Defining pumping systems

• Characteristics
• Positive Displacement family, Centrifugal pumps, Rotary pumps
• Pump Fundamentals, Pump Performance parameters and curves
• Parallel pumps
• Series pumping
• Pump vibration
• How pumps get damaged – 10 Ways
• Monitoring and Predicting Centrifugal Pump performance
• Predicting pump performance
• Preventive maintenance
→ Preventing bearing and seal failures
• Trouble shooting of centrifugal pumps
→ Centrifugal pumps – Troubleshooting guide
• Trouble shooting of Reciprocating Pumps
• Alignments Techniques
→ Types of Misalignment
→ Measurement Conventions
→ Pre-alignment Steps
→ 4 steps of alignment
→ Things to watch if alignment still does not happen
→ A few helpful tips
• Pump mounting
• How to start a pump
• Checklist

• 3 golden rules of Compressed Air usage
• Compressed air system – Supply side and Demand side
• Compressed air – One of the most expensive utilities on the shop floor
• Inappropriate use of compressed air
→ Open blowing
→ Sparging, Aspirating, Atomizing
→ Padding
→ Vacuum generation
→ Hand blowing
→ Unregulated End use
→ Abandoned equipment
• Potential for energy saving
• Overview of sub-systems and sub-components of a compressor system
→ Intake Air Filters
→ Compressed Air Filters
→ Why compressor cooling is required
→ Inter stage coolers
→ After coolers
→ Separators
→ Why air drying is essential
→ Air Dryers
→ Deliquescent air dryers
→ Refrigerated Air Dryers
→ Moisture drain traps
→ Air receiver
→ Lubrication
→ Heat recovery
→ Air distribution system
• Types of compressors
• Choice of compressors
• Reciprocating compressor
→ Single acting air cooled
→ Double acting water cooled
• Rotary compressor
→ Single stage
→ 2 stage
→ Screw Compressors
→ Lubricant injected
→ Oil free
• Centrifugal air compressors
• Compressor Prime Movers
• Comparison of compressors
• Capacity of a compressor
• Calculating compressor efficiency
→ Isothermal efficiency
→ Volumetric efficiency
• vLeaks
→ Defining and Quantifying leakage
→ how to calculate leakage
→ Cost of leakage
→ Leak detection
→ Ultrasonic leak detection
→ How to stop leaks
• Compressed air system performance opportunity roadmap
• Air quality
• Air quantity
• Load profile
• System pressure
→ Pressure drop and controlling system pressure
→ What causes pressure drop?
→ Minimizing pressure drop
→ Measurements necessary for pressure profiling a compressed air system
→ Stabilizing system pressure
→ Importance of Primary and Secondary Storage
→ Dedicated compressors
• Control strategy
→ Matching Demand and Supply
→ System controls
→ Multiple compressor controls
→ Pressure/Flow controllers
→ Variable loads
• Ensuring efficiency of compressed air end-use applications
• Heat recovery and compressed air systems
→ Air cooled, rotary screw compressors
→ Water cooled compressors
• Calculating cost of compressed power
• The 7 step action plan to analyse and improve compressed air system
• Tools needed for monitoring and base-lining compressed air system
• Using Power, Pressure, and Flow to base-line System Performance and Energy Consumption
• Maintaining air compressors
→ Lubrication
→ Cleaning
→ Belts
→ Air treatment equipment
→ Automatic traps
→ Point-of-use filters, regulators, lubricators
→ Shutting down for maintenance
→ Routine maintenance practices for various periodic frequency
• Energy saving ideas for compressor air system
→ Energy saving concept – Usage of VFD
Reading nomenclature of compressors

• Types of valves
→ Plate type
→ Finger type
• Loading and Unloading characteristics of compressors
• Types of unloading devices
• Types of Drainage systems
• Mounting
→ Horizontal
→ Vertical
• Type of lubrication
→ Soft
→ Outside
• Non lubricated compressor
• Foundation
• Condition monitoring
→ Temp analysis
→ Vibration analysis
→ Alignment analysis – axial and radial (laser based)
• Preventive / Predictive maintenance
• Breakdown maintenance
• Trouble shooting
• Checklist

• Type of gear box
• Selection of gear boxes
• Comparison of gears and their applications
• Installation gear box system
• Alignment
• Back lash (use of filler gaugaes)
• Starting of gear box system
• Analysing gear box failure
• Lubrication with various oils
• Maintenance schedules of gear boxes
• Condition monitoring
→ Bearing temp
→ Vibration
→ Back lash checking
→ Amps current to check load on the motor
→ Thermography

• Types of industrial fans and blowers
• Comparison and their applications
• Selection criteria
• Fan system characteristics
• Fan performance evaluation
• Air flow measurement and calculation
• Methods to reduce air flow
• Predictive and preventive maintenance
• Condition monitoring techniques

• Types of bearings
• Selection of bearings
• Bearing nomenclature and terminology
• Types and techniques used for Mounting and dismounting of bearings
• Industrial practices for Bearing Care
• Safety during bearing mounting
• Do’s and Don’ts of bearing usage and handling
• Lubrication of bearings
• Bearing life cycle

• Why alignment
• What is shaft alignment
• Types of couplings
• Types of misalignment
• Signs of misalignment
• Measuring misalignment
• Pre-alignment steps
• Alignment targets
• Alignment tolerances
• Soft foot
• Usage of shims
• Alignment of shafts
• Alignment of belt driven system
• Rules of thumb and tips

• Introduction
• Why Diesel Generator is required
• Type of diesel generator
• Parts of diesel generators
• Starting procedure of a diesel generator
• Pre-starting checks
• How to start DG set
• After starting checks
• Running parameters Stopping
• Protection devices
• Stopping procedure for a DG set
• Trouble detection and trouble shooting
• Why maintenance routine is required.
• Maintenance routine of diesel generator set
• Ill effects of under load running of a Diesel generator
• Generator glossary
• Preventive maintenance, shut down maintenance of DG sets
• Condition monitoring of DG sets

• Fundamentals of hydraulics: Basics of water and oil hydraulics
• Hydraulic system accessories: Reservoirs, filters, coolers, Instrumentation and accumulators
• Principle construction and working of components
• Hydraulic pumps: Pump basics positive & non-positive displacement pumps
• Pressure control: relief, reducing, regulating valves
• Flow control: FCV, non-return valves
• Actuators: Linear actuators, hydraulic motors, Hydraulic drives.
• Direction control valves: Direct operated, pilot operated
• ISO symbol and hydraulic circuit reading
• Performance evaluation and testing of Hydraulic pumps, Relief & DC valves
• Principle of solenoid valves
• Working principles of proportional valves and servo valves
• Interpretation and discussions of electro-hydraulic circuits in plant machinery
• Material handling system
• Proportional variable pump control system
• General troubleshooting and maintenance

• Theories of compressed air
• Operation & function of Pneumatic system components
• Design & drawing of air symbols
• Simulation of movement phases & function phases
• Drawing air circuits according to standards
• Dryers, air receivers
• Compressors
• Pneumatic actuators
• Air distribution systems
• Directional valves
• Flow valves
• Fault-finding & trouble shooting of compressed air control circuits
• Guidelines for industrial safety

• Introduction to Industrial Automation
• Role of PLC in automation
• Various systems used in automation
• Comparison between various automation system
• Introduction to PLC hardware,
• Architectural Evolution of PLC,
• PLC Fundamentals – (Block diagram of PLC’s),
• Information about various PLC components
→ Power supply, CPU, I/O modules and
→ Communication bus
• Introduction to Allen Bradley PLC system
• Various ranges available in Allen Bradley PLC system
• Detailed information about the CPUs, I/O modules and communication techniques used in Allen Bradley
• Connection of field inputs to PLCs
• Source and Sink concepts in PLCs
• Introduction to RS Logix PLC Programming S/W
→ Addressing Concepts in AB PLC
→ Introduction to Bit Byte and Word Concept
→ Concept of flags
→ Scan cycle execution
→ Various commands used in PLC programming
• Programming instructions arithmetic and logical
→ Load / and / or /out / and Read / Write
→ Compare / Add / Sub /And / Or – Blocks
→ Leading edge / trailing edge instructions
→ MOVE block application
• Programming instructions arithmetic and logical
→ Timer Blocks programming
→ Counter Block programming
→ File handling
→ Comment functions
• Upload, download, Monitoring of programs
• Programming instructions arithmetic and logical
→ Advanced instructions
• Documenting the projects
• Forcing I/P & O/P
• Monitoring / Modifying data table values
• Troubleshooting and fault diagnostics of PLC
→ Hardware fault detection
→ Replacing the faulty modules
→ Fault detection using RS Logix

• What is SCADA / HMI?
• Applications of SCADA / HMI.
• Info about leading SCADA companies
• Types of SCADA packages
• Licensing pattern
• Creating a new SCADA application development
→ Creating Database of Tags
→ Creating Windows / Mimic pages
→ Creating and Editing graphic display
→ Animating the objects
• Creating Real-time and Historical Trends
• Creating Alarm and Events
• Writing scripts
• Securities
• Communication technique used with SCADA / HMI system
• Communication with hardware
• Working On Line / Off Line
• Troubleshooting the application

• General
→ Purpose of instrumentation
→ Basic measurement concepts
→ Measurement Practices
→ Sensors- Inductive / Capacitive, Proximity, Ultrasoni
→ Introduction to various sensors used in the industry
→ Introduction to Temperature, Pressure and Flow measurement
→ Selection, Installation and Commissioning guidelines
→ Troubleshooting and Maintenance Guidelines