The course covers advanced maintenance techniques of pumping Technology reliability improvement strategies, and cutting-edge technologies to ensure high efficiency and operational stability of these critical mechanical systems.

By the end of this course delegates will be able to:

• Gain advanced knowledge of pumps and systems and their components.
• Learn advanced diagnostic and troubleshooting techniques.
• Master strategies for optimizing the performance and reliability of pumps.
• Enhance skills in predictive and preventive maintenance practices.
• Understand the latest technological advancements and best practices in the maintenance of pumps.

This course is intended for experienced professionals who are involved in the maintenance and management of pumps and compressors, including:

• Maintenance Engineers
• Mechanical Engineers
• Maintenance Technicians
• Reliability Engineers
• Operations Managers
• Plant Supervisors

This interactive Training will be highly interactive, with opportunities to advance your opinions and ideas and will include:
• Lectures
• Workshop & Work Presentation
• Case Studies and Practical Exercise
• Videos and General Discussions

Day 1

Advanced Pump Systems

• Introduction to pumping system
• Classification of pumps
• Overview of advanced pump types and their applications
• Major components of all types of the pumps and their function
• Pump selection and system design for optimal performance
• Energy efficiency and performance optimization
• Principle operation of Positive displacement pump
• Positive displacement pump types and their applications
• The differences between plunger pumps and piston pumps
• Basic Components of Reciprocating pumps
• Reciprocating Pumps lubrication system
• Process Calculations for Reciprocating Pumps
• Positive displacement pump Troubleshooting
• Auxiliary systems – lube oil, seal flush, and monitoring instruments

Day 2

Understanding head and Flow rate 

• Efficiency improvements and performance Curve
• Pump performance (dynamic and positive displacement pumps)
• Calculation: actual head, friction loss, static pressure, velocity
•  Net positive suction head available NPSHa and required NPSHr
• Vapor and gas cavitation problem in pumps and piping system
• Friction in valves, piping & fittings and effected to pump system
• Prepare Materials list for Major overhauling of pump  
• Special application pumps metering pumps, diaphragm pumps
• Failure mechanisms identification and monitoring

Day 3

Centrifugal Pumps

• Principle operation of Centrifugal pump
• Pump misalignment and corrected 
• Pump wear rings leakage and effected to pump efficiency
• Basic Components of Centrifugal pumps
• Balancing drum / disc and effected to axial forces
• Multi stage pumps arrangement and connection serials / parallel methods.
• Centrifugal pumps starting operation procedures
• Preventing cavitation
• Centrifugal Pump Characteristic Curves
• Centrifugal Pump protection and control system.
• Priming Centrifugal Pumps
• Centrifugal pump Troubleshooting
• Mechanical seal flush system procedures
• Conventional packing glands, mechanical seals & flush plans
• Performance analysis (flow rate versus head, motor loading and deduced efficiency).
• Failure mechanisms – identification and monitoring
• Maintenance and repair of mechanical seals

Day 4

Predictive and Preventive Maintenance

• Fundamentals of predictive maintenance
• Implementation of predictive maintenance programs
• Data acquisition and analysis for predictive maintenance
• Preventive maintenance best practices and procedures
• Maintenance planning and scheduling
• Lubrication system and bearings (Plain bearings, Anti-friction bearings)
• Couplings & alignment and Foundations & bedplates
• Pump maintenance, inspection, overhaul, diagnoses of pump troubles
• Water hammer situation
• Vibration analysis and predictive maintenance
• Diagnostics of pumping systems
• Pump drivers (types of drivers and calculations of fuel consumption rates)
• Suction and discharge Valves used in process isolation
• Types of valves and selection
• Valves Troubleshooting & Maintenance

Day 5

Reliability and availability of pumping System

• Reliability engineering principles and practices
• Reliability-centered maintenance (RCM) for pumps
• Asset management and lifecycle analysis
• Integration and digital twins in maintenance
• Case studies on reliability improvement and technology applications
• Advanced diagnostic tools and techniques
• Vibration analysis and condition monitoring
• Thermographic and ultrasound inspection methods
• Root cause analysis for pump and compressor failures
• Practical troubleshooting exercises and case studies

A RECTUS attendance certificate will be awarded to all participants who complete at least 80% of the total course duration.