Module 1 — Fundamentals of Industrial Pumps

Lessons

1. Introduction to industrial pumps
2. Purpose and applications of pumps
3. Pump terminology and basic concepts
4. Pressure, head, flow rate and velocity
5. Static head and friction head
6. Pump efficiency and power
7. Pump duty point
8. Pump system fundamentals
9. Pump classifications
10. Positive-displacement vs centrifugal pumps

Learning Outcomes

Participants will be able to:

• Explain the purpose of industrial pumps.
• Identify major pump types.
• Understand flow, pressure, head and efficiency.
• Describe basic pump-system relationships.

Practical Assignment: Identify and classify pumps used in a process plant.

Module 2 — Centrifugal Pump Principles

Lessons

1. Centrifugal pump operating principle
2. Pump casing
3. Impeller types and construction
4. Shaft and shaft sleeves
5. Wear rings
6. Bearings
7. Mechanical seals
8. Packing systems
9. Suction and discharge connections
10. Single-stage and multistage centrifugal pumps
11. Horizontal and vertical centrifugal pumps
12. End-suction and split-case pumps

Practical

• Identify centrifugal pump components from drawings and photographs.
• Trace the flow path through a centrifugal pump.

Module 3 — Positive Displacement Pumps

Lessons

1. Principles of positive displacement pumping
2. Reciprocating pumps
3. Piston pumps
4. Plunger pumps
5. Diaphragm pumps
6. Gear pumps
7. Screw pumps
8. Vane pumps
9. Lobe pumps
10. PD pump relief systems
11. Applications and limitations
12. Centrifugal vs PD pumps

Case Study

Selecting the appropriate pump for high-viscosity process fluid.

Module 4 — Pump Hydraulic Principles

Lessons

1. Flow and pressure relationships
2. Pump head
3. Total Dynamic Head (TDH)
4. Static head
5. Friction losses
6. System resistance
7. Pump affinity laws
8. Pump efficiency
9. Hydraulic power
10. Brake horsepower
11. Pump performance calculations
12. Operating point

Practical Calculations

• Calculate pump head.
• Calculate hydraulic power.
• Calculate pump efficiency.
• Determine system pressure losses.

Module 5 — Pump Performance Curves

Lessons

1. Understanding pump curves
2. Head vs flow curves
3. Efficiency curves
4. Power curves
5. NPSH required curves
6. System curves
7. Determining pump duty point
8. Best Efficiency Point (BEP)
9. Operating away from BEP
10. Pump curve interpretation
11. Series pump operation
12. Parallel pump operation

Practical Assignment

Analyze a manufacturer pump curve and determine the expected operating point.

Module 6 — NPSH, Cavitation and Pump Hydraulic Problems

Lessons

1. Introduction to NPSH
2. NPSH Available
3. NPSH Required
4. Understanding cavitation
5. Causes of cavitation
6. Cavitation symptoms
7. Cavitation damage
8. Vapor pressure
9. Suction-line losses
10. Preventing cavitation
11. Troubleshooting low suction pressure
12. Pump starvation

Case Study

Centrifugal pump experiencing vibration, noise and reduced flow.

Participants diagnose whether the problem is related to cavitation, suction restriction or another operating condition.

Module 7 — Pump Installation and Commissioning

Lessons

1. Pump foundation requirements
2. Baseplates and soleplates
3. Pump and motor installation
4. Piping installation
5. Suction piping requirements
6. Discharge piping
7. Valve installation
8. Strainers and filters
9. Coupling installation
10. Shaft alignment
11. Soft-foot inspection
12. Lubrication
13. Rotation checks
14. Pump priming
15. Pre-commissioning checks
16. Pump commissioning procedure

Practical Assignment

Develop a pump installation and commissioning checklist.

Module 8 — Pump Operation and Control

Lessons

1. Normal pump operating procedures
2. Pump start-up
3. Pump running checks
4. Pump shutdown
5. Emergency shutdown
6. Minimum-flow requirements
7. Recirculation systems
8. Flow control
9. Pressure control
10. Variable Frequency Drive (VFD) control
11. Automatic pump start/stop
12. Duty/standby pump operation
13. Pump sequencing
14. Operating limits

Practical

Create a standard operating procedure for starting and stopping a centrifugal pump.

Module 9 — Pump Mechanical Maintenance

Lessons

1. Pump maintenance philosophy
2. Preventive maintenance
3. Predictive maintenance
4. Corrective maintenance
5. Pump inspection
6. Bearing inspection
7. Mechanical seal inspection
8. Packing inspection
9. Impeller inspection
10. Wear-ring inspection
11. Shaft inspection
12. Coupling inspection
13. Lubrication maintenance
14. Pump overhaul procedures

Practical Assignment

Develop a preventive-maintenance schedule for an industrial centrifugal pump.