Pideya Learning Academy

Preventive Maintenance for Pumps and Compressors

Upcoming Schedules

  • Live Online Training
  • Classroom Training

Date Venue Duration Fee (USD)
10 Feb - 14 Feb 2025 Live Online 5 Day 2750
31 Mar - 04 Apr 2025 Live Online 5 Day 2750
12 May - 16 May 2025 Live Online 5 Day 2750
16 Jun - 20 Jun 2025 Live Online 5 Day 2750
21 Jul - 25 Jul 2025 Live Online 5 Day 2750
15 Sep - 19 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

In today’s competitive industrial environment, the reliability of rotating equipment such as pumps and compressors plays a pivotal role in sustaining safe, energy-efficient, and uninterrupted operations. Failures in these systems can lead to significant productivity losses, increased energy costs, and heightened safety risks. To address these challenges, Pideya Learning Academy introduces the comprehensive training course Preventive Maintenance for Pumps and Compressors, designed to equip maintenance professionals, engineers, and operations personnel with the technical insights and strategic frameworks required to manage these essential assets effectively.
Globally, the demand for industrial pumps and compressors continues to rise, with the industrial machinery market projected to exceed USD 835 billion by 2028 (Statista, 2024). Simultaneously, studies from Plant Engineering (2023) reveal that maintenance costs can consume up to 20% of a plant’s operational budget, while the U.S. Department of Energy highlights that inadequately maintained pump and compressor systems may consume up to 25% more energy than optimized systems. These figures emphasize the necessity of structured preventive maintenance programs that not only reduce downtime but also align with cost-efficiency and sustainability goals.
The Preventive Maintenance for Pumps and Compressors course is structured to empower participants with in-depth knowledge of various types of pumps and compressors—ranging from centrifugal and reciprocating to rotary and axial flow units. The program provides a systematic approach to understanding wear mechanisms, planning maintenance schedules, and identifying root causes of mechanical failures. Special emphasis is placed on predictive maintenance methods, including vibration monitoring, thermal imaging, lubrication analysis, and condition-based diagnostics to support a proactive reliability strategy.
Participants will gain proficiency in optimizing maintenance intervals, evaluating lubrication system efficiency, detecting bearing and seal degradation, and aligning asset care with organizational performance metrics. Throughout the training, industry case references will be discussed to contextualize theoretical knowledge with real-world reliability challenges and maintenance optimization outcomes.
This well-rounded training also fosters strategic thinking by integrating maintenance planning with energy management principles and asset lifecycle optimization. Participants will explore how maintenance decisions influence mean time between failures (MTBF), total cost of ownership (TCO), and safety performance indicators.
Several key highlights are seamlessly embedded in the learning journey to ensure maximum impact:
Clear understanding of pump and compressor types, working principles, and their typical failure patterns.
Identification and mitigation of lubrication, wear, and component fatigue issues using structured approaches.
Application of predictive maintenance strategies such as vibration and temperature monitoring to preempt equipment breakdowns.
Systematic troubleshooting frameworks that minimize downtime and improve asset availability.
Strategic maintenance planning tools to reduce mean time to repair (MTTR) and improve workforce efficiency.
Interpretation of condition monitoring data to support informed decision-making and optimize performance.
Insights into real-world case studies focused on reducing energy waste and extending equipment life expectancy.
By the end of the course, participants will be better equipped to diagnose system inefficiencies, reduce failure rates, and align maintenance efforts with business objectives—contributing directly to operational excellence.

Key Takeaways:

  • Clear understanding of pump and compressor types, working principles, and their typical failure patterns.
  • Identification and mitigation of lubrication, wear, and component fatigue issues using structured approaches.
  • Application of predictive maintenance strategies such as vibration and temperature monitoring to preempt equipment breakdowns.
  • Systematic troubleshooting frameworks that minimize downtime and improve asset availability.
  • Strategic maintenance planning tools to reduce mean time to repair (MTTR) and improve workforce efficiency.
  • Interpretation of condition monitoring data to support informed decision-making and optimize performance.
  • Insights into real-world case studies focused on reducing energy waste and extending equipment life expectancy.
  • Clear understanding of pump and compressor types, working principles, and their typical failure patterns.
  • Identification and mitigation of lubrication, wear, and component fatigue issues using structured approaches.
  • Application of predictive maintenance strategies such as vibration and temperature monitoring to preempt equipment breakdowns.
  • Systematic troubleshooting frameworks that minimize downtime and improve asset availability.
  • Strategic maintenance planning tools to reduce mean time to repair (MTTR) and improve workforce efficiency.
  • Interpretation of condition monitoring data to support informed decision-making and optimize performance.
  • Insights into real-world case studies focused on reducing energy waste and extending equipment life expectancy.

Course Objectives

After completing this Pideya Learning Academy training, the participants will learn:
Fundamental operating principles of industrial pumps and compressors.
How to recognize and differentiate various pump and compressor types in service.
Predictive maintenance methodologies including condition-based monitoring and diagnostics.
Effective troubleshooting and fault detection techniques for rotating equipment.
Methods to reduce downtime and energy consumption through improved maintenance strategies.
Identification of common wear and lubrication issues and how to mitigate them.
Selection and management of spare parts and component replacement schedules.

Personal Benefits

Advanced technical knowledge in pump and compressor systems maintenance.
Confidence in using diagnostic tools and interpreting maintenance data.
Skill development in maintenance scheduling and troubleshooting.
Ability to contribute to higher reliability and lower operational risk.
Enhanced value as a maintenance professional within the organization.

Organisational Benefits

Reduced unplanned downtime and improved equipment availability.
Lower energy and maintenance costs through predictive and preventive strategies.
Enhanced performance of pumps and compressors with optimized asset life cycle.
Improved team capability in identifying and resolving equipment faults efficiently.
Strengthened compliance with maintenance safety standards and operational best practices.

Who Should Attend

This course is ideal for:
Mechanical, plant, and maintenance engineers.
Process engineers and reliability professionals.
Maintenance technicians and supervisors responsible for pumps and compressor operations.
Technical personnel involved in asset integrity, operations support, or equipment reliability.
Facility managers and professionals tasked with maintenance planning and energy efficiency.

Course Outline

Module 1: Fundamentals of Industrial Pump Systems
Classification and operational principles of pump systems Centrifugal, positive displacement, and vertical pump applications Hydraulic principles: pressure head, velocity head, and head loss Hydraulic disturbances due to casing and system layout Impeller configurations and hydraulic balancing concepts Bearing classifications and lubrication fundamentals Pump system component overview: mechanical and hydraulic Energy conversion principles in pump operation
Module 2: Installation, Commissioning, and Operational Integrity of Pumps
Site preparation and leveling techniques for pump installation Integration with piping systems and mechanical interfaces Power transmission and energy efficiency metrics Calculating brake horsepower and system energy costs Alignment strategies: soft foot, vibration analysis, frequency mapping Use and maintenance of alignment tools and instruments Lubrication systems: selection of oils and greases Pump commissioning checks and documentation standards
Module 3: Diagnostic Techniques and Condition-Based Maintenance for Pumps
Common pump faults and failure indicators Loss of capacity: root cause analysis Predictive maintenance planning and scheduling Failure mode analysis and historical data utilization Lubrication monitoring and oil analysis Vibration diagnostics for early fault detection Maintenance tools selection and calibration Best practices in maintenance reporting and recordkeeping
Module 4: Rotating Equipment Maintenance: Motors, Bearings, and Couplings
Electric motor diagnostics: overheating, single phasing, insulation breakdown Bearing maintenance: identification, lubrication, removal, and replacement Coupling systems: types, precision alignment, and fault detection Introduction to vibration and thermal analysis tools Troubleshooting strategies for rotating machinery Motor-bearings alignment and critical inspection techniques
Module 5: Blowers and Mechanical Seal Technology
Classification and operation of blowers in industrial systems Preventive maintenance strategies for blower units Mechanical seal types and selection criteria Packed glands vs. mechanical seals: usage and replacement Seal failure diagnosis and reliability assessment Procedures for mechanical seal replacement Fluid sealing systems: design and maintenance protocols
Module 6: Industrial Compressor Technologies and Applications
Compressor classification: centrifugal, reciprocating, screw, axial, scroll Technical parameters: thermodynamics, flow rates, and efficiencies Limitations and suitability of various compressor types Compressor internals: rotors, diaphragms, impellers, casings Gland systems and seal arrangements in compressors Compressor balancing techniques and critical tolerances
Module 7: Compressor Installation and Alignment Techniques
Compressor installation: requirements and structural support Alignment methods: dial gauge, laser alignment, and thermal growth Cold vs. hot alignment: procedures and verification Support structures and foundation considerations On-stream monitoring and deviation corrections Frame load analysis and stage-by-stage performance assessment
Module 8: Selection and Sizing of Compressors
Selection criteria for centrifugal and screw compressors Use of characteristic curves and volumetric efficiency calculations Stability parameters in multi-stage compressors Application-specific compressor selection considerations Calculations for process load, frame load, and energy use Advantages and disadvantages of screw compressors
Module 9: Troubleshooting Strategies for Pumps and Compressors
Root cause analysis for mechanical and operational failures Identifying and resolving design-related issues Troubleshooting heat build-up, vibration, and noise Troubleshooting process capacity shortfalls and flow disruptions Case studies on compressor and pump failure modes Utilizing maintenance history for predictive troubleshooting
Module 10: Maintenance Planning and Technical Documentation
Developing a structured maintenance strategy Documenting inspection results and technical findings Maintenance manuals: usage and updates Leveraging OEM resources and databases Spare parts management and lifecycle analysis Maintenance performance metrics and decision support systems

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