Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Mechanical, Maintenance, and Reliability Engineers
• Maintenance Technicians and Supervisors
• Plant and Operations Engineers
• Utility and Marine Engineers
• Process and Equipment Inspectors
• Anyone involved in the maintenance or operation of pumps, valves, and diesel engines

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Understand the design and operation of pumps, valves, and diesel engines
• Perform proper inspection and maintenance procedures
• Identify and troubleshoot common equipment problems
• Apply best practices in installation, alignment, and lubrication
• Enhance reliability and performance of mechanical systems
• Implement preventive and predictive maintenance programs

DAY 1

Introduction to Equipment Maintenance Principles

• Welcome and Introduction
• Pre-Test
• Overview of Pumps, Valves, and Diesel Engines in Plant Operations
• Maintenance Fundamentals and Reliability Concepts
• Mechanical System Interactions and Performance Parameters
• Safety Precautions and Lockout/Tagout Procedures
• Preventive vs. Predictive Maintenance Approaches

DAY 2

Pumps: Design, Operation and Maintenance

• Classification and Operating Principles of Pumps
• Centrifugal and Positive Displacement Pump Designs
• Pump Components – Impellers, Casings, Bearings, Seals, Couplings
• Common Problems – Cavitation, Leakage, and Vibration
• Pump Alignment, Balancing, and Lubrication
• Performance Monitoring and Troubleshooting Techniques

DAY 3

Valves: Selection, Operation and Maintenance

• Overview of Industrial Valve Types – Gate, Globe, Ball, Butterfly, and Check Valves
• Control Valves and Actuators
• Valve Materials, Ratings, and Standards (API, ASME, ISO)
• Installation and Torque Requirements
• Common Valve Failures – Leakage, Sticking, Erosion, and Seat Damage
• Maintenance, Inspection, and Reconditioning Techniques

DAY 4

Diesel Engine: Operation and Maintenance

• Basic Diesel Engine Principles and Components
• Air, Fuel, Lubrication, and Cooling Systems
• Start-up, Operation, and Shutdown Procedures
• Engine Performance Parameters and Monitoring
• Preventive Maintenance Tasks and Schedules
• Common Engine Problems and Troubleshooting Methods
• Vibration, Smoke, and Overheating Diagnostics

DAY 5

Troubleshooting and Reliability Improvement

• Integrated System Reliability Concepts
• Root Cause Failure Analysis (RCFA) for Pumps, Valves, and Engines
• Condition Monitoring Techniques – Vibration, Temperature, and Oil Analysis
• Maintenance Planning and Recordkeeping
• Post-Test
• Certificate Ceremony