Pideya Learning Academy

Predictive Maintenance and Diagnostics for Pumps and Compressors

Upcoming Schedules

  • Live Online Training
  • Classroom Training

Date Venue Duration Fee (USD)
24 Feb - 28 Feb 2025 Live Online 5 Day 2750
31 Mar - 04 Apr 2025 Live Online 5 Day 2750
26 May - 30 May 2025 Live Online 5 Day 2750
23 Jun - 27 Jun 2025 Live Online 5 Day 2750
11 Aug - 15 Aug 2025 Live Online 5 Day 2750
01 Sep - 05 Sep 2025 Live Online 5 Day 2750
27 Oct - 31 Oct 2025 Live Online 5 Day 2750
24 Nov - 28 Nov 2025 Live Online 5 Day 2750

Course Overview

The uninterrupted performance of pumps and compressors is central to the reliability and efficiency of operations in critical sectors such as oil and gas, petrochemicals, power generation, manufacturing, and water treatment. These rotating machines form the backbone of fluid movement and energy transfer systems, and any malfunction or unplanned outage can cause substantial disruptions in production, safety, and cost management. Recognizing this industry need, Pideya Learning Academy introduces the Predictive Maintenance and Diagnostics for Pumps and Compressors training—an in-depth and strategically designed program that empowers professionals with the knowledge to maintain asset health, reduce unplanned downtime, and optimize system performance.
According to the International Society of Automation (ISA), nearly 60% of rotating machinery failures are linked to predictable wear and alignment issues—failures that could be prevented through predictive maintenance techniques. In addition, data from the U.S. Department of Energy highlights that pump systems alone account for over 25% of total electricity usage in industrial motor applications, making their efficient operation and timely servicing an essential contributor to both sustainability goals and cost reduction. Furthermore, studies show that predictive maintenance strategies can reduce breakdowns by 70%, lower maintenance costs by 25%, and extend equipment life by 20%, underlining the critical role of diagnostics in industrial settings.
This Pideya Learning Academy course offers a structured pathway for participants to gain expert-level understanding of pump and compressor operations, with emphasis on failure modes, diagnostics, and condition-based maintenance strategies. Participants will delve into pump and compressor classifications, application-specific configurations, wear mechanisms, alignment techniques, vibration control, and lubrication systems. By exploring real-world challenges and case studies across industries, the course provides valuable context on how predictive diagnostics can enhance system reliability and mitigate the risk of catastrophic failure.
Through a diagnostics-driven approach, this program facilitates early fault detection and precise root cause identification, enabling maintenance professionals to take corrective actions before issues escalate. The training blends global maintenance frameworks with proven engineering practices, offering a robust understanding of equipment lifecycle management, energy efficiency, and operational excellence.
Participants can expect to gain a well-rounded skillset with key learning features integrated into the course, including:
In-depth exposure to pump and compressor classification, configurations, and application domains
Comprehensive overview of lubrication regimes and wear prevention strategies
Diagnostics-based approach for early detection of mechanical faults and deterioration
Techniques to enhance service life and reduce equipment lifecycle costs
Alignment, balancing, and vibration control methods for rotating machinery
Discussion of global maintenance standards and reliability-centered maintenance principles
Real-world case examples across industries to demonstrate implementation impact
By addressing both the technical depth and strategic importance of predictive diagnostics, the Predictive Maintenance and Diagnostics for Pumps and Compressors training by Pideya Learning Academy ensures that participants walk away equipped to reduce failure rates, optimize maintenance schedules, and support long-term asset performance. This program is a valuable investment for any professional seeking to improve plant reliability, energy efficiency, and compliance with global maintenance practices.

Course Objectives

After completing this Pideya Learning Academy training, the participants will learn to:
Understand key operating principles and failure modes of pumps and compressors
Identify various pump and compressor types commonly used in industrial operations
Apply predictive maintenance techniques to monitor performance and detect anomalies
Minimize downtime by adopting condition-based fault detection methodologies
Recommend appropriate lubrication methods based on equipment and usage conditions
Implement vibration monitoring and alignment procedures to improve machine reliability
Analyze common causes of wear, cavitation, and performance loss in rotating equipment
Improve decision-making on component replacement, overhauls, and service intervals

Personal Benefits

Participants will gain:
Enhanced technical competence in managing rotating equipment
Confidence in troubleshooting and root cause analysis
Exposure to modern diagnostics and condition monitoring tools
The ability to contribute to plant performance and reliability improvements
Recognition as a skilled maintenance professional within their industry

Organisational Benefits

Organizations that nominate employees for this Pideya Learning Academy course will benefit through:
Reduced machinery downtime and improved plant availability
Lower maintenance costs through effective failure prevention
Enhanced technical capability in managing asset reliability
Increased energy efficiency in pump and compressor operations
Better compliance with international maintenance and safety standards

Who Should Attend

This training is ideal for:
Mechanical, maintenance, and plant engineers
Process engineers and reliability professionals
Technical personnel responsible for asset lifecycle management
Maintenance supervisors and foremen
Operational staff involved in pump and compressor performance monitoring

Course Outline

Module 1: Fundamentals of Pump Technologies
Classification of industrial pump systems Performance characteristics of various pump types Centrifugal, positive displacement, vertical, and submersible pumps Functional analysis of pump applications across industries Hydrodynamic principles influencing pump operation Pump casing configurations and hydraulic interference Impeller types and hydraulic balancing techniques Overview of bearing types used in pump assemblies Lubrication systems: Oil-based and grease-based Head loss, flow rate, velocity head, and pressure relationships in hydraulic circuits
Module 2: Pump Installation and Energy Dynamics
Power transmission concepts in pumping systems Electrical energy systems and power consumption in motors Brake horsepower (BHP) and water horsepower (WHP) calculations Pump efficiency analysis and energy cost optimization Foundation requirements and baseplate leveling Installation techniques for horizontal and vertical piping systems Cavitation causes and prevention during installation Proper use and calibration of mechanical installation tools Site conditions and alignment strategies during commissioning
Module 3: Pump Diagnostics and Reliability Techniques
Root cause analysis of capacity loss in pump systems Fault diagnosis tools and best usage practices Common alignment issues: Soft foot, parallel and angular misalignment Predictive maintenance planning and scheduling workflows Equipment failure classification and reliability-centred maintenance Troubleshooting strategies for mechanical and hydraulic faults Lubrication management and wear analysis techniques Vibration monitoring and frequency spectrum interpretation
Module 4: Rotating Equipment and Mechanical Component Maintenance
Maintenance of electric motors: Single phasing, overloads, insulation failure Bearing types: Ball, roller, thrust; mounting and removal procedures Coupling types: Rigid, flexible, grid; alignment and performance checks Blower systems: Axial, centrifugal, regenerative; maintenance routines Mechanical seals: Material compatibility, configuration types, leakage prevention Seal replacement methods and packed gland arrangements Visual inspection and measurement of worn or failed components Equipment overhaul: Cleaning, dimensional checks, assembly techniques Spare parts identification and component reconditioning
Module 5: Compressor Engineering and Operational Design
Introduction to compressors: Reciprocating, screw, centrifugal, axial, helical types Functional differentiation and application suitability Design parameters: Rotor dynamics, casing materials, diaphragm and seal systems Gland design and nozzle integration in compressor architecture Thermodynamic principles in gas compression systems Compressor efficiency calculations and volumetric flow characteristics Stability and surge control in centrifugal compressors Performance mapping and selection using characteristic curves Multi-stage compressors: Intercooling and load distribution Cold and hot alignment techniques: Laser and dial indicator methods
Module 6: Compressor Troubleshooting and Maintenance Strategies
Identification of design-induced compressor failures Troubleshooting methods for screw compressors and piston compressors Seal leakage, vibration, unbalanced loading: Common defect indicators Preventive maintenance best practices for gas compression systems Record keeping: Logs, repair history, trend analysis Documentation standards and digital maintenance platforms Development of standard operating procedures (SOPs) for compressor repair Skill enhancement plans for maintenance teams Maintenance manuals and OEM documentation interpretation
Module 7: Equipment Reliability and Condition Monitoring
Reliability engineering principles for rotating machinery Condition monitoring: Thermography, ultrasonics, oil analysis Early failure detection techniques and wear rate trending Data logging tools and computerized maintenance management systems (CMMS) KPIs and performance metrics for predictive programs Integration of condition-based maintenance into operations
Module 8: Lubrication Systems and Tribological Management
Lubricant selection: Viscosity, additives, and environmental factors Centralized and decentralized lubrication systems Friction and wear mechanisms: Adhesive, abrasive, erosive, fretting Lubrication interval planning and contamination control Analysis of oil degradation and grease application errors
Module 9: Component Balancing and Alignment Engineering
Dynamic and static balancing of rotors and impellers Influence of unbalance on vibration levels and bearing life Shaft alignment: Optical, laser, and reverse dial methods Alignment under operating temperature conditions (thermal growth) Soft foot detection and correction techniques

Have Any Question?

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