Multistage Pump Systems for Operators and Maintenance Personnel

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Duration

3 days

Aimed at

Technicians, Foremen, Maintenance Artisans and Senior Operators;

Overview

Multistage pumps, by their very nature, are complex and costly pieces of equipment that have an important role to play in plant processes. Optimising a pump set's Mean Time Between Failures (MTBF) requires careful planning and universally accepted operating procedures. This will include, good pump selection, correct installation and operation and the ability to observe changes in performance over time using condition monitoring. This course is structured around multistage pumps although some basic principles of pump operation are also covered.

The program content comprises 12 Units:

  • Unit 1: Which pump should I choose (briefly, is this the right pump for the job)?
  • Unit 2: Pump components and performance data (what is expected of each part and the pump as a whole)
  • Unit 3: What makes up a pump's duty point and how this affects system reliability (why tank full/empty, valve(s) open/closed etc is so important to MTBF)
  • Unit 4: Measuring pump performance (the meaning of gauge/meter readings)
  • Unit 5: Operating a pump correctly (there's more to it that pressing red & green buttons)
  • Unit 6: Bearing types and their operational requirements (How to drastically improve pump bearing life spans)
  • Unit 7: Pump shaft seals (the how's and why's of shaft seals and "O" rings)
  • Unit 8: Multistage hydraulic balancing devices (balance pistons & discs and impeller arrangements)
  • Unit 9: Stripping and assessment (a "crime scene approach")
  • Unit 10: Re-assembly of multistage pumps 
  • Unit 11: Installation and commissioning procedures (confirmation of work well done)
  • Unit 12: System trouble shooting and remedial procedures (ensuring it's unlikely to happen again)

ultimate Course objective:

Building a maintenance and operating team to maximise reliability and optimise Life cycle Costs (LCC) associated with the owning and operating of multistage pumps.

 

Pumping Systems: Design Installation & Operation

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Duration

4 days

Aimed at

Engineers, Technicians and Senior Foremen.

Overview

The course is structured around input from the course leader and case studies drawn from field experiences.  Feedback for all the assessments is provided during the course so as to maximise the learning experience.

Post course skills application

JTA offers delegates the opportunity to receive a CERTIFICATE OF MERIT should they complete a post course assignment comprising a structured survey of a working pump installation. At the end of the course, each delegate will be supplied with a password which will allow him/her access to the necessary documentation. If the information included in the completed forms meet with set standards, a CERTIFICATE OF MERIT will be issued.

Course objectives

  • Define pump types and how they function.
  • Describe the various sealing arrangements currently available in the market.
  • Give a description of the features and benefits of various bearing types.
  • Describe the effect that a given system has on the operation of a pump.
  • Calculating Total Dynamic Head (TDH).
  • Describe how cavitation occurs and its effect on a pumping system.
  • Determination of flow rates.
  • Detail requirements of an acceptable suction system.
  • Define how to handle liquids other than water.
  • Calculate energy requirements and define energy management systems.
  • Explain the data contained in pump published performance data.
  • Do cost effective pump selection.
  • Offer cost-effective solutions to varying pump performance.
  • Describe the effects of operating pumps in series and parallel.
  • Offer suggestions for the installation of appropriate hydraulic and electrical controls.
  • Trouble shoot pumping systems and carry out root cause analysis.
  • Detail what is Life Cycle Costing (LCC) and calculate the LCC of a given pumping system.

Pump Maintenance & Operation

Duration

3 days

Overview

We have been approached on a number of occasions by clients who require a programme which will cover the requirements of Workshop Supervisors, Artisans and Pump Operators. The course content is structured around the course leader's experience in the power station and general plant maintenance, mercantile marine and pump marketing and design disciplines. In addition, experience gained in a number of forensic investigations into pump repair services and numerous trouble shooting site visits is also added.

This programme is an ideal candidate for in-house presentation as the workshop facilities of the client can be combined with the classroom content to ensure a sound balance between appropriate theory and hands-on practical activities.

Course Objectives

At the end of this course, delegates will be able to:

  • Explain how single and multistage centrifugal pumps work.
  • Describe the importance of pump efficiency and its effect on energy costs.
  • Name the individual components of all types of centrifugal pumps and the respective roles they play.
  • Define what makes up the Total Dynamic Head "seen" by the pump and how these affect pump performance and reliability.
  • Explain what is a pump's "sweet" spot.
  • Detail the steps necessary to determine on what point of the performance curve an operating pump is working using pressure gauges, flow meters and electrical meters.
  • List the steps necessary to start and stop a pump.
  • Strip a pump and offer suggestions with respect to the possible root causes of failure.
  • Explain how to check that a minimum flow by-pass or a balance line is functioning to specification.
  • Detail the procedure for fitting and maintaining rolling and plain bearings.
  • Describe the procedure for fitting packed gland and mechanical shaft seals.
  • Reassemble a pump giving all the procedures necessary to check and correct shaft run out and rotating element balancing.
  • Explain the process of commissioning a pump set after repair and what to do about variations to expected performance.
  • Do basic trouble shooting on an operating pump set.

Electricity for Mechanicals

Duration

2 days

Aimed at

Practitioners in the fluid movement industry

Overview

Where possible, delegates will be given access to appropriate product literature such as performance data, cable selection charts and any other pertinent data. Delegates are also encouraged to bring to the course, any specific problems encountered in the field. Time will be allocated for the review and solution of these problems.

Course Objectives

  • Describe the electromagnetism phenomenon and it’s practical application in the products and services offered by the company.
  • Detail how single and three phase electricity is generated.
  • Give a basic overview of the common voltages used in the distribution and application of electrical energy in South Africa.
  • Explain the operating principle of an induction electric motor, both single and three phase.
  • Detail the construction of an induction electric motor.
  • Give a description of the relationship between amps, volts, ohms and kilowatts.
  • Describe the operating principle of a single phase control panel.
  • Give a description of how a basic three phase panel functions.
  • Give details of the purpose and operating principles of 5 commonly used protection and control relays.
  • Select cable from a selection chart, given the current absorbed by the motor and the length of cabling required.
  • Measure the amps and volts in an operational pumping system.
  • Measure the winding and insulation resistance in a electric motor.
  • Explain how input power is measured in an induction motor.
  • Convert motor input power into driven machine input power.
  • Do fault diagnosis and offer suggestions with regard to corrective actions.

Piping Systems: Design and Installation

Duration

4 days

Aimed at

Engineers, Technicians and Senior Foremen

Overview

The course is structured around input from the course leader, assessment exercises and case studies drawn from field experiences. Delegates will be expected to bring calculators (preferably scientific), a ruler and a flexible curve to draw system head curves. Feedback for all the assessments is provided during the course so as to maximise the learning experience.

Course Objectives

  • Select the most appropriate pipe specification and material for moderate duties.
  • Match the selected pipe with the most appropriate fittings.
  • Create a design which represents a cost effective solution to single pipeline systems for moderate duties.
  • Design the most cost effective pipe work system for the conveyance of any type of fluid.
  • Design pipe work systems which have more than one outlet.
  • Define the causes of water hammer, calculate its transient values and offer appropriate actions which will reduce or eliminate its occurrence.
  • Define the procedures necessary to install, test and commission a piping system.
  • Suggest appropriate protective coatings for pipe work systems.
  • Calculate the life cycle cost for a pipe system.

Valve Types: Selection, Installation and Operation

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Duration

4 days

Aimed at

Engineers, Technicians and Senior Foremen

Overview

This program is structured at a basic to intermediate level and is suitable for new entrants into the industry and those who have a limited amount of exposure to valves.

The course is structured around input from the course leader, assessment exercises and case studies drawn from field experiences. Delegates will be expected to bring calculators (preferably scientific). Feedback for all the assessments is provided during the course so as to maximise the learning experience.

Course Objectives

  • Explain system hydraulics with reference to valves
  • Detail the accepted methodology of classifying valves
  • Give a detailed explanation of valve components and their materials of construction
  • Give a detailed description of valves used in isolating applications
  • Explain the principle of operation of various regulating (control) valve patterns
  • Do valve basic isolating and control valve selection and sizing:
  • Give an overview of the principle of operation of valve actuators
  • List the more common standards applicable to valves currently available in South Africa

There are 9 units in the course:

  • Unit 1: System hydraulics including Cv and Kv values, losses in valves and cavitation, flashing and choked flow
  • Unit 2: Classification of valves by size, type and pressure/temperature rating. Commonly used specifications such as ANSI 16.34 and API 600 are covered
  • Unit 3: Valve components and materials of construction
  • Unit 4: Valve types: Isolating and Control
  • Unit 5: Valve Selection and sizing
  • Unit 6: Pressure relief devices
  • Unit7: Valve actuator types: Features and benefits
  • Unit 8: Overview of positioners
  • Unit 9: An overview of noise prediction and attenuation strategies

Contemporary Industrial Sales

Duration

2 days

Aimed at

Industrial sales staff (both internal and external)

Overview

While all the classic (basic) sales techniques are covered the content of each presentation is structured around the products and services offered by the client company. For this reason, this program is only offered on an in-house basis. This approach offers the very beneficial implementation of pre and post course activities aimed at maximising the internalisation of the knowledge and skills covered.

Course Objectives

  • At the end of this program, delegates will be able to:
  • Define the challenges currently being faced in the market
  • Write a commonly accepted version of the company’s current market offering
  • Construct a table showing the features and benefits of at least three products and/or services offered by the company
  • Detailing how they will apply the collaborative approach to selling
  • Actively seek out sales opportunities
  • Prepare for a sales call
  • Make a sales call that is flexible enough to meet the changing circumstances of the call
  • Establish credibility with the client
  • Identify real customer needs through questioning techniques and calling on all members of the Decision Making Unit (DMU)
  • Overcome objections in a manner which is constructive and beneficial to both parties
  • Close the sale and commit to service delivery in both the short and long-term
  • Gain support from other departments in ensuring that all customer relationships are long-term ones