Reliability & Maintenance
Compressors & Pumps — Operation, Troubleshooting and Maintenance
Operating principles, performance curves, failure modes, troubleshooting method and maintenance strategy for industrial pumps and compressors — taught from real vibration data, curves and failed components.
Industry focus: Power Generation & Electrical Engineering
Who Should Attend
Designed for these roles
- Rotating equipment, mechanical and maintenance engineers
- Operations engineers and senior technicians running critical machines
- Reliability engineers addressing repeat pump and compressor failures
- Planners and supervisors specifying overhaul scope
Delivery formats
- Customised in-house training at your plant or office
- Public classroom delivery, subject to schedule
- Live online delivery where suitable
- Recommended group size: 8–20 participants
Problems Solved
What this course fixes
Pumps run far from best efficiency point and fail repeatedly
Cavitation, recirculation and dry running misdiagnosed as bearing defects
Compressor surge and fouling managed by trip resets rather than analysis
Overhaul scopes copied from the last outage regardless of condition
Learning Outcomes
What participants can do after the programme
Outcomes are written as tasks, not topics — so managers can verify capability back at work.
- Read and use pump and compressor performance curves, including NPSH margin
- Diagnose cavitation, recirculation, imbalance, misalignment and looseness from symptoms and data
- Explain surge, stonewall and anti-surge control on centrifugal compressors
- Set condition monitoring and maintenance tasks matched to failure modes
- Build a defensible overhaul scope from condition evidence
Course Outline
Detailed programme content
Day 1 — Pumps
- Centrifugal and positive displacement types and selection
- Curves, system head, operating point and NPSH
- Seals, bearings, lubrication and installation practice
Day 2 — Compressors
- Centrifugal, screw and reciprocating machines
- Surge control, staging, intercooling and fouling
- Auxiliaries: lube oil, dry gas seals, drivers and couplings
Day 3 — Troubleshooting & Strategy
- Structured troubleshooting from vibration and process data
- Failure mode driven maintenance task selection
- Workshop: participant failure cases analysed as a group
Practical Work
Practical exercises and case studies
Sessions are built around calculations, data interpretation and technical decisions. Case material is generic or anonymised — no client-confidential project data is used.
Pump curve and system head exercises, including NPSH margin checks
Diagnosing cavitation, recirculation, misalignment and imbalance from symptom sets
Compressor surge control walkthrough using representative maps
Troubleshooting workshop on participant failure cases
Trainer Profile
Delivered by Sathish Kumar
Senior Trainer — Reliability, Maintenance & Rotating Equipment
19 years industry experience
Sathish builds maintenance strategies that survive contact with a real budget. His workshops use participants' own failure history, so teams leave with a revised task list rather than a certificate alone.
Real project exposure
- RCM implementation across critical pumps and compressors at a combined-cycle power plant
- Root cause failure analysis on repeat bearing failures in a boiler feed pump train
- Spare parts and criticality review for a palm oil refinery group
Certifications
- CMRP — Certified Maintenance & Reliability Professional
- Vibration Analyst Category III (ISO 18436-2)
- RCM2 Practitioner
Trainer allocation is confirmed in your proposal. Substitute trainers hold equivalent certification and sector experience.
Next Step
Run this programme for your team
We will confirm available dates, trainer, duration and HRD Corp claimable investment — and adjust the outline to your equipment and standards at no extra cost.
No obligation. Proposals include HRD Corp claim guidance.
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