Pumping Systems Course

Lesson 1 • Pressure and Head Concepts

Defines gauge, absolute, and differential pressure alongside hydraulic head. Connects pressure terminology to pump performance curves and system design.

Lesson 2 • Properties of Fluids

Covers density, viscosity, vapour pressure, and compressibility as they affect pump selection. Establishes the physical baseline for all subsequent system calculations.

Lesson 3 • Flow Regimes and Continuity

Distinguishes laminar from turbulent flow using Reynolds number analysis. Applies the continuity equation to predict velocity changes across pipe sections.

Lesson 4 • Friction and Minor Losses

Quantifies pipe friction using the Darcy-Weisbach equation and Moody diagram. Adds minor losses from fittings to build accurate system resistance curves.

Lesson 1 • Specialty and Emerging Pump Technologies

Introduces peristaltic, screw, and jet pump designs for niche applications. Expands selection knowledge beyond conventional centrifugal and PD categories.

Lesson 2 • Positive Displacement Pump Types

Covers reciprocating, gear, lobe, and diaphragm pump mechanisms. Contrasts fixed-volume delivery with centrifugal variable-flow behaviour.

Lesson 3 • Centrifugal Pump Fundamentals

Explains impeller-driven energy transfer and volute pressure recovery. Establishes centrifugal pumps as the baseline technology for system comparisons.

Lesson 4 • Pump Selection Criteria

Applies flow rate, head, fluid properties, and duty cycle to narrow pump type choices. Introduces selection matrices and vendor data sheet interpretation.

Lesson 1 • Reading Pump Performance Curves

Decodes head-flow, efficiency, power, and NPSH curves from manufacturer data. Builds the skill to extract operating parameters directly from published charts.

Lesson 2 • Operating Point Determination

Overlays pump and system curves to locate the actual operating point. Evaluates efficiency and power consumption at that intersection for optimisation.

Lesson 3 • Affinity Laws and Speed Changes

Applies affinity laws to predict performance shifts from speed or impeller diameter changes. Enables rapid re-rating without full re-testing.

Lesson 4 • System Curve Development

Constructs system resistance curves by summing static head and friction losses. Demonstrates how pipe diameter and length shift the curve and operating point.

Lesson 1 • Calculating Available NPSH

Walks through step-by-step NPSHa calculation for flooded and suction-lift installations. Accounts for suction pipe losses, elevation, and fluid temperature.

Lesson 2 • NPSH Fundamentals

Defines NPSHa and NPSHr and explains the margin required for safe operation. Connects vapour pressure and suction head to the risk of liquid vaporisation.

Lesson 3 • Cavitation Diagnosis and Correction

Uses vibration analysis, noise monitoring, and performance drop to confirm cavitation. Provides corrective actions including speed reduction, impeller change, and system redesign.

Lesson 4 • Cavitation Mechanisms and Damage

Explains bubble formation, collapse, and the resulting impeller erosion and noise. Distinguishes suction cavitation from recirculation cavitation by symptom pattern.

Lesson 1 • Seal Arrangements and API Plans

Covers single, double, and tandem seal arrangements with corresponding flush and barrier plans. Matches arrangement to fluid hazard, temperature, and regulatory requirements.

Lesson 2 • Seal Support System Design

Designs flush, quench, and cooling circuits to maintain seal face temperature and cleanliness. Sizes reservoirs, coolers, and instrumentation for reliable seal support.

Lesson 3 • Seal Failure Analysis and Prevention

Identifies dry running, thermal shock, and contamination as primary seal failure causes. Applies root cause analysis to prevent repeat failures and extend seal life.

Lesson 4 • Sealing Technology Overview

Compares packing, lip seals, and mechanical seals by leakage rate and maintenance demand. Establishes mechanical seals as the standard for modern process pumps.

Lesson 1 • Shaft Alignment Techniques

Covers angular and parallel misalignment measurement using dial indicators and laser tools. Correct alignment reduces vibration, bearing load, and seal wear significantly.

Lesson 2 • Piping Connection and Stress Management

Ensures piping is supported independently to prevent nozzle loads from distorting the pump casing. Covers flange alignment, gasket selection, and bolt torque sequences.

Lesson 3 • Foundation and Baseplate Requirements

Specifies concrete foundation mass, grouting procedures, and baseplate levelling for vibration control. Proper foundation design prevents misalignment and premature bearing failure.

Lesson 4 • Startup, Baseline Data, and Handover

Performs controlled startup, records flow, head, power, and vibration as baseline data. Formal handover documentation confirms the system meets design specifications.

Lesson 1 • Bearing Selection and Lubrication

Selects radial and thrust bearings based on load, speed, and temperature requirements. Specifies grease or oil lubrication type, quantity, and relubrication intervals.

Lesson 2 • Vibration Analysis for Pumps

Applies vibration spectrum analysis to detect imbalance, misalignment, bearing defects, and cavitation. Establishes alert and danger thresholds based on industry severity charts.

Lesson 3 • Preventive Maintenance Programmes

Structures time-based maintenance tasks for bearings, seals, couplings, and lubrication. Aligns task frequency with manufacturer recommendations and operating severity.

Lesson 4 • Predictive Maintenance and Condition Monitoring

Integrates vibration, temperature, oil analysis, and performance trending into a predictive programme. Enables data-driven maintenance decisions that reduce unplanned downtime.

Lesson 1 • Monitoring, Benchmarking, and Continuous Improvement

Establishes key performance indicators and benchmarking against industry efficiency standards. Drives continuous improvement through regular performance audits and corrective actions.

Lesson 2 • Energy Consumption Analysis

Calculates pump wire-to-water efficiency and identifies energy waste from oversized pumps. Establishes the economic case for system optimisation investments.

Lesson 3 • Variable Speed Drive Applications

Applies affinity laws to quantify energy savings from variable speed drive installation. Covers drive selection, control modes, and integration with process control systems.

Lesson 4 • System Redesign for Efficiency

Identifies pipe diameter increases, fitting elimination, and layout changes that reduce system resistance. Demonstrates how system curve flattening lowers required pump head.