Design, Operation and Maintenance of Process Pumps

4-day In-Classroom | Multiple cities and dates available

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Participants will leave the training with specific knowledge to eliminate mysterious pump failures, improve the running time and service life on a population of industrial pumps.

Learn why improper pump specification results in:

  • Unnecessary capital costs
  • Large long-term energy losses
  • Reduced pump reliability
  • Elevated maintenance costs
  • Reduced operation time
  • Poor hydraulic performance
  • Discover the key elements necessary to avoid these negative effects

Learn a troubleshooting approach that avoids TRIAL AND ERROR

Course Objective:

  • Find out how to focus on the real problem
  • Save wasted effort on unnecessary pump & motor repairs
  • Quickly determine a pump’s performance
  • Correlate pump reliability and hydraulic performance
  • Visually assess bearing & seal service
  • Predict time to probable component failure
  • How to properly install and commission a pump
  • Optimize mechanical seal service life
  • Optimize bearing life
  • Improve power train (motor, coupling, pump) efficiency
  • Predict pump performance changes with variable speed motors

Locations and Dates:

  • Houston, TX: 4-day event - Nov 5-8, 2018
  • Houston, TX: 4-day event - Mar 4-7, 2019
  • New Orleans, LA: 4-day event - Jun 3-6, 2019

* For other dates and cities or for in-company training contact us at [email protected] with details about your needs.

The course will be conducted over four consecutive days at a conveniently located conference center or hotel. Continental breakfast, lunch, mid-morning and mid-afternoon refreshments is included.



  • How do Pumps Work?
  • Pressure Measurement
  • Atmospheric Pressure (ATM)
  • Absolute Pressure
  • Gauge Pressure
  • Vacuum
  • Pump Head vs. Pressure
  • Specific Gravity
  • Pressure Measurement
  • Pressures inside the Pump
    • Suction Pressure
    • Discharge Pressure
    • Seal Chamber Pressure
  • Total Head
    • Suction Head
    • Discharge Head
    • Suction Lift



  • Definition of NPSHr (Required)
  • Definition NPSHa (Available)
  • Properties of Water
  • Atmospheric and Barometric Pressure Readings at Different Altitudes
  • Vapor Pressure


  • Vapor Pressure Definition
  • Cavitation Definition
  • The Effects of Vapor Pressure on Pump Performance
  • Cavitation: A Practical Discussion
    • Holes in the liquid (Cavitation)
  • Three recognized types of cavitation
    • Vaporization Cavitation
    • Internal Re-circulation
    • The Vane Passing Syndrome
  • Two conditions that mimic cavitation
  • Review for Preventing Cavitation
    • Increase the NPSHa
    • Reduce the Pump’s NPSHr


  • The Affinity Laws and Speed
  • The Affinity Laws and the Impeller Diameter
  • Practical Applications of the Laws


  • Energy, Work, Power, BHp, kW
  • Pump Efficiency
  • Factors that Affect the Efficiency
  • Calculating Pump Efficiency


  • Positive Displacement Pumps
    • Isaac Newton and Viscosity
    • Rotary PD Pumps
    • Reciprocating PD Pumps
    • Volute Pumps
    • Diffuser Pumps
    • Concentric Centrifugal Pumps
    • Specific Duty Pumps
    • ANSI-American National Standards Institute Specification
    • API (American Petroleum Institute) Specification
    • Vertical Pumps
    • Non-Metallic Pumps
    • Magnetic Drive Pumps
    • Canned Motor Pumps
  • Centrifugal Pumps
  • Pump Impellers
    • Enclosed Impellers
    • Semi-open Impellers
    • Open Impellers
    • Special Duty Impellers
  • Suction Specific Speed, Nss
    • Pump operation window
  • Specific Speed, Ns
    • Radial Force and Impeller Design


  • Head and Pressure
  • H-Q, Head-Flow
  • Pump Efficiency
  • The Power Curve
  • The Pump’s Minimum Requirements (NPSH)
  • MCSF-Minimum Continuous Stable Flow


  • The System Controls the Pump
  • The Elements of the Total Dynamic Head (TDH)
    • Determining the elevation differential (Hs)
    • Determining the pressure differential (Hp)
    • Calculating velocity and friction losses (Hv and Hf)
      • The Hazen and Williams Formula
      • The Darcy/Weisbach Formula
      • The Bachus & Custodio Formula
    • Pipe and Accessories Friction Constants
  • TDH Calculation
  • The Dynamic System and Pump Operation
  • Parallel Pumps vs Alternating Pumps
  • Pumps in Parallel and Pumps in Series
  • Combined Parallel and Series Pump Operation
  • Simple Pipe Systems
  • Complex Pipe Systems


  • 60° y 240°
  • Operation and Design induced Shaft Deflection
  • Interpreting the Evidence of Shaft Deflection
  • The Sweet Zone
  • The Double Volute Pump


  • Types of Misalignment
    • Vertical Angular Misalignment
    • Vertical Parallel Misalignment
    • Horizontal Angular Misalignment
    • Horizontal Parallel Misalignment
  • Alignment Techniques
    • Reverse Dial Indicator Alignment
    • Rim and Face Alignment
    • Laser Alignment
  • General Observations on Alignment
    • Alignment Intervals
    • Eliminate Pipe Strain
    • Soft Foot
    • Equipment Alignment Sequence
  • Simple, Self-aligning and Spacer Coupling


  • Bearing Lubrication
    • Oil Lubrication
    • Grease
  • Bearing Failure
  • Bearing Temperature
  • Bearing Seals
    • The Mechanical Seal for Bearings
    • The Labyrinth Seal
    • The Lip Seal


  • History
  • Packing composition
    • Natural Fibers
    • Mineral Fibers
    • Synthetic Fibers
    • Lubricants
    • Fillers
  • Braiding
    • Square Braid
    • Inter-braid
  • Packing for Reciprocating Shafts
  • Packing for Rotary Shafts
  • The Lantern Ring
  • Packing Lubrication
  • Stages in the Life of Packing
  • Proper Packing Techniques


  • History of the Mechanical Seal
  • The Modern Mechanical Seal
    • The Single, Inside Mounted Seal
    • The Single, Outside Mounted Seal
  • Seal Balance
  • Secondary Seals, O-rings, Gaskets
  • Cartridge Mechanical Seals
  • Cartridge Double Seals
    • Tandem, Back-to-Back, Face-to-Face Dual Seal
  • Support Systems for Dual Seals
    • Thermal Convection Tank
    • The Pumping Unit


  • Maintenance induced Seal Failure
  • Operation induced Seal Failure
  • Design induced Seal Failure
  • Secondary Seal Failure
    • Common O-Ring Compounds
    • Chemical Attack
    • Extrusion
    • Compression Set
    • Ozone Attack
    • Nicks and Cuts
    • The Elastomer Vulcanizes to the Shaft
  • The Springs Clog and Jam
  • Shaft Fretting
    • The O-ring Seal rides in Fret Groove
  • Incorrect Installation Dimension
  • Environmental Controls for Difficult Pumps and Seal Applications
  • Difficult Pumping Applications
  • Environmental Controls
    • Suction Bypass
    • External Flush
    • Thermal Jacketed Seal Chamber
    • Slurry Seal with Evacuation Line
    • Quench and Drain
    • Heat Exchanger
    • Double Mechanical Seal
  • Difficult sealing situations
    • Crystallization
    • Liquids that Solidify
    • Vaporizing Liquids, Gases
    • Film or Skin Formation
    • Very High Temperature
    • Non-Lubricating Liquids
    • Dry Running the Pump
    • Dangerous Liquids
    • Slurries and Suspended Solids
    • Cryogenics
    • Corrosive Liquids
    • Very High Pressures
    • Extremely High Velocity Shaft Speed


  • Suction Piping
  • Draining Tanks
    • Submergence Laws
    • Vortices
    • Air Entrainment
    • The Waterfall Effect
  • Suction Pipe, Elbows, Valves, and Fittings
  • Incline into the Pump
  • Suction Nozzle Piping
  • Discharge Piping
  • Don’t Lose the Energy in the Pipe
  • Filters and Strainers
  • Pipe Runs
  • Altering the System
  • Adding New Devices
  • Balance and Attenuate the System after Alterations

Who should take this course:

  • Plant Engineers,
  • Consulting Engineers,
  • Maintenance Managers,
  • Instrumentation Technicians,
  • Pump Operators,
  • Mechanical Foremen and
  • Process Engineers.

Your Instructor

Larry Bachus
Larry Bachus

Larry Bachus has over 40 years experience working with industrial pumps. His areas of expertise include diagnosing pump problems and seal failures. He has taught pump and seal improvement courses at many major plants and industries all over the world.

Larry began his work career as a pump mechanic apprentice in a southern steel mill. He continued working on pumps while serving in the US Navy. After completing his military service, Larry graduated from the University of Alabama in Birmingham. He worked selling and installing pumps, while designing his own products at night. For a period of time, Larry ran his own pump rebuild shop. He began incorporating some of his original ideas to improve the service life of the pumps. Larry incorporated his own company in 1988 after developing a tool that broke the code on identification of rubber compounds used in o-rings and other seals and gaskets. Today, this tool is the standard in the industry.

At first Larry lectured on how to correctly rebuild pumps and seals. Over the years the courses have taken another tack. Nowadays the lectures are dedicated toward how to STOP rebuilding pumps and seals by recognising maintenance, operational and design errors and identifying and eliminating the factors that lead to failure of process pumps. Larry has authored a book on pump theory, design and maintenance. The book is titled: “Know and understand Centrifugal pumps” and is published by Elsevier Science. Larry published his own version of the book in Spanish.

Larry has taught as adjunct faculty at Cumberland University and also at the Tennessee Technological Center. He is an active member of the ASME. When not teaching, Larry lives in Tennessee, where he continues inventing new products.

Class Curriculum

  Welcome to the course
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  Course Feedback
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  Completion Certificate
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Frequently Asked Questions

What are the dates and locations for this event?
This event is available for multiple locations and dates included in the course description
What's the cancellation/refund policy?
If you cancel or request a refund up to 90 days from training date, you will receive 100% of your payment back minus any transaction costs (credit card, wire transfer, stripe or paypal charges). If you cancel or request a refund up to 60 days from training date, you will receive 60% of your payment back minus any transaction costs (credit card, wire transfer, stripe or paypal charges).. If you cancel or request a refund up to 30 days from training date, you will receive 30% of your payment back minus any transaction costs (credit card, wire transfer, stripe or paypal charges). No refunds or cancellation allowed less than 30 days from sessions first day. Cancellations can only be requested via email to [email protected] . Please understand that courses have a minimum number of students required to cover instructor costs and we may cancel events that don't reach the threshold. Before making travel arrangements contact us at [email protected]
What's covered in the course price?
We will cover: - Instructor-led training as outlined in the course description. - Material - Breakfast, Lunch and Snacks - Completion certificate
Where will the training take place?
If an exact location is not yet included within the course description, it will be released in a timely manner. Facilities are usually in a convenient location near energy hubs or airports.
How can I signup multiple people?
You can email [email protected] and we will create a bulk order for your convenience.
Is this course available for in-company training?
Yes, We can bring the instructor to your facility. Please contact us at [email protected] and we can coordinate.

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