High Pressure Pump Operation, Maintenance, Overhauling & Troubleshooting

What are the Goals?

• Know the basics principal of High Pressure pump operations
• Learn the different types of pumps
• Understand the pump construction
• Learn how the performance curve of pump is measured
• Use the similarity laws to calculate the pump
• Performance at different speed and rotor size
• Highlight the importance of the related international standards of pumps
• Familiarize with different auxiliary systems for pumps (oil system and protection system)
• Understand the basics of sealing systems
• Learn the maintenance procedure of pumps
• Learn the common causes of pump failures (e.g. cavitation and vibrations)
• Understand the mechanical design of the mechanical seal
• Highlight the importance of seals on the rotating machines availability
• Learn the Up-to date maintenance of the mechanical seal
• Learn the failure analysis and troubleshooting the mechanical seal
• Learn about different types of alignments
• Learn about Casing, wear rings and impeller types and their usage

Who is this Training Course for?

This training course is targeted to a wide range of professionals working in pump operation, maintenance selection, testing and commissioning and will greatly benefit;

• Facility/Utility engineers
• Operation Personnel
• Maintenance and troubleshooting Personnel
• High Pressure pumps Operators
• Supervisors & Technicians
• Team Leaders

Daily Agenda

Day One:  Introduction and Pumping Fundamentals

• Hydraulics - A Few Basics
• Vapor Pressure
• Operating Parameters
• Pump Types and Pump Classification
• Centrifugal via Displacement action
• Rotary displacement pumps
• Centrifugal Pump Basics
• Principle of Operation
• Pumping vertically & pumping horizontally
• Single-stage, Double-stage and Multi-stage pumps
• Volute & Diffuser pumps
• Closed impeller, open, impeller or Semi-open impeller
• Casing Construction (Radially Split, Axially Split, Double Casing)
• Impeller Shrouds (Open, Partially Open, Closed)
• Shaft Position (Horizontal, Vertical)
• Wear Ring Running Clearances

 Day Two: Pumps Performance and Operation

• Pump performance curves
• Limits of operation
• The significant of the Specific Speed and the Specific Diameter
• How to use Specific Speed number in pumps selection process
• Operating procedures and conditions
• Pump curve against piping system curve
• NPSH available, required and measurement
• Best operating condition

Day Three:  High Pressure Pump Selection and Materials

• Material selection
• Corrosion and erosion
• Abrasion resistant materials
• Materials resistant to cavitation damage
• Overall procedure in selecting a pump
• Parameters affecting the pump selections
• Properties of liquids being pumped
• Economic consideration
• Pumps application

Day Four: Pump Auxiliary System 

• Sealing Methods
• Difference between packing and mechanical seal
• Characteristics and Types of Mechanical Seals
• Sealing and Flushing Fluids
• Pump Bearings
• Lubrication of bearing
• Bearings – failure modes and how to extend life
• Alignment and Couplings

Day Five: Maintenance and Troubleshooting

• Pump Maintenance
• Maintenance Inspections
• Bearing Maintenance
• Shaft Seal Maintenance
• Pump Overhauling
• Disassembly/dismantling Procedure
• Pump Troubleshooting and Failure Analysis
• Shaft Deflection
• Cavitation in Pumps
• Pump Vibration
• Operation and Maintenance Troubleshooting
• Root-causes, Case Studies
• Discussion and Post-Test
• Last Day Review
• Presentation of Certificates