Pumps, valves, and piping systems are fundamental to every process industry, and their reliable operation is crucial for plant throughput and safety. This course provides comprehensive training on the best practices for the inspection, troubleshooting, repair, and precision maintenance of these interconnected fluid handling assets. We will cover pump hydraulic principles, advanced valve diagnostics, and the integrity of piping systems and supports. Participants will gain the practical skills needed to reduce hydraulic losses, extend asset life, and prevent costly leaks and environmental incidents through standardized, high-quality maintenance.
Pump, Valve, and Piping System Maintenance
Maintenance and Engineering
October 25, 2025
Introduction
Objectives
Upon completion of this course, participants will be able to:
- Understand pump hydraulic curves and operating limits (e.g., NPSH, cavitation).
- Perform precision alignment and installation of centrifugal and positive displacement pumps.
- Identify and troubleshoot common valve types (gate, globe, ball) and actuator faults.
- Develop effective preventive maintenance routines for piping systems and supports.
- Apply flange and gasket best practices for leak-free joint assembly.
- Utilize condition monitoring techniques (vibration, acoustics) for pump and valve diagnostics.
- Determine the root causes of pump cavitation, recirculation, and surging.
- Understand regulatory and safety requirements related to pressure piping systems.
Target Audience
- Mechanical Maintenance Technicians and Fitters
- Maintenance Engineers and Supervisors
- Reliability and Vibration Analysts
- Pipefitters and Integrity Inspectors
- Process Engineers and Fluid System Specialists
- Maintenance Planners for fluid handling equipment
Methodology
- Hands-on workshop using pump curves to solve hydraulic problems
- Practical lab session on controlled bolting procedures and flange assembly
- Case studies on catastrophic pump failure caused by poor alignment or cavitation
- Group activity developing a PM checklist for a control valve and its actuator
- Field trip (simulated) for piping system support inspection and defect identification.
Personal Impact
- Gain specialized expertise in critical fluid system maintenance.
- Improve ability to diagnose complex hydraulic and mechanical problems.
- Master precision assembly techniques for pumps and bolted joints.
- Enhance environmental and safety compliance knowledge related to leaks.
- Become a key contributor to energy efficiency through optimized pump operation.
Organizational Impact
- Reduce unplanned downtime from pump and valve failure.
- Eliminate costly leaks and improve environmental compliance.
- Lower energy costs through optimized pump operation and reduced friction.
- Extend the service life of pumps, seals, and bearings.
- Improve safety by ensuring the integrity of pressure piping systems.
- Achieve higher performance from all fluid handling assets.
Course Outline
Unit 1: Pump Reliability and Hydraulics
Centrifugal Pump Principles- Understanding pump curves, flow, head, and efficiency.
- Defining Net Positive Suction Head (NPSH) and preventing cavitation.
- Troubleshooting common hydraulic problems (recirculation, surging, air binding).
- Best practices for baseplate grouting and piping strain prevention.
- Precision alignment techniques for pump-motor sets.
- PM procedures for pump bearings, seals, and impellers.
Unit 2: Valve Maintenance and Diagnostics
Valve Types and Applications- Operating principles and maintenance for isolation valves (gate, ball, plug).
- Control valve function, maintenance, and packing replacement.
- Testing and certification procedures for Pressure Relief Valves (PRVs).
- Using non-intrusive methods (acoustics, thermography) for leak detection.
- Diagnosing actuator failures (pneumatic, electric).
- Techniques for in-line valve repair and troubleshooting.
Unit 3: Piping System Integrity
Piping Components and Damage- Understanding piping codes, standards, and material selection.
- Common damage mechanisms (internal/external corrosion, fatigue, erosion).
- Inspection of piping supports, hangers, and restraint systems.
- Gasket selection, storage, and handling.
- Controlled bolting procedures and tensioning vs. torquing.
- Achieving leak-free, high-integrity flanged joints.
Unit 4: System Troubleshooting and Leak Management
System Troubleshooting- Diagnosing problems at the system level (e.g., low flow, high vibration).
- Using system schematics (P&IDs) for effective troubleshooting.
- The impact of system design on pump and valve reliability.
- Developing a structured leak management program (Fugitive Emission Monitoring).
- Techniques for sealing high-pressure leaks temporarily and permanently.
- Environmental and safety implications of system leaks.
Unit 5: Predictive and Preventive Strategies
Condition Monitoring Application- Using vibration analysis to detect pump unbalance and bearing defects.
- Applying ultrasonic technology for valve seat leakage detection.
- Monitoring pump performance parameters (pressure, temperature) via SCADA.
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