Technical Courses-Mechanical courses-Pump Maintenance & Troubleshooting

Course Objective:

By the end of the program, the trainee will be able to:

Explain the importance of pump troubleshooting in reducing downtime and costs.
Apply a systematic approach to diagnosing pump problems.
Identify causes and remedies for common pump faults (no start, no flow, low flow, overheating, vibration, noise).
Diagnose leakage at seals and gaskets.
Identify causes of cavitation and its effects on pump performance.
Troubleshoot impeller-related faults (wear, clogging).
Troubleshoot volute-related faults (erosion, corrosion, cracking).
Troubleshoot shaft-related faults (misalignment, wear/scoring).
Troubleshoot stuffing box and packing faults.
Troubleshoot mechanical seal faults.
Troubleshoot bearing faults (noise, overheating).
Explain the relationship between NPSH and cavitation prevention.
Complete maintenance work request, planning/scheduling, and daily work sheet documentation.
Apply preventive practices to extend pump lifespan.

Course Outlines:

Introduction to Pump Troubleshooting
Importance of pumps in industrial operations
Impact of pump failure on downtime, safety, and cost
Systematic troubleshooting approach (inspection, data analysis, condition monitoring)
Maintenance Reporting Formats
Maintenance work request
Planning and scheduling
Daily work sheet
General Pump Troubleshooting Guide
Pump fails to start
Pump runs but no flow
Low flow rate
Excessive vibration
Overheating
Noisy operation
Leakage at seals or gaskets
Frequent circuit tripping
Cavitation
Pump loses prime
Suction problems
Component-Level Troubleshooting
Impeller: wear/damage, clogging
Volute: erosion/corrosion, cracking
Shaft: misalignment, wear/scoring
Stuffing box: leakage, packing wear
Seals: leakage, failure
Bearings: noise, overheating
Cavitation – Causes and Effects
Relationship between fluid boiling point and pressure
Role of suction eye pressure and NPSH
Physical effects: pitting, bearing failure, shaft breakage, seal failure
Observations: pressure drop, temperature rise, flow disturbance
Downstream problems caused by unresolved cavitation
Preventive Practices and Reliability
Regular inspection routines
Prompt response to warning signs
Long-term reliability improvement

Who Can Benefit?

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MC12

Pump Maintenance & Troubleshooting