PUMPS SERIES

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Mastering Centrifugal Pumps

Centrifugal Pumps: Design, Selection, Applications and Performance Analysis
24 - 25 Feb 2014 The Royale Chulan Kuala Lumpur, Malaysia

Centrifugal Pumps: Operations, Maintenance & Troubleshooting

26 - 27 Feb 2014 The Royale Chulan Kuala Lumpur, Malaysia

Your Expert Trainer

EATS! LIMITED S Discount if

15 Jan 2014

ird 10% Early B nd pay before a k o you bo

HIMADRI SEN

Founder and CEO Pumpsense Fluid Engineering

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. 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 re ghting 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 protability 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 ttings, elbows, lter, strainer, meter, etc will be provided in the exercise
Some of the Companies that have attended our Courses:

OLYGEN SDN BHD | www.olygen.com | rhey.waban@sg.olygen.com | | Tel: +603 2201 2354 | Fax: +603 2178 4789 |

Mastering Centrifugal Pumps

24 - 25 Feb 2014 26 - 27 Feb 2014 Key Takeaways The Royale Chulan Kuala Lumpur, Malaysia The Royale Chulan Kuala Lumpur, Malaysia

Centrifugal Pumps: Design, Selection, Applications and Performance Analysis Centrifugal Pumps: Operations, Maintenance and Troubleshooting

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 eld experience. Identify opportunities for energy optimization in your existing pumping systems. Use most energy-efcient way of controlling ow through your existing pumps and decide when to use a variable-speed driver Decide whether to replace an inefcient pump or retrot 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-benet analysis of any energy optimization project involving pumping systems. Compute life cycle cost of your pumping system. Decide on specic energy efcient and environment friendly construction features for your application. Understand and quantify environmental impact of your pump specication.

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 benet 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 elds will allow you to derive full benet from these programs. In particular, the following groups may nd the programs of direct benet: 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. Timetable 0830 0900 0900 1030 1030 1045 1045 1230 1230 1330 1330 1500 1500 1515 1515 1700 Registration First Morning Half Morning Break Second Morning Half Lunch First Afternoon Half Afternoon Break Second Afternoon Half

Customisation:
The programme will be further customised to t your priorities through the pre-course questionnaire (PCQ).

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

OLYGEN SDN BHD | www.olygen.com | rhey.waban@sg.olygen.com | | Tel: +603 2201 2354 | Fax: +603 2178 4789 |

Mastering Centrifugal Pumps

24 - 25 Feb 2014 26 - 27 Feb 2014 The Royale Chulan Kuala Lumpur, Malaysia The Royale Chulan Kuala Lumpur, Malaysia

Centrifugal Pumps: Design, Selection, Applications and Performance Analysis Centrifugal Pumps: Operations, Maintenance and Troubleshooting

DAY 01
1. Introduction to Program - Structure and Schedule 2. Centrifugal Pumps - Types, Construction, Specications & Applicable Standards Types & selection criteria for centrifugal pumps Product variants Major components Functions of components Classication of impellers & collectors Design criteria for pump shafts Stufng 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 ow Bernoullis equation and Eulers equation Hydraulic power and pump efciency NPSHA & NPSHr Afnity laws & their applications Dimensional analysis & factoring laws Specic speed, suction specic speed & suction energy Efciency & specic speed 4. Workshop 1: Pumps - Types, Construction, Specications & Standards 5. Centrifugal Pumps - Hydraulic & Mechanical Performance (Part 1) Losses & their classications Partow and over-capacity operation Axial thrust & Radial thrust Flow separation & recirculation Minimum ow - 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 Principles & Performance Characteristics 8. Worked Examples in Centrifugal Pump Selection and Application

DAY 02
9. Pumping Systems Pumping systems Various system curves Proper selection of pumps-optimisation of pump-system 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 Pumps in Various Industries Renery & Petrochemical Mining Marine & Off-shore Airconditioning Fire protection Municipal services 13. Workshop 3: Pumps - Hydraulic & Mechanical Performance 14. Bid Evaluation. Tender Optimization. Pump Specications & Data Sheets Pump specication & selection Steps in selecting & purchasing pumps Pump datasheets /specications Bid evaluation Bid evaluation - point rating system 15. Workshop 4: Pumping systems, Testing & Pump Selection 16. Case Studies 17. Worked Examples in Centrifugal Pump Selection and Application 18. Conclusion and Feedback

OLYGEN SDN BHD | www.olygen.com | rhey.waban@sg.olygen.com | | Tel: +603 2201 2354 | Fax: +603 2178 4789 |

Mastering Centrifugal Pumps

24 - 25 Feb 2014 26 - 27 Feb 2014 The Royale Chulan Kuala Lumpur, Malaysia The Royale Chulan Kuala Lumpur, Malaysia

Centrifugal Pumps: Design, Selection, Applications and Performance Analysis Centrifugal Pumps: Operations, Maintenance and Troubleshooting

DAY 03
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 Specic speed & range of operation Mechanical considerations - Forces in centrifugal pumps Vibration & Noise 4. Energy Optimization in Pumping Systems, LCC Analysis & Retrot Opportunities Energy efciency in pumping systems-an overview Proper selection of pumps-optimisation of pump-system interaction Pump efciency norms-a survey of guidelines Control methods for varying pump output-energy implications LCC analysis & energy optimisation in pumping systems Pump retrot 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 04
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, modications 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 tted pumps. Installation and dismantling of both balanced and unbalanced seals are also shown. 15. Film World of Pumps The lm 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

Testimonials
The presenter is well skilled and he claried all the questions - EIT Chem (Pongola Mill), TSB Sugar RSA The presenter is a pump man - Project Superintendent, Anglo Gold Ashanti Ltd Very knowledgeable Senior Process Engineer, Sasol Synfuels Very knowledgeable and experienced. Shares unlimited knowledge with others and provide guidance. Good clarify in presentations - Process Safety Engineer, Petronas Chemicals MTBE Sdn. Bhd.

OLYGEN SDN BHD | www.olygen.com | rhey.waban@sg.olygen.com | | Tel: +603 2201 2354 | Fax: +603 2178 4789 |

Centrifugal Pumps: Design, Selection, Mastering Centrifugal Pumps Applications and Performance Analysis
24 Case - 25 Feb 2014 Studies The Royale Chulan Kuala Lumpur, Malaysia

Centrifugal Pumps: Design, Selection, Applications and Performance Analysis Centrifugal Pumps: Operations, Maintenance and Troubleshooting
26Case - 27No. Feb 2014 The Royale Chulan Kuala Lumpur, Malaysia Case Topic Industry Segment Workshop Segment
CS1 Municipal Services - Water Supply Scheme Pumping system/materials of construction/retrot for energy optimization Mechanical & hydraulic performance of pumps/pumping systems Calcutta water supply scheme. retrot & upgrade of a raw water pumps installed in 1920s

CS2

Process Industry Petrochemical plant

Consequence of part ow 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

CS3

Metallurgical Industry - Iron & Steel Plant

Pumping systems

CS4

Process Industry - Renery

Hydraulic principles - losses in centrifugal pumps

Trimming impeller with or without shrouds - API 610 end suction pump in SE Asia

Centrifugal Pumps: Operations, Maintenance & Troubleshooting

Case Studies
Case No. Industry Segment
Process Industry - Petroleum Renery

Workshop Segment
Pump diagnostics & troubleshooting

Case Topic
Frequent shaft failure of circulating water pumps in an oil renery due to aprt ow operation & radial loading

CS1

CS2

Marine & Offshore

Pump diagnostics & troubleshooting

Selecting appropriate materials of construction for a sea water pumping application in Australia

CS3

Metallurgical Industry - Iron & Steel Plant

Conditioning monitoring

1. Bearing failure in split case pump 2. High vibration in split case cooling water pumps

CS4

Metallurgical Industry - Iron & Steel Plant

Conditioning monitoring

High vibration & cavitation noise in cooling water pumps 1. Stable head capacity characteristics for high drainage pump in a cooper mine. 2. High corrosion/erosion of pump casing & internals due to acidic mine water

CS5

Mining Industry

Pump diagnostics & pumping systems Material of construction

CS6

Mining Industry

REGISTRATION
OLYGEN SDN. BHD. | TEL: +603 2201 2354
MASTERING CENTRIFUGAL PUMPS The Royale Chulan Kuala Lumpur, Malaysia

Contact: Rhey Waban FAX: +603 2178 4789

EARLY BIRD RATE (Book and pay before 15 Jan 2014)

REGULAR RATE USD 2,795/pax USD 2,795/pax USD 4,295/pax

Centrifugal Pumps : Design, Selection, Applications and Performance Analysis | 24 - 25 Feb 2014 (IN1401MY) Centrifugal Pumps : Operations, Maintenance and Troubleshooting | 26 - 27 Feb 2014 (IN1402MY) Attend both programmes at more than 20% discounts!

USD 2,495/pax USD 2,495/pax USD 3,795/pax

*Fees include course documentation, luncheon and refreshments. Delegates are responsible for their own accommodation.

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TERMS & CONDITIONS

Payment Terms: Payment is required within 7 days of invoice date. Olygen reserves the right to refuse admission IF payment is not received before the event date. Transfer: Transfer is allowed upon written notication. 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 Olygen 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: Olygen 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 Malaysia, 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 clients country of origin, if any. Marketing: Olygen 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 Malaysia and the parties submit to the exclusive jurisdiction of the Malaysian Courts in Malaysia. Indemnity: Should for any reason outside the control of Olygen, the event be cancelled due to an act of terrorism, extreme weather conditions or industrial action, Olygen shall endeavour to reschedule but the client hereby indemnies and holds Olygen harmless from and against any and all costs, damages and expenses, including attorneys fees, which are incurred by the client.