PUMPS SERIES

M ASTERING C ENTRIFUGAL P UMPS

C ENTRIFUGAL P UMPS : D ESIGN , S ELECTIO N ,
A PP LICATIO NS A ND P ERFORMANCE A NALYSIS
3–4 DEC 12 MALAYSIA (GRAND MILLENNIUM KUALA LUMPUR)
17-18 FEB 13 QATAR (DOHA)
13–14 MAY 13 SOUTH AFRICA (HOLIDAY INN JOHANNESBURG – ROSEBANK)

C ENTRIFUGAL P UMPS : O P ERATIO NS , M AINTENANCE

& T ROUBLESHOOTING
5–6 DEC 12 MALAYSIA (GRAND MILLENNIUM KUALA LUMPUR)
19-20 FEB 13 QATAR (DOHA)
15–16 MAY 13 SOUTH AFRICA (HOLIDAY INN JOHANNESBURG – ROSEBANK)

Himadri Sen is a veteran with more than 35 years experience in

YOUR EXPERT TRAINER centrifugal pump on both process and mechanical side. He started
his career in 1974 with Mather & Platt Limited, one of the pioneers

H IMADRI S EN 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
Founder and CEO
Pumpsense Fluid Engineering planning, and in his last position, served as Senior General Manager
in Pump Division.
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 | syafiq.mobin@olygen.com |
| Tel: +603 2282 0973 | Fax: +603 2178 4789 |

M A STERI NG C ENTRI FUG A L P UM PS

3 - 6 DEC 2012 MALAYSIA (GRAND MILLENNIUM KUALA LUMPUR)
17 – 20 FEB 2013 QATAR (DOHA)
13 – 16 MAY SOUTH AFRICA (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: Timetable for both days

Due to the interactive format of the programme, the class size will be kept small to ensure 0830 – 0900 Registration
facilitator’s attention and effective class discussion. 0900 – 1030 First Morning Half
1030 – 1045 Morning Break
1045 – 1230 Second Morning Half
Customisation: 1230 – 1330 Lunch
The programme will be further customised to fit your priorities through the pre-course 1330 – 1500 First Afternoon Half
questionnaire (PCQ). 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: alvin.yong@olygen.com
dvanced Cost Management Masterclass | 28-29 July
 INGENUS PTE LTD
| www.ingenustraining.com | syafiq.mobin@olygen.com |
| Tel: +603 2282 0973 | Fax: +603 2178 4789 |

CENTRIFUGAL PUMPS: DESIGN, SELECTION, APPLICATIONS

AND PERFORMANCE ANALYSIS

Day 1 Day 2
1. Introduction to Program - Structure and Schedule 9. Pumping Systems
• Pumping systems
2. Centrifugal Pumps - Types, Construction,
Specifications & Applicable Standards • Various system curves
• Types & selection criteria for centrifugal pumps • Proper selection of pumps-optimisation of pump-
system interaction
• Product variants
• Control methods for varying pump output & their
• Major components
energy implications
• Functions of components
• Sump design guidelines
• Classification of impellers & collectors
• Suction piping arrangements
• Design criteria for pump shafts
• Stuffing box sealing units - gland packings & 10. Materials of Construction
mechanical seals • Factors affecting material selection
• Anti-friction & sleeve bearings • Material properties
• Driver selection criteria • Corrosion, erosion & wear
• Pump standards • Common & special materials of construction
• Material selection guidelines - Hydraulic Institute &
3. Hydraulic Principles & Performance Characteristics
other sources
of Centrifugal Pumps
• Materials for major pump parts
• General liquid characteristics and properties
• Physical principles of centrifugal pumps 11. Quality Assurance & Testing of Centrifugal Pumps
• Concepts related to pressure, head and flow • Inspection & test standards
• Bernoulli's equation and Euler's equation • Material inspection
• Hydraulic power and pump efficiency • Destructive & non-destructive tests
• NPSHA & NPSHr • Pressure tests
• Affinity laws & their applications • Performance tests
• Dimensional analysis & factoring laws • NPSHr testing procedures
• Specific speed, suction specific speed & suction • Acceptance criteria
energy • Quality plans
• Efficiency & specific speed • Inspection agencies
4. Workshop 1: Pumps - Types, Construction, 12. Applications of Centrifugal Pumps in Various
Specifications & Standards Industries
5. Centrifugal Pumps - Hydraulic & Mechanical • Refinery & Petrochemical
Performance (Part 1) • Mining
• Losses & their classifications • Marine & Off-shore
• Partflow and over-capacity operation • Airconditioning
• Axial thrust & Radial thrust • Fire protection
• Flow separation & recirculation • Municipal services
• Minimum flow - Thermal & Stable 13. Workshop 3: Pumps - Hydraulic & Mechanical
Performance
6. Centrifugal Pumps - Hydraulic & Mechanical
Performance (Part 2) 14. Bid Evaluation. Tender Optimization. Pump
• Temperature Rise Specifications & Data Sheets
• Cavitation • Pump specification & selection
• Noise problem & its solution • Steps in selecting & purchasing pumps
• Vibration in pumps & remedial measures • Pump datasheets /specifications
• Pressure surge & pressure pulsation • Bid evaluation
7. Workshop 2: Pump - Hydraulic Principles & • Bid evaluation - point rating system
Performance Characteristics 15. Workshop 4: Pumping systems, Testing & Pump
Selection
8. Worked Examples in Centrifugal Pump Selection
and Application 16. Case Studies
17. Worked Examples in Centrifugal Pump Selection
and Application
18. Conclusion and Feedback

dvanced Cost Management Masterclass | 28-29 July


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 pump-
system 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
S TRE SS T ESTI N G
dvanced Cost Management Masterclass | 28-29 July
INGENUS PTE LTD
| www.ingenustraining.com | alvin.yong@olygen.com |
| Tel: +65 3152 0150 | Fax: +65 6725 0768 |
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
 INGENUS PTE LTD
| www.ingenustraining.com | syafiq.mobin@olygen.com |
| Tel: +603 2282 0973 | Fax: +603 2178 4789 |

CENTRIFUGAL PUMPS: DESIGN, SELECTION,

APPLICATIONS AND PERFORMANCE ANALYSIS
Case Studies

Case No. Industry Segment Workshop Segment Case Topic

Pumping system/materials Calcutta water supply scheme. Retrofit &

Municipal Services –
CS 1 of construction/retrofit for upgrade of a raw water pumps installed in
Water Supply Scheme
energy optimization 1920’s

Consequence of part flow operation.

Mechanical & hydraulic
Process Industry – Impeller damage due to increase in system
CS 2 performance of
Petrochemical plant loss - cooling water pumps in a
pumps/pumping systems
petrochemical plant
Low discharge from cooling water pumps
Metallurgical Industry
CS 3 Pumping systems due to high pressure drops across chillers –
– Iron & Steel Plant
pumps at a coke plant in a steel mill
Process Industry - Hydraulic principles – Trimming impeller with or without shrouds
CS 4
Refinery losses in centrifugal pumps – API 610 end suction pump in SE Asia

CENTRIFUGAL PUMPS: OPERATIONS, MAINTENANCE &

TROUBLESHOOTING
Case Studies

Case No. Industry Segment Workshop Segment Case Topic

Frequent shaft failure of circulating

Process Industry – Pump diagnostics &
CS 1 water pumps in an oil refinery due to part
Petroleum Refinery troubleshooting
flow operation & radial loading
Selecting appropriate materials of
Pump diagnostics &
CS 2 Marine & Offshore construction for a sea water pumping
troubleshooting
application in Australia
1.Bearing failure in split case pump
Metallurgical Industry
CS 3 Conditioning monitoring 2.High vibration in split case cooling
– Iron & Steel Plant
water pumps
Metallurgical Industry High vibration & cavitation noise in cooling
CS 4 Conditioning monitoring
– Iron & Steel Plant water pumps
1. Stable head capacity characteristics for
Pump diagnostics &
high head drainage pump in a copper
pumping systems
CS 5 Mining Industry mine.
2. High corrosion/erosion of pump casing
Material of construction
& internals due to acidic mine water

dvanced Cost Management Masterclass | 28-29 July

REGISTRATION
I
Contact: Syafiq Mobin
INGENUS
nteractive PTE LTDof|the
format TEL: +603 2282the
programme, 0973 F A X : attention
class size will be kept small to ensure facilitator’s + 0 3 2and
1 7effective
8 4 7 class
8 9:
M AS TE R I N G C E N TR I F UG AL P UM P S Kuala Lumpur Doha Johannesburg
Centrifugal Pumps: Design, Selection, □ 3-4 Dec 12 □ 17-18 Feb 13 □ 13-14 May 13 USD 2,795/pax
Applications and Performance Analysis (IN1202MY) (IN1301QA) (IN1303ZA)
Centrifugal Pumps: Operations, □ 5-6 Dec 12 □ 19-20 Feb 13 □ 15-16 May 13USD 2,795/pax
Maintenance and Troubleshooting (IN1203MY) (IN1302QA) (IN1304ZA)
Attend both programmes at more than □ 3-6 Dec 12 □ 17-20 Feb 13 □ 13-16 May 13USD 4,295/pax
20% discount!
Fees include course documentation, luncheon and refreshments. Delegates are responsible for their own accommodation.
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Ingenus Pte. Ltd.
Title
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Bank Address: 80 Raffles Place UOB Plaza Singapore 048624
Signature USD Account No: 422-901-401-8
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TERMS & CONDITIONS

Payment Terms: Payment is required within 7 days of invoice date. Ingenus reserves the right to refuse admission IF payment is not received
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