COURSE OVERVIEW:

Multi-stage pump overhauling is a highly specialized mechanical maintenance procedure required for the high-pressure water injection and boiler feed pumps central to industrial operations. This course provides an in-depth technical guide to the disassembly, inspection, and reassembly of these complex machines, which feature multiple impellers arranged in series. Participants will explore the precise engineering tolerances and hydraulic balancing requirements that define the performance of multi-stage centrifugal pumps.

The scope of this training covers the mechanical intricacies of various multi-stage designs, including ring-section (BB4) and axially-split (BB3) configurations. Coverage includes the critical inspection of wear rings, balance drums, inter-stage bushings, and the complex shaft sealing arrangements required for high-pressure service. Emphasis is placed on the dimensional metrology needed to ensure that internal clearances are restored to original equipment manufacturer (OEM) specifications to prevent internal recirculation and efficiency loss.

Furthermore, the course addresses the challenges of rotor dynamics and alignment specific to long-shaft multi-stage pumps. Trainees will learn the techniques for checking shaft runout, performing dynamic balancing of the complete rotor assembly, and managing the thermal expansion during startup. By mastering these overhauling best practices, maintenance technicians and engineers can significantly extend the Mean Time Between Failures (MTBF) of these critical assets and ensure the reliable delivery of high-pressure fluids in demanding plant environments.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Identify the structural differences between axially split and radially split multi-stage pumps.
• Execute a systematic disassembly sequence for a high-pressure multi-stage pump.
• Utilize precision metrology tools to measure internal clearances and fits.
• Inspect impellers for cavitation damage, erosion, and shroud integrity.
• Evaluate the condition of balance drums and thrust-balancing devices.
• Perform a shaft runout check and determine straightening requirements.
• Install multi-stage mechanical seals and packing systems accurately.
• Calculate and verify the total "float" or axial travel of the rotor assembly.
• Implement proper torque sequences for casing bolts and tie-rods.
• Conduct a dynamic balance of the multi-stage rotor assembly.
• Identify the symptoms of inter-stage leakage and internal recirculation.
• Execute a comprehensive post-overhaul commissioning and test run.
• Document all dimensional data and repair activities in a professional overhaul report.

TARGET AUDIENCE:

This course is designed for Senior Mechanical Technicians, Pump Specialists, Maintenance Engineers, and Workshop Supervisors responsible for the repair of high-pressure pumping systems.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.