Pump Short Courses

A Short Course is a full-day training session presented concurrently with other sessions on the first day of the symposium.

Short Course P1/T1: Vibration Problems and Solutions in Pumps & Turbomachinery

Monday, September 24, 2012 8:30 – 5:00 Level Three, Room 351D

Instructors:
William D. Marscher , Paul A. Boyadjis, Maki M. Onari (Mechanical Solutions, Inc.,Whippany, NJ)

Description:
Vibration evaluation of rotating machinery will be covered on a practical basis, with focus on centrifugal pumps, axial and centrifugal compressors, and steam and gas turbines. Analysis concepts, test procedures, diagnostic methods, and troubleshooting approaches will be presented, all in the context of machinery internal construction and physical functioning of the machine. Representative Case Histories will be provided for a variety of equipment and problems.

Ten Rules in Turbomachinery Operation for “Good Vibrations”:

  1. Match Design Point to System Head & Flow Requirements
  2. For Pumps, Require NPSHA Above NPSHR, with Margin
  3. Use a Long Straight Piping Run to the Inlet
  4. Careful When & How You Throttle
  5. Avoid H-Q Slopes Being Similar, Machine vs. System
  6. Minimize Nozzle Loads & Use Exp Joint Tie Rods
  7. Avoid Structural Natural Frequencies & Rotor Criticals
  8. Minimize Load Cycling, if Practical
  9. Select Materials Based on Corrosion, Galling, Fatigue & Erosion Resistance
  10. You Get What You Spec & Pay For
Conclusions:
  • There’s More to Turbomachinery Vibrations than Expected
  • Keys to Success: Knowledge, Experience, the Right Tools
  • Good Rules-of-Thumb Exist for Troubleshooting and Diagnosis
  • Good Vibration Methods & Instrumentation Are Getting Better

 

Short Course P2/T2: The Utilization of Computational Fluid Dynamics in Turbomachinery Design and Analysis

Monday, September 24, 2012 8:30 – 5:00 Level Three, Room 360C

Instructors:
Dr. Edward M. Bennett and Travis A Jonas (Mechanical Solutions Incorporated); Vishwas Iyengar (Prospect Flow Solutions, Houston, TX); Grant O. Musgrove and Andrew H. Lerche (Southwest Research Institute, San Antonio, TX); James Hardin (Elliot Company, Jeanette, PA)

Description:
Computational Fluid Dynamics (CFD) has emerged as a leading tool for the design and analysis of incompressible and compressible turbomachinery. CFD is now routinely applied to solve problems of performance, forced response, cavitation and multiphase flows, heat transfer and rotordynamics. As with all computational tools, CFD must be used with care to ensure accurate and reliable results.

This course will serve as an introduction to the use of CFD using as examples a variety of problems in incompressible and compressible turbomachinery. It will cover the basics of CFD, and then proceed directly to a number of case studies where CFD has been applied to resolve challenging fluid dynamic, thermodynamic, and forced response issues that routinely arise in turbomachinery, for selected situations involving pumps, compressors, and turbines of various designs and services. The course will demonstrate the effectiveness of this tool to resolve complex phenomena when used with caution as well as a full understanding of its capabilities and limitations.

The course will cover several key parts:
AM Session – Incompressible Turbomachinery Flow:

  1. Fundamental Concepts
  2. Pump Case Study One: Cavitating Pump
  3. Pump Case Study Two: Axial Pump Stage
  4. Hydraulic Turbine Case Study Three: Francis Turbine Stage
PM Session – Compressible Turbomachinery Flow:
  1. Pitfalls of CFD
  2. Performance Predictions
  3. Role of CFD in RCFA
  4. Fluid Structure Interaction (FSI)
  5. Rotordynamics
  6. Conjugate Heat Transfer

 

Short Course P3: Pumps 101

Monday, September 24, 2012 8:30 – 5:00 Level Three, Room 370D

Instructors:
John P. Joseph II (Rotating Equipment System Technical Association, Friendswood, TX) and Daniel Wood (DuPont, Wilmington, DE)

Description:
This course is aimed at engineers and technical professionals who need a broad-based introduction to basic pump selection, application and operation. This course starts with the basics and builds to provide a full understanding of centrifugal, rotary and reciprocating pumps. The course will include the following topics: centrifugal, rotary and reciprocating pump similarities/differences; centrifugal, rotary and reciprocating pump configurations; nine fundamental principles for reliable pump operation; developing pump specifications; understanding pump curves; developing system curves; choosing a type of pump for a specific application. The course will answer the question “What are the things I need to worry about when selecting, specifying and operating pumps?” At the completion of the course, the attendees will hold a strong understanding of basic concepts. This knowledge will act as a springboard to further growth understanding of more complex pump concepts. An emphasis is placed on providing practical information with minimal theory and thus, comprehension of the information presented requires little to no mathematical skills in hydraulic or mechanical design. This is NOT a pump design and/or maintenance class.

Topics Covered:

  • Pump Types and Construction
    • Classification and Nomenclature
      • Centrifugal Pump Types
      • Special Designs
      • Special Effect
      • Positive Displacement Pump Types
    • Basic Pump Design
      • Centrifugal Pumps, Rotary Pos Displacement Pumps, Recip Positive Displacement Pumps
  • Comparison of Centrifugal, Rotary and Reciprocating Pumps
  • Materials of Construction
  • Centrifugal Pump Performance
    • Performance Curves
    • Specific Speed (NS)
    • Suction Specific Speed (NSS)
    • Family of Curves
    • Suction Conditions and Limitations on Suction Performance
    • System Curves - Affinity Laws
    • Parallel and Series Operation
  • System Design - The Nine Principles You Must Follow for a Reliable Pump Installation
  • Services and Selection of Pumps
    • System Analysis
    • Selecting the Right Type of Pump for the Application
    • Selecting the Right Pump Features for the Application
    • Procuring the Pump
  • Installation, Operation and Maintenance

 

Short Course P4: Fundamentals of Centrifugal Pump and System Interaction

Monday, September 24, 2012 8:30 – 5:00 Level Three, Room 370F

Instructor:
Michael Volk (Volk & Associates, Inc., Oakland, CA)

Description:
This short course is offered for engineers and technicians who are responsible for system design, pump selection, operation, maintenance, or repair. The primary objective is to examine the relationship between centrifugal pumps and the systems in which they operate. The course shows how the system affects pump operation, energy consumption, and the relative amount of pump maintenance problems. This course follows up on many of the topics introduced in a formerly offered short course, “Basic Pump Hydraulics with a Minimum of Mathematics,” though that course is not a prerequisite.

Outline:

  • Pump performance curves
  • Head-capacity, horsepower, and NPSHR curves
  • Effects of operation at other than BEP
  • System head curves
  • All-static system
  • Dynamic system
  • Changes in system head curve
  • Branch-line pumping systems
  • Viscous liquids
  • Effects on pump performance curves
  • Effects on system head curve
  • Multiple pump operation
  • Parallel operation
  • Series operation
  • Oversizing pumps
  • Variable speed pumping – how it works, benefits
  • Software solutions - benefits of software for system analysis, case studies using software, summary of available software

 

Short Course P5: Pump Cavitation Physics, Prediction, Control, and Troubleshooting

Monday, September 24, 2012 8:30 – 5:00 Level Three, Room 371A

Instructors:
Bruno Schiavello (Flowserve Pump Division, Phillipsburg, NJ) and Frank C. Visser (Flowserve Pump Division, Etten-Leur, Netherlands)

Description:

  • Session 1: Cavitation Physics
  • Session 2: Cavitation Prediction
    Emphasis will be on the most influencing parameters rather than on actual mathematical formulas, which can help both the Engineer and the User to assess the relative importance of the key aspects for: a) correct pump selection and specification and b) successful field troubleshooting failure analysis. Moreover, the value and potential use of CFFD will be highlighted.
  • Session 3: Cavitation Control *NPSHR3%, NPSHA, Life Expectancy
    • Pump designer role
    • Highlights on critical evaluation of design target, basic design criteria, and system designer role
    • Highlights on acceptable critical marginal pump operations and pump abuse
    • Pump selection and specification
  • Session 4: Cavitation Failure Analysis (Methodology)
    • Cavitation modes recognition
    • Diagnostic approach
    • Solution strategy

 

Short Course P6: Ever-Tightening Environmental Regulations – Meet Them or Shut Down

Monday, September 24, 2012 8:30 – 5:00 Level Three, Room 371C

Instructors:
Henri Azibert (A.W. Chesterton, Groveland, MA), Ron Carlson (Flint Hills Resources, Corpus Christi, TX), Rich Davis & Brian Hasha (Flexitallic LP, Deer Park, TX), Peter Koegl (Hermetic Pumps, Houston, TX)

Outline:

  1. Introduction
    1. Gasket Systems – Rich Davis with training device
    2. Brief coverage of EP A regulations and end user experience – Ron Carlson
    3. Sealless Pump Technology – Peter Koegl
    4. Mechanical Seals – Henri Azibert
  2. Gasket Systems
    1. Gaskets Function and Design
    2. Gasket Types
    3. Installation and Assembly
  3. Miscellaneous Information From an End User
    1. First attempt cleaning
    2. Honing gasket surfaces
    3. Coating or spraying shafts
  4. Some coverage of EPA regulations
    1. Leak Detection And Repair (LDAR)
    2. HON and VOC
    3. Links to EPA web site for additional information
  5. Mechanical Seals
    1. Elements of mechanical seals
    2. Liquid Lubricated
      1. Leak rates
      2. Forces
      3. Power consumption
      4. Limitations
    3. Non Contacting Seals
      1. Definition
      2. Face technology
      3. How to meet emission regulations
      4. Seal operating environment
      5. Double seals
    4. Conclusion
  6. Sealless pumps
    1. Types of Sealless Pumps
      1. Magnetic Drive Pumps
      2. Canned Motor Pumps
    2. Comparison of the features and capabilities
    3. Examples of installations

 

Short Course P7: Mechanical Seals 101

Monday, September 24, 2012 8:30 – 5:00 Level Three, Room 372A

Instructors:
Michael Huebner (Flowserve Corporation, Deer Park, TX), Henri Azibert (A.W. Chesterton, Groveland, MA), Eric Boyce (John Crane, Webster, TX), Eric Vanhie (EagleBurgmann, Houston, TX)

Description:
Mechanical seals are a critical component in the reliability of any centrifugal pump and pumping system. Understanding the fundamentals of these components is critical to ensuring their proper maintenance and operation. This short course will examine the basics of mechanical seals and their interaction with pumps and support systems, Students will learn about the function and considerations for seal piping plans and support systems. The course will also cover installation procedures and failure analysis. Finally, the students will learn about tools which will allow them to evaluate the life cycle costs of sealing alternatives. The presenters will have examples of various seal models and failed components for examination and discussions.

Short Course P8: Rolling Element Bearings

Monday, September 24, 2012 8:30 – 5:00 Level Three, Room 372C

Instructors:
Brian Dahmer (SKF USA Inc., Lansdale, PA), Bob Eisenmann (BP), Terry Roehm (Marathon Oil), Morg Bruck (Hydraulic, Measurement, and Inspection Consulting, LLC, Dayton, OH)

Description:
Bearings are a critical component in a pump or turbo machine. The machine cannot perform well unless the bearings are accomplishing their tasks of supporting and positioning the shaft, allowing shaft and housing to rotate relative to each other with minimal friction while transferring loads from the shaft to the housing. Bearings are complex items themselves. Internal components in bearings are subjected to very high pressures while separating rolling components on a lubricant film that is thinner than one ten thousandth of an inch. In addition to the mechanical complexity inherent in today's rolling element bearings, there are many different types and features that must be understood to maximize performance of a bearing system.

The purpose of this course is to provide an overview of the purpose of rolling element bearings, the different types of bearings, bearing components and their function, standardized dimensions plans and bearing materials. Typical arrangements, loading conditions and selection of bearing size are also covered. Design of adjoining components (shafts and housings) will be discussed. Lubrication methods and lubricant selection are included as are friction and heat generation. Handling, storage and installation are included as well. Lastly, common failure modes and their causes will be covered.

Completion of this short course should provide an overall understanding of the complexity of rolling element bearings and the elements of the bearing system. Bearings themselves are dependent on adjoining components, seals and lubrication in order to function well so understanding the interdependence and interaction is very important. Understanding bearing selection, even for those individuals that are not designing bearings systems, is important since an understanding of the different bearing types and life calculations allow the individual to predict the effects of changing loading, speed, bearing type of lubricant on the bearing.

This short course is intended for anyone working with bearings. This would include machinery designers, field service personnel, assembly supervisors, consultants, reliability engineers, troubleshooters and anyone else with a need to understand bearings more completely.

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