mather & Platt, including sales, product development and strategic planning, and in his last position, served as Senior General Manager in Pump Division.

YOUR EXPERT TRAINER

H IMADRI S EN
Founder and CEO Pumpsense Fluid Engineering Ltd

In 1993, he joined Best & Crompton Limited as Vice President of Weir, Ochsner and Worthington product ranges. He founded Allied Centrifugal Pumps Private Limited (ACP) in 1995 to manufacture split case and large end suction pumps for building, industrial services and marine fire fighting applications. In 2005, ACP merged with WILO SE and Himadri took on the responsibility as Product Expert-High Flow Pumps for Wilo group. He also joined the board of Mather & Platt at this time. In 2009 Himadri left ACP to form Pumpsense Fluid Engineering Ltd to provide training and consulting services to the users and manufacturers of centrifugal pumps around the world.

OVERVIEW
As the process of industrialization and modernization gathers momentum in the environment of liberalization or globalization, the demand for pumps and its connecting parts is expected to be enhanced, hence extra care is to be taken at the selection of right type of pump for desired pumping service for obtaining reliability as well as profitability in the present competitive industrial market. There are three types of problems mostly encountered with centrifugal pumps: Design errors Poor operation Poor maintenance practices

FORMAT OF WORKSHOP:
40% Theory 60% Exercise and Case Study **P&ID with complete details of all types of fittings, elbows, filter, strainer, meter, etc will be provided in the exercise

dvanced Cost Management Masterclass | 28-29 July

INGENUS PTE LTD

| www.ingenustraining.com | jerry.cheng@za.olygen.com | | Tel: +603 2282 0369 | Fax: +603 2282 0379 |

13 16 MAY 2013 22 25 JULY 2013

M ASTERI NG C ENTRI FUG AL P UM PS

MILLENNIUM HOTEL SIRIH JAKARTA HOLIDAY INN JOHANNESBURG - ROSEBANK

KEY TAKEAWAYS
The course is designed to combine theoretical and global best practices. After attending the training program you should be able to: Decide how to operate the pump within the intended service condition envelop. Carry out mechanical, hydraulic and installation review of your existing pumping plants. Understand and evaluate hydraulic performance of your existing centrifugal pumps. Determine whether the pumps are performing optimally. Understand the failure modes - power, temperature, corrosion, leakage, pressure, vibration, etc. Decide on monitoring frequency and control limits. Familiarize yourselves with various means of monitoring pump performance and health parameters. Avoid common operator errors and improve MTBF. Estimate cost of spares and the best ways of procuring them. Change materials of construction of pump components based on field experience. Identify opportunities for energy optimization in your existing pumping systems. Use most energy-efficient way of controlling flow through your existing pumps and decide when to use a variable-speed driver Decide whether to replace an inefficient pump or retrofit the pump with a custom-designed impeller. Identify energy optimization projects with low risk but high energy saving potential. Understand critical pump parameters you need to review when evaluating the offers for pumps for new projects. Do cost-benefit analysis of any energy optimization project involving pumping systems. Compute life cycle cost of your pumping system. Decide on specific energy efficient and environment friendly construction features for your application. Understand and quantify environmental impact of your pump specification.

TARGET AUDIENCE
These programs have been prepared for people who have some exposure to centrifugal pumps and are seeking a greater understanding of the design variables, selection process, operation and maintenance of these machines so that they can apply the knowledge in their work environment. The programs will most benefit those who are involved in some aspect of pumping system design, pump application, or operation of centrifugal pumps. Engineering/Technical educational background coupled with some experience in pump related fields will allow you to derive full benefit from these programs. In particular, the following groups may find the programs of direct benefit: Operations and maintenance engineers in the mining, power, process and general industries Pump manufacturers and distributors of engineered centrifugal pumps. Rotating equipment engineer in the process industries. Engineers working for consultancies and involved in the selection of centrifugal pumps Engineers involved in urban water supply and sewage disposal schemes
HVAC & Fire System engineers in the building services industries Small Class-Size: Due to the interactive format of the programme, the class size will be kept small to ensure facilitators attention and effective class discussion. Customisation: The programme will be further customised to fit your priorities through the pre-course questionnaire (PCQ).

Timetable for both days 0830 0900 Registration 0900 1030 First Morning Half 1030 1045 Morning Break 1045 1230 Second Morning Half 1230 1330 Lunch 1330 1500 First Afternoon Half 1500 1515 Afternoon Break 1515 1700 Second Afternoon Half

Internal Training: This programme is available as an internal training. Email us to find out more at: inhouse@olygen.com

dvanced Cost Management Masterclass | 28-29 July

INGENUS PTE LTD

| www.ingenustraining.com | jerry.cheng@za.olygen.com | | Tel: +603 2282 0369 | Fax: +603 2282 0379 |

CENTRIFUGAL PUMPS: DESIGN, SELECTION, APPLICATIONS AND PERFORMANCE ANALYSIS

Day 1
1. Introduction to Program - Structure and Schedule 2. Centrifugal Pumps Types, Construction, Specifications & Applicable Standards Types & selection criteria for centrifugal pumps Product variants Major components Functions of components Classification of impellers & collectors Design criteria for pump shafts Stuffing box sealing units - gland packings & mechanical seals Anti-friction & sleeve bearings Driver selection criteria Pump standards 3. Hydraulic Principles & Performance Characteristics of Centrifugal Pumps General liquid characteristics and properties Physical principles of centrifugal pumps Concepts related to pressure, head and flow Bernoulli's equation and Euler's equation Hydraulic power and pump efficiency NPSHA & NPSHr Affinity laws & their applications Dimensional analysis & factoring laws Specific speed, suction specific speed & suction energy Efficiency & specific speed 4. Workshop 1: Pumps - Types, Specifications & Standards Construction, Mechanical

Day 2
9. Pumping Systems Pumping systems Various system curves Proper selection of pumps-optimisation of pumpsystem interaction Control methods for varying pump output & their energy implications Sump design guidelines Suction piping arrangements 10. Materials of Construction Factors affecting material selection Material properties Corrosion, erosion & wear Common & special materials of construction Material selection guidelines - Hydraulic Institute & other sources Materials for major pump parts 11. Quality Assurance & Testing of Centrifugal Pumps Inspection & test standards Material inspection Destructive & non-destructive tests Pressure tests Performance tests NPSHr testing procedures Acceptance criteria Quality plans Inspection agencies 12. Applications of Centrifugal Industries Refinery & Petrochemical Mining Marine & Off-shore Airconditioning Fire protection Municipal services Pumps in Various

5. Centrifugal Pumps - Hydraulic & Performance (Part 1) Losses & their classifications Partflow and over-capacity operation Axial thrust & Radial thrust Flow separation & recirculation Minimum flow - Thermal & Stable

6. Centrifugal Pumps - Hydraulic & Mechanical Performance (Part 2) Temperature Rise Cavitation Noise problem & its solution Vibration in pumps & remedial measures Pressure surge & pressure pulsation 7. Workshop 2: Pump - Hydraulic Performance Characteristics Principles &

13. Workshop 3: Pumps - Hydraulic & Mechanical Performance 14. Bid Evaluation. Tender Optimization. Specifications & Data Sheets Pump specification & selection Steps in selecting & purchasing pumps Pump datasheets /specifications Bid evaluation Bid evaluation - point rating system Pump

8. Worked Examples in Centrifugal Pump Selection and Application

15. Workshop 4: Pumping systems, Testing & Pump Selection 16. Case Studies 17. Worked Examples in Centrifugal Pump Selection and Application 18. Conclusion and Feedback

dvanced Cost Management Masterclass | 28-29 July

INGENUS PTE LTD

| www.ingenustraining.com | jerry.cheng@za.olygen.com | | Tel: +603 2282 0369 | Fax: +603 2282 0379 |

CENTRIFUGAL PUMPS: OPERATIONS, MAINTENANCE & TROUBLESHOOTING

Day 3
1. Introduction to Program - Structure and Schedule 2. Centrifugal Pumps - Introduction to Components and Their Functions Types & selection criteria for centrifugal pumps Product variants Major components Functions of components 3. Centrifugal Pumps - Review of Key Hydraulic & Mechanical Concepts Performance characteristics Suction Performance & NPSH Specific speed & range of operation Mechanical considerations - Forces in centrifugal pumps Vibration & Noise 4. Energy Optimization in Pumping Systems, LCC Analysis & Retrofit Opportunities Energy efficiency in pumping systems-an overview Proper selection of pumps-optimisation of pumpsystem interaction Pump efficiency norms-a survey of guidelines Control methods for varying pump output-energy implications LCC analysis & energy optimisation in pumping systems Pump retrofit and upgrades for energy optimisation 5. Workshop 1: Pumping Systems & LCC Analysis 6. Condition Monitoring in Centrifugal Pumps Purpose of condition monitoring Condition monitoring frequency Condition monitoring- various parameters Condition monitoring - control limits 7. Maintenance Diagnostics & Troubleshooting of Centrifugal Pumps Failure Analysis - causes of pump malfunction Pump Reliability Factors Rules for preventive maintenance of pumps Pump troubleshooting charts 8. Case Studies in Diagnostics & Troubleshooting

Day 4
9. Mechanical Seals for Centrifugal Pumps Mechanical Seal types & construction Design criteria of mechanical seals Materials of construction of mechanical seals Seal Standards and Flushing Plans Mechanical Seal failure analysis 10. Erection & Commissioning Issues in Pumping Installations Pre-installation instruction Site selection & site preparation Design & dimensions of the pump foundation Installation & commissioning Concrete & epoxy pour Base plate & sole plate preparation Grouting Alignment & pre-commissioning checks 11. Workshop 2: Mechanical Seals for Centrifugal Pumps 12. Frequently Asked Questions on Pump Operation, Maintenance and Troubleshooting This segment tries to answer frequently asked questions on pump performance, modifications at site, material alterations, spare parts, piping issues, diagnostics and resolving site problems 13. Workshop 3: Pump Operation & Maintenance 14. Assembly & Dismantling of Pumps This segment demonstrates, through a series of photographs, assembly and dismantling sequence of packed gland and mechanical seal fitted pumps. Installation and dismantling of both balanced and unbalanced seals are also shown. 15. Film World of Pumps The film takes the participants through all the major steps in the manufacture of industrial centrifugal pumps - design, pattern building, casting of components, machining, assembly and performance testing. 16. Conclusion and Feedback

S TRE SS T ESTI N G

dvanced Cost Management Masterclass | 28-29 July

INGENUS PTE LTD

| www.ingenustraining.com | jerry.cheng@za.olygen.com | | Tel: +603 2282 0369 | Fax: +603 2282 0379 |

CENTRIFUGAL PUMPS: DESIGN, SELECTION, APPLICATIONS AND PERFORMANCE ANALYSIS

Case Studies
Case No. Industry Segment Municipal Services Water Supply Scheme Workshop Segment Pumping system/materials of construction/retrofit for energy optimization Mechanical & hydraulic performance of pumps/pumping systems Case Topic Calcutta water supply scheme. Retrofit & upgrade of a raw water pumps installed in 1920s Consequence of part flow operation. Impeller damage due to increase in system loss - cooling water pumps in a petrochemical plant Low discharge from cooling water pumps due to high pressure drops across chillers pumps at a coke plant in a steel mill Trimming impeller with or without shrouds API 610 end suction pump in SE Asia

CS 1

CS 2

Process Industry Petrochemical plant

CS 3

Metallurgical Industry Iron & Steel Plant Process Industry Refinery

Pumping systems Hydraulic principles losses in centrifugal pumps

CS 4

CENTRIFUGAL PUMPS: OPERATIONS, MAINTENANCE & TROUBLESHOOTING

Case Studies
Case No. Industry Segment Process Industry Petroleum Refinery Marine & Offshore Metallurgical Industry Iron & Steel Plant Metallurgical Industry Iron & Steel Plant Workshop Segment Pump diagnostics & troubleshooting Pump diagnostics & troubleshooting Conditioning monitoring Case Topic
Frequent shaft failure of circulating water pumps in an oil refinery due to part flow operation & radial loading Selecting appropriate materials of construction for a sea water pumping application in Australia 1.Bearing failure in split case pump 2.High vibration in split case cooling water pumps

CS 1

CS 2

CS 3

CS 4

Conditioning monitoring Pump diagnostics & pumping systems

High vibration & cavitation noise in cooling water pumps

1. Stable head capacity characteristics for high head drainage pump in a copper mine.

CS 5

Mining Industry Material of construction

2. High corrosion/erosion of pump casing & internals due to acidic mine water

dvanced Cost Management Masterclass | 28-29 July

Contact: Jerry Cheng Ffacilitators AX: +6 0 3 2and 2 8effective 2 0 3class 7 9: INGENUS LTD TEL: +603 2282 0369 nteractive PTE format of|the programme, the class size will be kept small to ensure attention
I

REGISTRATION
M AS TE R I N G C E N TR I F UG AL P UM P S

Centrifugal Pumps: Design, Selection, Applications and Performance Analysis

USD 2,795 per delegate Centrifugal Pumps: Operations, Maintenance and Troubleshooting Attend both programmes at more than 20% USD 4,295 per delegate discount! Fees include course documentation, luncheon and refreshments. Delegates are responsible for their own accommodation.
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Jakarta Johannesburg 13-14 May 13 22-23 July 13 (IN1310ID) (IN1303ZA) 15-16 May 13 24-25 July 13 (IN1311ID) (IN1304ZA) 13-16 May 13 22-25 July 13

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Payment Terms: Payment is required within 7 days of invoice date. Ingenus reserves the right to refuse admission IF payment is not received before the event date. Transfer: Transfer is allowed upon written notification. Cancellation: Registration carries a 50% cancellation liability, notwithstanding, full fee is payable when cancellation is less than two (2) weeks before the event. Cancellation has to be done in writing. If Ingenus decides to cancel or postpone this event, it is not responsible for covering airfare, hotel, or other travel costs incurred by clients. The fee will not be refunded, but credited to a future event. No Show: No show does not constitute transfer or cancellation and the full fee is payable. Changes: Ingenus reserves the right to change event dates, venue, speakers, or omit event features, or merge the event with another event, as it deems necessary without penalty, refunds or alternative offers. Tax: Registration fees exclude tax. For clients outside Singapore, the sum payable is as the listed fees, exclusive of tax. To this sum shall be added any other local tax or withholding tax from client's country of origin, if any. Marketing: Ingenus may use your companys logo or business name or otherwise refer to your company in our website, any marketing, promotional or advertising material as a client of our services. Governing law: This Agreement shall be governed and construed in accordance with the law of Singapore and the parties submit to the exclusive jurisdiction of the Singaporean Courts in Singapore. Indemnity: Should for any reason outside the control of Ingenus, the event be cancelled due to an act of terrorism, extreme weather conditions or industrial action, Ingenus shall endeavour to reschedule but the client hereby indemnifies and holds Ingenus harmless from and against any and all costs, damages and expenses, including attorneys fees, which are incurred by the client.