PUMPS: MAINTENANCE, DESIGN

AND RELIABILITY CONFERENCE

BRISBANE
AUSTRALIA
13th & 14th May 2009
Royal on the Park
Brisbane, Australia

Featuring:
peakers
Keynote S
E R N A R D DA CRUZ
B IA
- AUSTolneRScAotLt Pty Ltd
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Director - Li

H A M J E F FERSON
GRA
- MALerA, SoYutSh IA
East Asia
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BENEFITS OF ATTENDING: Regional Man oldings Pty Ltd
- Compete H
• Increase your knowledge of the latest PUMPS technology
• Hear real world PUMPS case studies from your industry 12TH MAY 2009
• Unashamedly non-commercial presentations - No Sales Pitches PRE-CONFERENCE WORKSHOPS:
• Practical and state of the art advice to maximise the value of your PUMP systems 1. Modeling and Simulation for
• Excellent networking opportunities - learn from experts in the field Optimised Pump Performance
Presented by Graham Jefferson

2. Centrifugal Pumps: Optimising

WHO SHOULD ATTEND: Efficiency and Energy Consumption
• Chemical and Process Engineers • Engineering Managers Presented by Bernard Da Cruz
• Control and Instrumentation Engineers • Production Engineers
and Technicians
• Maintenance Managers
• Plant Engineers, Supervisors and
Managers
• Consulting Engineers REGISTER NOW
• Process Technicians
• Plant Operations and Maintenance www.idc-online.com
Personnel • Pump Sales Engineers
• Process Control Engineers and • Pump Service Contractors
Supervisors Presented by:
• Training Managers
• Mechanical Engineers
• Tradespersons working with Pumps
• Design Engineers

Proudly Sponsored by:

Technology Training that Works
AUSTRALIA • CANADA • INDIA • IRELAND • MALAYSIA
NEW ZEALAND • POLAND • SINGAPORE • SOUTH AFRICA
UNITED KINGDOM • UNITED STATES • VIETNAM
INTRODUCTION TO PUMPS: MAINTENANCE, DESIGN AND RELIABILITY
This conference is essential for anyone involved in pumps design, specification,
installation, commissioning and maintenance.
Pumps account for 20% of the world's electric energy demand, and studies have shown that
improved energy efficiencies and matching pumps to system curves can save up to 15% to
40%. The emphasis at the conference will be on practice and lessons learnt from current
installations and the future potential in applying new pump technologies.
Consideration will also be given to life-cycle costing of pumps (including maintenance,
energy and disposal costs) as opposed to the more traditional capital cost. Figures presented
in 1992 suggest that of the total pump cost, 5% accounts for capital cost, 10% to 15% for
maintenance and 85% for energy consumption.
The objective of the conference is to provide you with the latest know-how and practice in
pumps technology. You will have an opportunity to discuss pump construction, design
applications, operations, maintenance and management issues and be provided with the
most up-to-date information and best practice in dealing with the subject. This will offer
CONFERENCE DAY 1 - 13th May 2009
8.00am Registration
8.30am Opening Address
Graham Jefferson - Compete Holdings Pty Ltd
8.45am Pump Characteristic Curves: A Hands on Approach to
Efficient Design, Efficient Operation; Improved Reliability
& Maintenance, plus Reduced Carbon Emissions
Session Bernard Da Cruz
1 Director, Lincolne Scott Pty Ltd
KEY Every pump is a unique piece of equipment that is built to operate most efficiently for one
specific duty. However, most pumps operate outside the duty they were built to service most
NOTE efficiently. This paper presents the various scenarios where a pump/pumps can operate and
the implications of these operations using pump curves on: a) Pump heads and flows; b)
Pump operation and maintenance; and c) Pump efficiencies. The paper further evaluates
situations where currently installed systems and pumps are a cause for unpredictable
shortcomings. It also investigates opportunities available to overcome the problems in the
operating system, or to reduce the impact on the system performance, using pump curves
as a means to ascertain the cause of the problem.
9.45am Energy Saving & Efficiency Improvements
Session Phil Giles
2 Technical Director, Becker Pumps Australia
CASE This presentation will focus on the increasing awareness of effective energy saving and
STUDY efficiency improvements by using variable frequency drives. Vacuum pumps are commonly
seen as ineffective power users, caused by, but not limited to, the basic sizing of electric
motors, incorrect application and little consideration to the process cycle. We would like
to make the industry aware of correctly applying pumps to save energy and extend their
life cycle with an emphasis on vacuum pumps. Innovative use of variable frequency drives
help solve these problems by delivering only the vacuum required by the process, slowing
the pump during low demand times resulting in lower wear rates.
10.30am Morning Tea
11.00am New High Tech Communication & Remote Control
Systems for Pumping Systems
Session Richard Bird
3 Managing Director, Greenbird Technology
New digital control systems for pumps, combined with the introduction of electronic
engines, has made possible a revolution in the way that pumps can be controlled and
monitored. These systems incorporate control features that enable complex operating
procedures to better control pumping, increase efficiency and improve fuel consumption.
This paper will explain the features of the new control systems and how they can be
utilised, creating cost savings and improve efficiency. It will also examine new
opportunities for remote control and monitoring, available with these new systems.
Examples will be given and delegates will have the opportunity to discuss their
requirements and how they can be met.
11.45am Pump Safety in the Manufacturing and Process Sector
Session Alistair Keenan
4 QLD & NT State Sales Manager, Pilz Safe Automation
This presentation will demonstrate how safety can be applied to pumps in the
manufacturing and process sector. The discussion will be in the form of a case study,
illustrating the use of programmable safety PLCs to ensure the safety of personnel whilst
controlling safely the shut-down process of industrial pumping solutions. Methods such as
"selective shut-down" programming and Tank Farm control techniques, taken from the
process industries will be used to examine what can be achieved.
12.30pm Lunch
REGISTER Fax: Mail:
NOW: 1300 138 533 PO Box 1093, West Perth, WA 6872
participants the opportunity to discuss practical aspects of applications of pumps and
pumping systems. The focus throughout is on the practical experiences of users. The
conference will be attended by those who are interested in technical solutions to their
problems, industry trends and new techniques to solve old problems.
This conference is essential for anyone involved in
pumps design, specification, installation, commissioning
and maintenance.
1.30pm Investigating Energy Savings in Pumps & Pumping
Systems by the Thermodynamic Method
Session Simon Carthwright
5 Director & Principal Electrical/Controls Engineer, Better Technical Options Ltd
The thermodynamic method of pump performance measurement enables measurement of
the minute temperature increase of the fluid as it passes through the pump. This has a direct
relationship to the energy lost to the fluid. This information, in conjunction with the pump
head and input power, can calculate a pump's efficiency far more accurately and with better
repeatability than any other method presently available for in-situ testing. A study that was
conducted under controlled conditions, using the thermodynamic method, to determine the
effect on a pump's performance by a mechanical overhaul and the application of 'low
friction' coating will be discussed.
2.15pm Optimisation of Pump Overhauls
Session Ray Beebe
6 Senior Lecturer / MRE Co-ordinator, Monash University
Pumps wear at differing rates, varying with design, duty and liquid pumped. Overhauling
at regular intervals can be costly and lead to unnecessary work and expense. Condition
monitoring has been used for many years to detect and trend wear so that overhauls can
be done when needed, rather than at an often arbitrary time interval. But, how far do you
go? When is the optimum time to overhaul a pump when degradation has been detected?
The condition monitoring methods available and the optimisation method Ray has
developed (and published) will be explained. The method will be explained with an
example, and a worksheet will be available, plus a spreadsheet application.
3.00pm Afternoon Tea
3.30pm Continuous Automated Performance Monitoring of
Pump Performance
Session Graham Jefferson
7 Regional Manager, South East Asia- Compete Holdings Pty Ltd
This presentation introduces a framework for the automated monitoring and "health
checks" of Centrifugal pumps. As pumps account for a significant portion of plant
operating costs (60-70% in the water industry), early diagnosis of performance problems
can save operational and maintenance dollars. Early diagnosis of degraded performance
is achieved by online automated multivariable analysis of the key process variables. The
performance of the operation can be optimised by ensuring that the pumps are running at
acceptable levels of efficiency. A case study will be presented where these issues are
discussed and addressed by using equipment health and performance monitoring
software. The key benefits are; simple overviews of pump health superimposed with
process data, reduced energy consumption, improved pump reliability, and reduced
operating and maintenance costs.
o LIVE INTERACTIVE WEBCAST FROM CAPE TOWN, SOUTH AFRICA:
4.15pm Pump Condition Monitoring Through Vibration Analysis
Session Dr. Cornie Scheffer
8 Associate Professor, Department of Mechanical and Mechatronic Engineering,
Stellenbosch University, Cape Town
It is well-known that vibration analysis is a powerful tool for the condition monitoring of
machinery. This especially applies to rotating equipment such as pumps. Through the years
a variety of vibration-based techniques have been developed and refined to cost-effectively
monitor pump operation and the onset of failures. This paper is an overview of a variety of
vibration-based condition monitoring techniques for pumps. Based on the information
presented, pump users can select the appropriate techniques and available tools to ensure
cost-effective condition monitoring for their operations. This will lead to an overall
improvement in plant efficiency and reliability.
5.00pm Closing
E-mail: Web Site:
idc@idc-online.com www.idc-online.com
 CONFERENCE DAY 2 - 14th May 2009
8.30am A Man is not an Island; Neither is a Pump 1.15pm Pumping Systems - Solutions, Case Studies
Session Graham Jefferson & Deficiencies
9 Regional Manager, South East Asia- Compete Holdings Pty Ltd Session Bernard Da Cruz
KEY There are many situations where multiple assets such as pumps, compressors, fans and 13 Director, Lincolne Scott Pty Ltd
boilers are used together to feed a product into a common point under varying operating Pumping Systems Engineers like most designers believe in safety margins. Safety margins
NOTE conditions. For example, a pipeline may need one pump to satisfy the flow at low demand, and the extent of these margins can give rise to some unintentional pumping problems.
three pumps at high demand or any combination in between. When more than one pump Pumping systems; in most instances; operate well below their optimum efficiency levels,
(fan or compressor) is used to produce a flow then an almost infinite number of operating whilst meeting their process demand requirements. This presentation is aimed at providing
scenarios are possible. This paper will explore the challenges of operating multiple energy insights into the pumps and pumping systems requirements, including opportunities
sources that are coupled by the process (e.g. parallel pumps into a common header) and available to design and operate an efficient system; as well as to review opportunities to
how operating costs can be significantly reduced through the use of sophisticated
algorithms in the control system. A case study will be investigated where these techniques optimise the existing system performance.
yielded savings in excess of $400,000 per annum in electricity costs alone.
2.00pm Tuning Your Pump
9.30am Wireless & Pump Control: History & New Horizons Session Ray Beebe
Session Brett Biondi 14 Senior Lecturer / MRE Co-ordinator, Monash University
10 Sales and Marketing Manager, ELPRO Technologies Pty Ltd Designers estimate the resistance to flow of a system of pipes, fittings and plant items;
The capital cost of pump utilisation consists of 5% life cycle costs, and 95% operating costs then add on a safety margin when selecting a pump to ensure that the duty will be met.
(e.g. energy usage and maintenance) all of which excludes commissioning, costs of labour, Whether using data sheets from handbooks or software, a system can differ from that
conduit and cable. This is set against a backdrop of a difficult macroeconomic expected, such that the pump is well oversized and has to be throttled to prevent
environment’s ever increasing emphasis on plant operational effectiveness and cash flow. excessive flow. Depending on design, a pump impeller can be trimmed by up to 20% with
This paper presents a background on the use of wireless technology in commissioning, little effect on efficiency. This paper will examine how to estimate the cut in diameter
controlling and reducing operating costs of pump operation. Practical examples will needed by machining the blades to reduce the diameter and the costs of energy saved.
highlight how problems have been tackled before and the consequent outcomes. The paper It may be better to obtain a new impeller and keep the existing one in case the duty or
finishes with a précis on the emergent standards in wireless technology and how you can system change in future.
apply this to your pump applications.
2.45pm Afternoon Tea
10.15am Morning Tea
3.15pm An Approach to Water Savings
10.45am Practical Pumping System Design Session Paul Xuereb
Session John M. Sullivan 15 Technical Sales Manager, John Crane Australia
11 Principal Piping Engineer, Ausenco Ltd Opportunities for water conservation abound in industry within areas that are
Engineers are under increasing pressure to meet tight project timeframes. This raises the traditionally overlooked. Centrifugal pumps found in most mineral processing and
question: "is it possible to deliver safe, cost-effective, design, rather than being forced into industrial manufacturing environments, can be substantial users of water. With the right
adopting overly conservative or inefficient design approaches?" It is the authors' shared approach, significant water reductions can be realised offering savings, not only in
water consumption, but as a result of increased reliability and the associated lowering
belief that design excellence can still be achieved. This presentation proposes a set of
of maintenance costs. This paper will examine practical applications of SmartFlow.
guidelines/tools that have been developed for one significant area of the engineering
design process, namely pumping system design. The presentation will cover the basis of
these guidelines and tools; the practicality of their application, and include a number of CLOSING DISCUSSION:
interesting examples of their real life application.
4.00pmj Major Troubleshooting, Problems and Solutions for
11.30am Applying Today's Technology to Yesterdays Pumps Pumps in Australia
Session Ross Bertoli Session Presented by Bernard Da Cruz, Graham Jefferson & Ray Beebe
12 General Manager, Hydro Australia 16 In line with the conference's mission of exchanging ideas and practical experiences, this
In today's energy conscious environment, companies are looking for the opportunity to session will draw on participants to discuss safety control systems in their workplace,
increase the performance and efficiency of their pumping systems and in turn decrease covering typical problems and possible solutions.
their energy costs, thereby reducing carbon emissions. Over many years the methods
utilized in the overhaul and repair of pumps have been improved upon and now are far 4.45pm Closing
more expansive and effective in the pursuit of this requirement. This presentation will
highlight opportunities for companies to improve the performance of their pumping
systems through a variety of common sense applications.

12.15pm Lunch Sponsorship

Opportunities
All conference papers are reviewed and selected for their high quality
Representing your business at the 2009 Pumps
and technical value by our panel of specialists experienced in the Conference will provide you the opportunity to reach
theory and practice of Pumps Maintenance, Design and Reliability. key decision makers from a multitude of industries.
For more information on sponsorship and exhibition
opportunities please contact Jasmin Hazelton via
FOR FURTHER Phone: email jasmin@idc-online.com
INFORMATION: 1300 138 522
 PRE-CONFERENCE WORKSHOPS - 12th May 2009
WORKSHOP 1 8.30am - 12.30pm
Modeling and Simulation for Optimised Pump Performance
This practical workshop is aimed at providing an insight into building simple hydraulic
models to simulate the operation of pumps and the entire system based on various operating
scenarios. The focus is on building and using simple models that enable the user to test
"what if" situations and examine the operational and economic impacts of these situations.
The model will progress to a typical pumping application such as controlling the level of
liquid in a tank by manipulating the speed of a pump and/or using a control valve and the
effects of different operating regimes, the effects of loop tuning etc. will all be demonstrated
in this workshop. Modeling and simulation of processes is typically a high-level, theoretical
undertaking, however this workshop will be aimed at simple, yet effective, material that can
help uncover many potential problems even in the simplest of designs.
WORKSHOP 2 1.30pm - 5.30pm
Centrifugal Pumps: Optimising Efficiency and Energy Consumption
Pumps account for over 25% of energy consumption in industry. A centrifugal pump is a
veritable workhorse found in a wide variety of applications and industries. Centrifugal
pumps are synonymous with transportation of liquid and slurries (liquid with suspended
solids) with applications ranging from potable water supply and waste water handling for
towns and cities to dredging seabeds for deepening access to harbours; as well as to form
manmade islands. This workshop presents a closer look at; opportunities available to
optimise the design and selection of pumps for an energy efficient outcome, operation of the
centrifugal pump/pumps for optimising performance and energy outgoings, and some basic
tools available to establish the need for maintenance as well as review pump performance
after the pump is refurbished and put back in service.

Your presenter: Your presenter:

GRAHAM JEFFERSON Regional Manager Asia Pacific, Compete Professional Services
Graham has experience in management of multi-disciplinary teams in various process
control applications in the minerals processing, food, boiler/burner management systems,
delivery of training material on the subject of process control systems world wide.
Graham is regarded as the foremost leader in the area of design, implementation and
tuning of all aspects of regulatory process control systems. Graham has experience in
modelling and simulation of various process control applications such as Evaporator
plants, HVAC systems, multiboiler firing sequences and multiple pump station simulation.
He also is a TÜV certified Functional Safety Engineer.
BERNARD DA CRUZ Director, Lincolne Scott Pty Ltd
Bernard has a wealth of experience as a Mechanical Engineer in a wide range of industrial
and commercial projects throughout the Asia Pacific region. His vast industrial knowledge
within operations, maintenance and management is well respected internationally by
consulting and construction companies. He is retained by industry as a Mechanical
Consultant and has worked on projects as diverse as the Melbourne Museum,
Commonwealth Serum Laboratories and St Patrick's Cathedral. Bernard's experience and
knowledge combined with his positive and enthusiastic manner when presenting
workshops, has made him a sought after instructor.

REGISTRATION FORM: PUMPS: Maintenance, Design and Reliability Conference GENERAL INFORMATION
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