DAY 1 — FUNDAMENTALS OF PUMP HYDRAULICS
What is a pump?
Centrifugal vs Positive displacement pumps
How pumps actually work
System resistance concept
Static head vs friction head
Differential head understanding
Flow vs pressure relationship
Pump operating philosophy
Real field failures caused by hydraulic misunderstanding
Practical Understanding:
Why pumps fail even after correct selection
Hydraulic behavior in real plants
DAY 2 — SUCTION SIDE ENGINEERING & NPSH
NPSH Available vs NPSH Required
Cavitation mechanism
Suction line sizing criteria
Suction velocity limitations
Eccentric reducer philosophy
Air pocket formation
Straight length requirements
Negative suction systems
Suction vessel hydraulics
Real Case Studies:
Cavitation troubleshooting
Seal failure due to suction issues
Noise & vibration diagnosis
DAY 3 — DISCHARGE SIDE & SYSTEM CURVE ANALYSIS
Discharge pressure calculations
System curve generation
Pump curve interpretation
Operating point determination
Control valve effects
Parallel pump operation
Series pump operation
Minimum flow philosophy
Shut-off head understanding
Real Plant Learning:
Why pumps operate away from BEP
How wrong discharge philosophy damages pumps
DAY 4 — PUMP SIZING & SELECTION (EPC STYLE)
Design flow determination
Design margins
Hydraulic calculations
Differential pressure calculations
Density & viscosity effects
Temperature impact
Pump type selection philosophy
API vs ANSI pump selection
Multi-stage vs single-stage selection
Pump efficiency evaluation
Industrial Approach:
Real EPC sizing methodology
Vendor interaction philosophy
DAY 5 — PUMP TROUBLESHOOTING MASTERCLASS
Cavitation
Vibration analysis
Seal failures
Bearing overheating
Low flow problems
Motor overloading
Recirculation issues
Air entrainment
Hydraulic instability
Chronic plant failures
Real-Time Troubleshooting:
Rajasthan plant case study
Distillation plant failures
Ethanol recovery pump problems
Real P&ID troubleshooting logic
DAY 6 — VENDOR DOCUMENT REVIEW & TECHNICAL BID EVALUATION (TBE)
Pump datasheet review
Vendor offer review
Technical compliance check
Deviation identification
Pump curve verification
NPSH verification
Motor sizing review
Mechanical seal review
API compliance understanding
Technical Bid Evaluation (TBE)
Practical Industry Exposure:
How EPC companies evaluate vendors
How to identify hidden technical risks
DAY 7 — EXCEL SHEET DESIGN FOR PUMP ENGINEERING
Building pump sizing sheets
Hydraulic calculation automation
Line pressure drop calculations
NPSH calculation logic
Differential head calculations
Pump power calculations
System pressure logic
Excel formula structuring
Engineering sheet development philosophy
Advanced Understanding:
Real engineering workflow
How professionals develop reusable engineering tools
