Generic Failure Modes for Horizontal Pumps provides an in-depth
understanding of the factors that impact annual operating & maintenance
costs. This training enables personnel to better identify root causes, as well as
understand and apply cost-effective solutions to achieve best-in-class
performance and life for centrifugal pumps.
This training will positively affect the “bottom line” by providing information to
help eliminate pump-related forced outages, achieve best-in-class reliability
and life, and reduce annual pump-related operating & maintenance costs.

Learning Outcomes:

• Identify critical failure mechanisms for horizontal pumps
• Understand state-of-the-art upgrades to eliminate failure mechanisms
• Apply diagnostic methods based on pump design and observed condition
• Gauge risk of operation at different points on the performance curve
• Understand hydraulic rerates’ role in system and energy optimization
• Calculate annual energy savings from hydraulic modifications

Who Should Attend?

Engineers
Maintenance Professionals
Managers

Knowledge Level:

Intermediate

Completion Certificate:

12 PDH

Chapter Summaries:

CHAPTER 1 OPERATION AWAY FROM BEP - IMPELLER SUCTION RECIRCULATION
This Chapter examines the operation of pumps away from the Best Efficiency Point (BEP), defining and addressing the implications of such operation. It delves into the causes of suction recirculation, particularly the influence of large inlet areas and off-BEP operation, and explores its impact on pump performance and longevity. Methods for determining a pumps operational position relative to its BEP and identifying suction recirculation are detailed. The Chapter also presents strategies to optimize pump performance by operating closer to the BEP and preventing suction recirculation, thereby enhancing overall pump efficiency and reliability.

CHAPTER 2 IMPELLER DISCHARGE RECIRCULATION - HIGH IMPACT LOADING
This Chapter provides an in-depth analysis of impeller discharge recirculation, detailing the mechanisms and regions where it occurs and its impact on pump performance. It also addresses impact loading, detailing its causes and effects on pump integrity. The Chapter outlines methodologies for assessing the effects of discharge recirculation and identifying impact loading. Furthermore, it offers detailed strategies for mitigating discharge recirculation and preventing impact loading, ensuring enhanced pump efficiency, optimal operation, and prolonged longevity.

CHAPTER 3 PREMATURE CLEARANCE OPENING - POOR PUMP PERFORMANCE
This Chapter provides a comprehensive overview of acoustic resonance and premature clearance opening in pumps, detailing their causes and specific locations within the pump. It explains the impact of these issues on pump performance, integrity, and operating life. Methods for detecting acoustic resonance and premature clearance opening are outlined, along with practical solutions to correct and prevent these problems. By addressing these factors, the Chapter aims to enhance pump efficiency, reliability, and longevity.

CHAPTER 4 HIGH BEARING TEMP - PUMP SEIZURE
This Chapter examines several critical issues affecting pump performance and reliability: high motor amperage, hot bearings, excessive noise, and pump seizure. It explores the causes and effects of increased horsepower, bearing overheating, noise pollution, and mechanical seizure on pump systems. Diagnostic methods for identifying each problem are outlined, along with practical solutions to prevent and mitigate these issues. By addressing these factors, the Chapter aims to enhance pump efficiency and reliability.

CHAPTER 5 EXCESSIVE PACKING LEAKAGE - CASING LEAKAGE
This Chapter provides a comprehensive overview of critical issues affecting pump performance, including mechanical seal leakage, excessive packing leakage, black oil, and accelerated material erosion. It explains the occurrence and probable causes of each issue, detailing their impact on pump performance, integrity, and maintenance costs. The Chapter outlines diagnostic methods for identifying these problems and describes their noticeable characteristics. Additionally, it offers engineering solutions to prevent and mitigate these issues, ensuring optimal pump functionality, reliability, and longevity.

CHAPTER 6 CONFIGURATION DESIGN UPGRADES
This Chapter details the occurrence of casing leakage in pumps, focusing on the underlying causes such as thermal factors, improper gasket material selection, and erosion due to leaks. It provides a comprehensive analysis of how these factors contribute to casing leaks, impacting pump reliability’ and efficiency


This is an on-demand pay-per-view course (one-time access to each course segment for a period of 30 days from first login.)
Duration: 10-14 Hours
Instructor: Mike Mancini.