This comprehensive course provides a practical and theoretical foundation in the design, selection, operation, and maintenance of various industrial pumping systems critical to oil, gas, and process industries. Participants will gain a deep understanding of pump hydraulics, performance curves, and the distinction between centrifugal and positive displacement pumps. The program focuses on best practices for troubleshooting common operational issues, optimizing efficiency, and ensuring the long-term reliability of pumping assets. By covering key industry standards and advanced diagnostic techniques, this course equips engineers and technicians to manage pumping systems effectively, minimizing downtime and maximizing productivity across all phases of the lifecycle.
Introduction
Objectives
Upon completion of this course, participants will be able to:
- Distinguish between and correctly select centrifugal and positive displacement pumps for specific applications.
- Analyze and interpret pump performance curves and system head curves.
- Calculate and mitigate Net Positive Suction Head (NPSH) issues and cavitation.
- Develop effective troubleshooting strategies for common pump failures (e.g., vibration, seal leaks).
- Implement maintenance best practices, including alignment and balancing procedures.
- Understand the design and function of mechanical seals and various bearing types.
- Apply energy efficiency principles to optimize pump operation and reduce life-cycle costs.
- Adhere to relevant industry standards such as API 610 for centrifugal pumps.
- Identify appropriate monitoring techniques for pump condition-based maintenance (CBM).
Target Audience
- Mechanical Engineers
- Maintenance and Reliability Technicians
- Plant Operators and Supervisors
- Process Engineers
- Rotating Equipment Specialists
- Project Engineers involved in equipment specification
- Procurement and Technical Auditors
Methodology
- Scenario-based troubleshooting exercises and RCA workshops
- Group activities on pump selection and sizing for a given service
- Case studies of industrial pump failures and reliability improvements
- Practical exercises in interpreting pump performance and NPSH curves
- Discussions on API 610 compliance and maintenance planning
Personal Impact
- Expertise in diagnosing and solving complex pump operational issues.
- Improved ability to select the most reliable and energy-efficient pump for an application.
- Enhanced understanding of mechanical seal and bearing system reliability.
- Greater competence in applying API standards and best maintenance practices.
- Development of robust pump reliability and condition monitoring skills.
- Formal training to advance a career in rotating equipment management.
Organizational Impact
- Reduction in unscheduled pump downtime and costly catastrophic failures.
- Lower operational costs through optimized pump efficiency and energy consumption.
- Extended Mean Time Between Failures (MTBF) for critical pumping assets.
- Improved safety performance through reliable equipment operation and leak prevention.
- Standardization of pump maintenance procedures across the organization.
- Optimized inventory of spare parts and reduced maintenance burden.
Course Outline
Unit 1: Pump Fundamentals and Classification
Section 1: Basic Pump Hydraulics- Principles of fluid dynamics, flow, pressure, and power
- Head, flow, and efficiency calculations
- Understanding system head curves and determining the operating point
- Affinity laws and their application to pump speed changes
- Classification, components (impellers, casings, diffusers), and specific speed
- Multistage, vertical, and API 610 configurations
- Parallel and series operation of centrifugal pumps
- Minimum flow requirements and recirculation systems
Unit 2: Positive Displacement (PD) Pumps
Section 1: PD Pump Technology- Reciprocating pumps (piston, plunger, diaphragm)
- Rotary pumps (gear, screw, vane, progressive cavity)
- Sizing and operation of PD pumps versus Centrifugal pumps
- Pulsation dampening, relief valves, and pressure control in PD systems
Unit 3: Operation, NPSH, and Cavitation
Section 1: Cavitation and NPSH Management- Causes and destructive effects of cavitation on pump components
- Calculating Net Positive Suction Head Available (NPSHA) and Required (NPSHR)
- Strategies for NPSH improvement and mitigation of low NPSH operation
- Addressing suction and discharge piping arrangements and friction losses
Unit 4: Mechanical Seals, Bearings, and Drivers
Section 1: Sealing Systems and Plan Selection- Types of mechanical seals (single, double, cartridge) and selection criteria
- API Plan selection for seal flush and barrier systems (API 682)
- Packing systems, gland adjustments, and conversion to mechanical seals
- Installation, commissioning, and common failure modes of mechanical seals
- Types of bearings (sleeve, rolling element) and best lubrication practices
- Coupling selection, alignment (laser), and balancing procedures
- Pump drivers: Motors, turbines, and Variable Speed Drives (VSDs)
- Controlling pump noise, vibration, and thermal expansion effects
Unit 5: Maintenance, Reliability, and Troubleshooting
Section 1: Lifecycle Management and CBM- Developing effective preventative maintenance (PM) schedules and tasks
- Predictive maintenance (PdM) strategies and condition monitoring (CBM)
- Vibration analysis and thermography for pump diagnostics
- Root cause analysis (RCA) of common pump failures
Unit 6: API Standards and Commissioning
Section 1: API 610 and Testing- Key requirements of API 610 for centrifugal pump specification
- Witnessing and interpreting factory acceptance testing (FAT) results
- Field installation and commissioning best practices
- Total cost of ownership and life-cycle cost analysis
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