This course is designed to enhance the technical expertise of mechanics, maintenance personnel, technicians, operators, and planners who are associated with equipment maintenance.
Our teaching methods include heavy class participation, visual aids, texts, and actual components. Our instructors have many years of experience and take a non-intimidating, no-nonsense approach in their presentation. Attendees should bring note taking material. This course is a 3-day course.
FOREWORD
Centrifugal pumps called Non Positive Displacement Pumps are the types of pumps used for pulp and paper processing.
Due to the fact that the operation cycle duty is very high it is important to establish a good maintenance schedule program to assure the minimum mill down time due to pump failure.
Also, a routine maintenance program can extend the life of your pumps. Well-maintained equipment will last longer and require fewer repairs.
A maintenance record must be kept; this helps to pinpoint potential causes of problems.
The main objective of this course is to reduce down time due to pump failures, increase production, reduce repair costs, and to transmit to all participants the proper technique for installation, inspection, adjustment, and repair of centrifugal pumps, and also to make a good preventative maintenance operation and trouble shooting program.
Section I
Safety, Pump Startup and Shutdown
Day 1
A. Pump as Pressure Vessels
· Pressurized Containing Device
· Cracks Explosion
· Rotating Parts Under Unbalanced Conditions
· Locking Procedure
· Operating Procedures
· Results of Damages or Destruction
B. Warning - Do Nots
· Use of Heat to Remove Impeller or Disassemble Other Parts
· Run Pump Without Coupling Guard
· Operating Pumps Beyond the Rated Conditions
· Run Pump Without Proper Priming (Casing)
· Running Pumps Below Recommended Minimum Flow or Dry
· Running Pumps Without Safety Devices
· Running Pumps With Discharge Valve Closed
· Running Pumps With Suction Valve Closed
· Change Condition of Service Without Consulting Manufacturer
· Repair Pumps Without Proper Safety Wears
C. Pumps Startup
· Priming
· Injector Priming Device
· Valves Positions
· Cooling Flow
· Pressure Delay Observation For All Pump Conditions
· Flow Pressure
· Temperature
· Inlet Pressure
· Freezing Condition
D. Shutdown
· Valves Conditions
· Flushing
· Draining
Section II
Pump Disassembly Procedure Inspection and Reassembly
Day 2
A. Preparation and Removal - Lockout, Flushing, Draining, Required Tools, Hoist, Etc.
· Line
· Guard
· Oil Sample
· Bearings
· Back Pullout
· Impeller
· Seal Chamber Cover
· Seals Packing Adapter
· Power End
· Bearing Housing
· Bearing Seals
· Bearing Frame
B. Parts Inspection
· Cleaning
· Inspection of Casing and Tolerances
· Impeller
· Frame Adapter
· Shaft
· Shaft Sleeve
· Bearing Frame
· Seal Repeller
· Stuffing Box and Cover
· Bearings
· Bearing Housing
C. Pump Assembly
· Rotating Element and Bearing Frame
· Outboard Bearing
· Bearing Seals
· Shaft Assembly Frame Foot
· Inboard Bearing
· Bearing House
· Check Shaft End Play
· Sleeve Runout
· Frame Face Runout
· Install Frame Adapter
· Labyrinth Oil Seal
· Installation of Mechanical Seal or Packing
· Installation of Back Pull-Out Assembly on Casing
Section III
Post Assembly Checks, Trouble Shooting, Lubrication,
Mill Tour, Preventative Maintenance
Day 3
A. Post Assembly and Trouble Shooting
· Shaft End Play
· Shaft Sleeve Runout
· Bearing Frame Flange Runout
· Frame Adapter Runout
· Seal Chamber and Stuffing Box Runout
· Impeller Tip Runout
B. Lubrication
· Lubrication Grease Conversion
· Conversion From Flood Oil to Oil Mist Installation
· Conversion From Flood Oil to Regreasable
C. Preventative Maintenance
· Recommended Lubricant as Per Application
· Bearing Lubrication and Schedule
· Bearing Free Play and Schedule
· Vibration Analysis and Schedule
· Discharge Pressure and Schedule
· Temperature Monitoring and Schedule
· Routine Inspection and Schedule
· Check for Unusual Noise Vibration and Bearing Temperature
· Inspection of Pump and Piping For Leaks
· Check Seal Chamber/Stuffing Box Leak Mechanical Seal For Leak
· Packing Leakage and Readjustments
D. Checks
· Oil Changes Schedule
· Oil Requirements
· Grease Relubrication Schedule
· Grease Compatibility
· Shaft Seal (Mechanical)
· Dynamic-Seal
· Impeller-Clearance-Setting With Dial Ind. Or Feeler Gauge Technique
· Packing Leakage and Readjustments
· Foundation and Hold Down Shaft Alignment
· Packings After Long Period of Time Idle Pump Capacity, Pressure, and Power
Section IV
Trouble Shooting
Day 3
Trouble Shooting
Problems - Causes - Remedies
Quiz - 40 Questions
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