• Fundamentals of Electricity

• Electromagnetism

• Electricity Generation & Distribution Fundamentals

• Understanding Electrical Symbols and Single Line Diagram

• Hand Tools

• Cables and Wiring

• Electrical Measuring Devices and Testing

• Electrical Distribution

• L. V. Switchgear

• Working with Electrical panels

• Motors

• Transformer

• Electrical Safety

• Workshop for the trade

• Motor control using DRIVE (VFD)

Pumps

• Defining pumping systems

• Most important characteristics of a pumping system

• Types of pumps

• Positive Displacement family tree

• Basic difference between Centrifugal and PD pumps

• Rotary pumps

• Market applications and Selection of Pumps

 → Applications of PD pumps

 → General guidelines for pump selection

 → Pump characteristics v/s market applications

 → Application – High Viscosity, Low and variable viscosity

 → Application – Low shear pumping, Solids handling capability

 → Application – Multi-phase flow

 → Process Condition – High pressure

 → Process Condition – Low flow, Efficiency

 → Process Condition- Combination of high pressure / low flow and efficiency

 → Process Condition – Flow control

 → Environmental system requirements

• Centrifugal Pump

 → Basics

 → Types (Construction based)

 → Construction of an impeller

 → Types of impellers

 → Seal chamber and stuffing box

 → Defining Suction Head

 → Capacity, Input horsepower, output horsepower, Efficiency

• Pump Fundamentals

 → Pressure

 → Head v/s Pressure

 → Effect of specific gravity on Head

 → Kinetic energy

 → Design of volutes and flow patterns

 → Specific gravity and pump performance

 → Effect of fluid velocity

 → Gauge height correction

 → What is TDH and TH

• Pump Performance parameters

 → Head-Flow characteristics

 → Power-Flow characteristics

 → Pump Efficiency

 → Efficiency v/s Flow

 → Net Positive Suction Head (NPSH) and its Characteristics

• NPSH and Cavitation

 → Cavitation process

 → Cavitation damage

• Preferred operating range of a centrifugal pump

 → Allowable operating range

• Pump characteristic curves

→ Effect of RPM

→ System curves

→ System Head

→ Energy requirements to lift the fluid

→ Power required to lift the fluid

→ Static Head

→ Dynamic Head

→ Sources of Friction

→ Parameters influencing frictional losses

→ Standard Pipe Head Loss Tables

→ Calculating frictional losses

→ Frictional loss coefficients

→ Pipe lengths and associated Heads

→ Types of System Curves

→ System Curve – No control valve

→ System Curve – With control valve

• Parallel pumps

→ Parallel pumping system

→ Parallel pumping system – Low friction

→ Parallel pumping – Mismatched pumps

• Series pumping

• Pump vibration

• New generation pump example

• How pumps get damaged – 10 Ways

• Monitoring and Predicting Centrifugal Pump performance

→ If the pump does not deliver enough water

→ If the pump does not deliver enough pressure

→ If the pump does not prime properly

→ If the pump is drawing too much amperage

→ Monitoring Wet end of the pump

→ Monitoring Stuffing box and Seal area

→ Monitoring Bearing case

• Predicting pump performance

• Preventive maintenance

→ Preventing bearing and seal failures

→ Good maintenance practices for seals and bearings

→ Recommended daily preventive maintenance checks for centrifugal pumps and drives

→ Recommended monthly and 6 monthly preventive maintenance checks for centrifugal pumps and drives

→ Recommended yearly preventive maintenance checks for centrifugal pumps and drives

• Trouble shooting of centrifugal pumps

→ The pump is hooked up to the piping and it is running

→ The pump is still hooked up to the piping, but it is not running

→ The pump has been taken into the workshop, but has not yet been disassembled and you will be present at the disassembly

→ The pump has been disassembled. You were not present, but the parts are available for your inspection

→ Troubleshooting four possibilities of rub or wear marks

→ Centrifugal pumps – Troubleshooting guide

• Trouble shooting of Reciprocating Pumps

→ Pump storage tips

• Alignments Techniques

→ What is coupling alignment?

→ Types of coupling

→ Co-linearity

→ Types of Misalignment

→ Offset, or Parallel

→ Angular

→ Measurement Conventions

→ Pre-alignment Steps

→ Alignment Tolerances

→ Thermal Growth Targets

→ Not correcting for soft foot

→ Not roughing in

→ Usage of shims

→ Not controlling backlash or unwanted movement

→ Incorrect sequence of moves

→ 4 steps of alignment

→ Angular misalignment in the Vertical Plane

→ Parallel Offset in the Vertical Plane

→ Angular misalignment in the Horizontal Plane

→ Parallel Offset in the Horizontal Plane

→ Things to watch if alignment still does not happen

→ A few helpful tips

• Pump mounting

→ Foundations

→ Housekeeping pads

→ Inertia bases

→ Base plate selection

→ Foundation preparation

→ Base plate installation

→ Grouting

→ Pump and Motor Installation

→ Pipe Installation

→ Pipe strain

How to start a pump

→ Pump rotation

→ Motor Solo

→ Couplings

→ Other Startup Considerations

→ Pump Start up

→ Final Vibration Acceptance

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

• Leaks

→ 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