Participants will learn to:

• Identify and select appropriate pumps and piping for various chemical processes
• Analyze and optimize fluid transfer systems based on process requirements
• Understand failure mechanisms, reliability practices, and material selection
• Apply API, ASME, and chemical industry standards in pump and piping design
• Implement troubleshooting, monitoring, and energy-saving measures

  Who should attend:

• Mechanical, Process, and Design Engineers
• Maintenance & Reliability Engineers
• Plant Supervisors and Technical Staff
• Project Engineers in chemical and industrial sectors
• Piping Designers and Inspectors

Target Competencies:

• Pump and piping system integration
• Material compatibility and corrosion resistance
• Energy efficiency and system diagnostics
• Standards compliance (API, ASME, NACE)
• Failure prevention and lifecycle cost analysis

Training Deliverables:

• Course workbook & piping/pump engineering guide
• API/ASME/NACE standards summary sheets
• Sample troubleshooting checklist & RCA template
• Pump selection and sizing spreadsheet
• Certificate of Completion

Day 1 – Pump Fundamentals for Petrochemical Applications

• Pump classifications and functions in chemical plants
• Centrifugal vs. Positive Displacement: pros & cons
• API 610: Standards for centrifugal pumps
• Pump performance curves and system matching
• Chemical compatibility and sealing systems

 Exercise: Select suitable pump types for 3 different petrochemical fluids

Day 2 – Piping Systems and Flow Design

• Pipe materials: Carbon steel, stainless, alloys, lined pipes (PTFE, FRP)
• Pressure drop, flow velocity, and pipe sizing
• Design for thermal expansion, vibration, and support
• Valve types and placement for process safety
• Piping codes: ASME B31.3, ANSI, ASTM

 Workshop: Calculate pressure drop for a high-viscosity fluid transfer line

Day 3 – System Integration, Hazards & Control

• Suction conditions and cavitation prevention
• Net Positive Suction Head (NPSH) and pump location
• Relief systems, back-pressure control, and anti-surge setups
• Corrosive and hazardous service: double seals, magnetic drive
• Flammable and toxic service considerations

 Activity: Create a system layout that includes tank, pump, valve, and safety devices

Day 4 – Troubleshooting, Reliability & Maintenance

• Root cause analysis of pump and pipe failures
• Common failures: seal leaks, misalignment, erosion, fatigue
• Predictive maintenance tools: vibration, thermography, ultrasonic
• Asset integrity & reliability-centered maintenance (RCM)
• Condition-based vs. time-based maintenance strategies

 Case Study: Analyze failure data to propose a preventive maintenance schedule

Day 5 – Energy Efficiency, Smart Monitoring & Best Practices

• Energy losses in piping and pumping systems
• Variable Speed Drives (VSDs) and efficiency tuning
• Digital monitoring systems and remote diagnostics
• Lifecycle cost analysis of pumps and piping networks
• Wrap-up, Q&A, and group presentation of system design

 Final Exercise: Redesign an inefficient system using performance and failure data

CDGA attendance certificate will be issued to all attendees completing a minimum of 75% of the total course duration