This in-depth three-day training program provides a comprehensive, hands-on education in the installation, maintenance, and overhaul of industrial pumps per API Standard 610. Designed to meet the stringent requirements for marine and LNG/LPG applications, this extended course allows for deeper exploration of critical engineering principles and advanced practical skills. Participants will master the intricacies of pump types—including between-bearing and vertically suspended designs—and develop expert-level competency in mechanical seal technology.
The curriculum progresses from fundamental performance analysis and material science to advanced repair techniques, precision assembly, and systematic commissioning. The additional day facilitates extensive hands-on workshops, detailed case studies on cavitation and vibration, and a complete simulation of pump calibration and reporting. This course is engineered to certify and empower technical teams with the knowledge and practical confidence to execute all pump-related work to the highest standards of reliability, safety, and client/classification society approval.
COURSE OBJECTIVES
Upon successful completion of this course, participants will be able to:
- Interpret and apply API Standard 610 requirements to the selection, installation, and maintenance of between-bearing and vertically suspended pumps.
- Perform detailed pump performance analysis, including flow and head calculations, and interpret characteristic curves for system integration.
- Identify causes of cavitation and vibration, implement mitigation strategies, and understand the application of protective coatings in the flow area.
- Execute advanced shaft repair procedures, including the methodology for undersize repair with Heat Treatment (HT).
- Correctly install bearings and mechanical seals by interpreting engineering drawings and performing necessary load and pressure calculations.
- Conduct systematic pump disassembly, inspection, and precision reassembly, ensuring all clearances and alignments meet specification.
- Plan and execute complete pump pre-commissioning, commissioning, and calibration procedures, including performance testing.
- Generate accurate and comprehensive technical reports and calibration documentation in soft copy format compliant with operational and class standards.
COURSE METHODOLOGY
At Intelliness, our training methodology is built around delivering meaningful learning experiences that translate into real workplace capabilities. Each program is carefully engineered to blend theory with practice, ensuring participants not only understand the concepts but can confidently apply them on the job.
Engaging Learning Environment
Sessions are conducted using real case studies, scenario-based discussions, and collaborative activities that encourage critical thinking and practical problem-solving.
Practical Skill Application
Participants take part in structured hands-on exercises and simulations designed to mirror real operational challenges, enabling them to develop confidence through doing—not just listening.
Smart Learning Tools
Our programs leverage modern digital platforms, including LMS-based modules, interactive content, and online resources that support flexible learning and continuous progress monitoring.
Ongoing Evaluation & Guidance
Regular checkpoints, quizzes, and facilitator feedback help track understanding, close knowledge gaps, and ensure each learner progresses at the right pace.
After-Training Reinforcement
To promote long-term retention, we provide post-training materials, optional follow-up sessions, and access to expert guidance, ensuring learners can continue applying their skills effectively beyond the classroom.
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Module 1: Introduction to API Standard 610 & Pump Principles-
- Scope and requirements of API 610 for centrifugal pumps.
- Detailed comparison of Between-Bearing (BB) and Vertically Suspended (VS) pump designs, including applications for LNG/LPG.
- Pump hydraulic fundamentals: understanding head, flow, NPSH, and system curves.
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Module 2: Pump Performance & System Analysis
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- Hands-on session: Calculating pump flow in and out and interpreting performance data.
- Understanding affinity laws and their impact on pump operation and selection.
- Workshop: Matching a pump to a system curve using provided data sets.
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Module 3: Advanced Failure Analysis & Material Technology
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- Cavitation: Mechanisms (incipient vs. damaging), identification, and design/operational solutions.
- Vibration Analysis: Theory, causes of vibration, and hands-on vibration point marking on a pump casing.
- Material Science: Selection of casing/impeller materials and the purpose/application of protective coatings in the flow area.
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Module 4: Mechanical Seal Mastery
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- In-depth study of seal types, arrangements (single, double, tandem), and selection criteria per API 682.
- Seal failure modes and root cause analysis (RCA) techniques.
- Principles behind seal re-tightening procedures and pressure calculations.
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Module 5: Advanced Component Repair Techniques
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- Shaft Repair Workshop: Detailed methodology for undersize repair with HT (Hardening/Treatment), including machining limits and inspection.
- Bearing technology: types, failure analysis, and the principles of bearing placement according to drawing specifications and load respect.
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Module 6: Hands-On Workshop I – Systematic Disassembly & Inspection
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- Safe and systematic disassembly of a BB or VS pump.
- Detailed inspection of components: shaft runout, impeller wear, casing erosion, and wear ring clearances.
- Documenting inspection findings and determining repair requirements.
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Module 7: Hands-On Workshop II – Precision Reassembly
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- Step-by-step reassembly focusing on critical tolerances.
- Practical session: Installing bearings with correct fits and pre-load.
- Practical session: Installing a mechanical seal using proper tools, following drawings, and applying calculated seating forces.
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Module 8: Commissioning, Calibration & Performance Testing
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- Pre-commissioning checks: alignment (laser demonstration), lubrication, and system flushing.
- Commissioning procedure: safe startup, operational monitoring, and performance data collection.
- Pump calibration: methods for calibrating flow, pressure, and temperature instrumentation; creating a calibration report.
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Module 9: Troubleshooting, Reporting & Final Certification
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- Interactive case studies on common field problems (e.g., low flow, overheating, seal leaks).
- Developing a comprehensive final work report (soft copy form) including all test data, parts used, and calibration certificates.
- Course review, final assessment, and discussion on achieving client and class approval for yard work.
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