Course Objectives:

By the end of the program, the trainee will be able to:

• Explain common causes of pump mechanical failure.
• Identify symptoms of pump cavitation.
• Identify symptoms of pump misalignment.
• Identify symptoms of pump imbalance.
• Diagnose common bearing failure modes.
• Identify causes of premature bearing wear.
• Interpret vibration patterns linked to bearing defects.
• Explain the role of lubrication in machinery reliability.
• Identify causes of lubrication failure (contamination, degradation, insufficient/excess lubricant).
• Select appropriate lubricant type and application method.
• Apply a structured troubleshooting approach to pump/bearing problems.
• Identify seal-related failure symptoms.
• Recognize early warning signs through condition monitoring.
• Apply preventive actions to extend equipment life.

Course Outlines:

• Introduction to Mechanical Troubleshooting
  • Importance of reliability in rotating equipment
  • Cost impact of pump/bearing failures
  • Overview of troubleshooting methodology

  Pump Fundamentals and Failure Modes

  • Centrifugal pump operating principles
  • Common causes of pump failure
  • Cavitation: causes and symptoms
  • Misalignment effects on pumps
  • Imbalance effects on pumps
  • Suction and discharge system issues

  Bearing Fundamentals and Failure Analysis

  • Types of bearings (rolling element, journal/sleeve)
  • Common bearing failure modes (fatigue, wear, corrosion, electrical damage)
  • Causes of premature bearing failure
  • Bearing defect frequencies and vibration signatures
  • Bearing installation and handling best practices

  Lubrication Principles

  • Purpose and function of lubrication
  • Types of lubricants (oil vs. grease)
  • Lubricant selection criteria
  • Lubrication methods (manual, automatic, oil mist, circulating systems)
  • Common lubrication failures: contamination, degradation, over/under-lubrication
  • Oil analysis basics

  Seals and Auxiliary Components

  • Mechanical seal types and functions
  • Common seal failure symptoms
  • Gland packing considerations

  Troubleshooting Methodology

  • Structured troubleshooting approach (symptom → root cause → corrective action)
  • Common troubleshooting tools (vibration analysis, thermography, oil analysis)
  • Case-based troubleshooting scenarios

  Condition Monitoring and Preventive Strategy

  • Vibration monitoring basics
  • Temperature and noise monitoring
  • Preventive vs. predictive maintenance approaches
  • Building a reliability improvement plan

Who Can Benefit?

• Electrical, mechanical, and chemical Engineers
• Senior technicians who work in the electrical control and power utilities
• Technicians who would like to refresh their knowledge
• Mechanical and chemical Engineers who are interested in control subjects

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