Course Details

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

• Plant Operators
• Maintenance Technicians
• Mechanical Engineers
• Process Engineers
• Reliability Engineers
• Supervisors
• Technicians
• Junior Engineers

• 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:

• Explain the working principles and safe operating procedures for common industrial pumps and valves.
• Accurately identify and select the appropriate pump and valve type for specific process applications.
• Execute essential preventive maintenance tasks like lubrication and sealing checks for equipment longevity.
• Diagnose common operational faults such as cavitation leaks and vibration using systematic methods.
• Safely perform minor repairs and corrective actions to restore equipment to optimal condition.
• Evaluate and interpret key performance indicators for efficient and reliable pump and valve operation.

DAY 1

Fundamentals of Pumps and Valves

• Welcome and introduction
• Pre-test
• Introduction to Pumps and Valves in Industrial Systems
• Overview of Pump Types: Centrifugal, Positive Displacement, Gear, Diaphragm, Screw, etc.
• Overview of Valve Types: Gate, Globe, Ball, Butterfly, Check, Control Valves
• Basic Hydraulic Principles (Flow, Pressure, Head, NPSH)
• Pumps and Valves Selection Criteria
• Pumps and Valves Material Compatibility and Application Considerations
• Quiz

DAY 2

Operation Principles and Performance Monitoring

• Operating Characteristics of Pumps (Performance Curves, Efficiency, System Head)
• Valves Operating Principles and Flow Characteristics
• Cavitation and its Effects on Pumps
• Pumps Proper Startup and Shutdown Procedures
• Pumps Arrangements (Series/Parallel) and Flow Control Methods
• Understanding System Curves and Matching Pump Curves
• Quiz

DAY 3

Maintenance Practices and Schedules

• Preventive vs Predictive Maintenance
• Lubrication Techniques and Intervals
• Mechanical Seals, Packing, Bearings: Inspection and Replacement
• Valve Stem Packing and Gland Maintenance
• Maintenance Planning and Recordkeeping
• Spare Parts Management and Inventory Best Practices
• Case study

DAY 4

Troubleshooting Techniques

• Diagnosing Common Pump Problems (No Flow, Low Flow, Overheating, Vibration, Noise)
• Valve Troubleshooting (Leakage, Sticking, Actuator Issues)
• Root Cause Analysis Techniques
• Vibration and Temperature Monitoring
• Use of Diagnostic Tools (Flow Meters, Pressure Gauges, Thermal Imaging, Vibration Analyzers)
• Emergency Response to Pump or Valve Failures
• Case study

DAY 5

System Integration, Safety, and Case Studies

• Integration of Pumps and Valves into Piping Systems
• Automation and Control Systems (SCADA, PLC for valves/pumps)
• Safety Considerations: Lockout/Tagout (LOTO), Pressure Hazards
• Environmental and Operational Risks
• Real-World Case Studies of Failures and Solutions
• Post-Test
• Certificate ceremony