COURSE OVERVIEW:

Understanding the gap between theoretical pump design and actual field performance is essential for maintaining process efficiency. This course provides a comprehensive guide to conducting performance tests on centrifugal pumps and interpreting the resulting data to diagnose operational issues. Participants will learn how to utilize field instrumentation to calculate head, flow, and efficiency, allowing them to pinpoint whether a problem resides within the pump, the piping system, or the process control logic.

The scope of this training focuses on the practical application of the Affinity Laws and the analysis of system-head curves. We will explore the methodologies for field testing without the need for sophisticated laboratory equipment, teaching participants how to use pressure gauges and ultrasonic flow meters to map a pump's actual operating point. The course emphasizes the diagnostic value of performance curves, showing how shifts in the curve can indicate internal wear, impeller blockage, or suction-side restrictions.

Coverage includes advanced troubleshooting techniques for complex hydraulic problems, such as parallel pumping instabilities and system surges. Attendees will learn how to systematically eliminate variables to find the root cause of low flow, high vibration, or excessive power consumption. By mastering these testing and troubleshooting skills, participants will be able to maximize pump uptime and ensure that their systems are operating as close to the Best Efficiency Point (BEP) as possible.

COURSE OBJECTIVES:

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

• Interpret pump performance curves: Head, Power, Efficiency, and NPSHr.
• Conduct a field performance test using standard plant instrumentation.
• Calculate Total Dynamic Head (TDH) from suction and discharge readings.
• Utilize the Affinity Laws to predict performance at different speeds.
• Identify the symptoms of operating the pump "back on the curve."
• Analyze the interaction between the Pump Curve and the System Curve.
• Diagnose internal pump wear based on performance degradation.
• Troubleshoot issues with pumps operating in parallel or series.
• Determine the actual efficiency of a pump to justify repair or replacement.
• Identify suction-side problems using vacuum gauge readings.
• Assess the impact of fluid viscosity and density on pump performance.
• Utilize ultrasonic flow meters for non-invasive performance auditing.
• Develop a systematic troubleshooting logic for hydraulic failures.
• Formulate recommendations for system modifications to improve reliability.

TARGET AUDIENCE:

Operations Engineers, Maintenance Supervisors, Performance Analysts, Plant Operators, and Mechanical Engineers responsible for the efficiency and troubleshooting of fluid handling 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.