Maintenance of pump

INTRODUCTION.
This discussion covers the operation and maintenance of
pumps used in water supply and treatment facilities.
It also covers the motors, engines, and accessories
(together called pump drivers) that provide the mechanical
source of energy to pumps

1
 WHAT IS MAINTENANCE
• maintenance is a set of organized activities that are
carried out in order to keep an item
Types of Maintenance
1. Run to Failure Maintenance (RTF)
2. Preventive Maintenance (PM)
3. Corrective Maintenance (CM)
4. Improvement Maintenance (IM)
5. Predictive Maintenance (PDM in its best
operational condition with minimum cost acquired.
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1. Run to Failure Maintenance (RTF)
• The required repair, replacement, or restore action
performed on a machine or a facility after the occurrence of
a failure in order to bring this machine or facility to at least
its minimum acceptable condition.
• It is the oldest type of maintenance.
 It is subdivided into two types:
• Emergency maintenance: it is carried out as fast as possible
in order to bring a failed machine or facility to a safe and
operationally efficient condition.
• Breakdown maintenance: it is performed after the
occurrence of an advanced considered failure for which
advanced provision has been made in the form of repair
method, spares, materials, labour and equipment.
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 2 Preventive Maintenance (PM)
• . Preventive Maintenance It is a set of activities
that are performed on plant equipment,
machinery, and systems before the occurrence
of a failure in order to protect them and to
prevent or eliminate any degradation in their
operating conditions
3.Corrective Maintenance (CM)
• In this type, actions such as repair, replacement,
or restore will be carried out after the occurrence
of a failure in order to eliminate the source of this
failure or reduce the frequency of its occurrence.
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4 Improvement Maintenance (IM)

• It aims at reducing or eliminating entirely the need for

maintenance.
• This type of maintenance is subdivided into three types as
follows
• 1 Design-out maintenance which is a set of activities that
are used to eliminate the cause of maintenance, simplify
maintenance tasks, or raise machine performance from the
maintenance point of view by redesigning those machines
and their long term repair or replacement cost is very
expensive.
• 2. Engineering services which includes construction and
construction modification, removal and installation, and
rearrangement of facilities.
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• ….cont.
• 3. Shutdown improvement maintenance, which is a set of
improvement maintenance activities that are performed
while the production line is in a complete stoppage situation
5.Predictive Maintenance (PDM)
• Predictive maintenance is a set of activities that detect
changes in the
physical condition of equipment (signs of failure) in order to
carry out the
appropriate maintenance work for maximising the service life
of equipment
without increasing the risk of failure.
• It is classified into two kinds according to the methods of
detecting the signs
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It is classified into two kinds according to the methods of
detecting the signs
of failure:
1.Condition-based predictive maintenance
2.Statistical-based predictive maintenance
1.Condition-based maintenance predictive: depends on
continuous or
periodic condition monitoring equipment to detect the signs
of failure.
2.Statistical-based predictive maintenance: depends on
statistical data from
the meticulous recording of the stoppages of the in-plant
items and
components in order to develop models for predicting
failures.
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 What is a Pump
• A Pump is a mechanical device that uses to transfer different fluids
from one location to another.
• It is a hydraulic device that lifts fluids from low to high levels, moves
fluids from low to high-pressure areas.
• The pump transfers fluid by converting the fluid’s mechanical energy
into pressure energy (hydraulic energy)
• The hydraulic pump can also be utilized in processes that require high
hydraulic pressure.
• It can be observed with heavy equipment.
• In general, heavy equipment needs lower suction pressures and high
pressures of discharge.

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• …..cont.
• All pump have (an in let, out let, casing)
• During operation liquid enter the pump through the in let
location
 this side of the pump is also called the section side
The pressure of liquid is lower at the point
• The purpose of pump of casing is to contain the liquid inside
the pump during the operations
The casing housing all of the pump internal part
• The liquid leaves the pump through the out let
This side of the pump is also called discharging side
• The pressure of the liquid is higher at the point

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• ….cont.
• There are different types of pumps but two main
types of the pump are given below:
• 1. Positive Displacement Pump
• 2. Dynamic Pump
• 1) Positive Displacement Pump
• : Positive Displacement Pumps In these types of
pumps, the moving parts (gears, lobes, plungers,
pistons, and rotors) drain fluid from the pump
housing and increase the hydraulic pressure at the
same time.
• Therefore, a positive displacement pump does not
build up pressure.
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….cont.
• It just generates fluid flow.
• It also doesn’t need manual priming because it has the self-
priming capability.
• The positive displacement pumps further divide into the
three types.
1. rotary types of positive displacement pump
1.Gear pump
2.Screw pump
3. rotary pump
2.Reciproceting types of positive displacement pump
1. Piston Pump
2.plunger pump
3.diaphragm
3.Liner
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types of positive displacement 12
2. Dynamic Pump
• A dynamic pump transfers the fluid by increasing its
pressure as it passes through the impeller and diffuser.
• In this type, the impeller increases the speed of the fluid
and
• the diffuser converts this speed into pressure energy.
• It uses centrifugal force for the pumping of fluid.
• A dynamic pump further divides into two types
1. Centrifugal Pumps 2.special pump
• Radial Flow Pumps .cantilever pump
• Axial Flow Pumps . Jet pump
• Mixed Flow Pumps .turbine pump

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What Are the Symptoms of Water Pump Failure

1. .Leaks:
2. Abnormal noise:
3. Excessive vibration:
4. Corrosion:
5. Overheating:
6. Clogging:

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 Types of Pump Maintenance
• The pump maintenance has the following types:
1. Routine Maintenance
2. Annual Maintenance
3. Daily Maintenance
1.Routine Maintenance of Pump
Routine maintenance of the pump includes the
inspection of the following parts:
i) Bearing and Lubricant Condition
ii) Shaft Seal Condition
iii) Overall Pump Vibration
iv)Pump Discharge Pressure
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 I) Bearing and Lubricant
Condition
• Daily monitor and record bearing temperature,
lubricant levels, and vibrations.
• The lubricant must be clear and without foaming.
• If there are air bubbles, it means that your bearing
lubrication has a high temperature, and you must
add more lubricant to lower the bearing
temperature.
• If the bearing vibration increases, it may cause due
to the failure of your bearing, and you must replace
it immediately

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ii) Shaft Seal Condition
• It would be best if you regularly inspected the
mechanical seal of your pump.
• If there is any sign of leakage, it represents
that your shaft seal has been leaked.
• During the shutdown, check the packing of
the pump to ensure proper lubrication.
• If the stuffing box packing appears dry and
compressed, replace it and add lubricant
according to the instruction manual.

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iii) Overall Pump Vibration
 An impending pump failure can detect via monitoring the
entire pump vibration.
 Changes in pump alignment, bearing failure, cavitation, and
blockages in the suction and discharge lines can cause
excessive vibration.
 iv) Pump Discharge Pressure
 The total delivery pressure of the pump can be determined
from the pressure difference on the inlet and outlet pressure
gauges.
 Make sure the readings are within the pump’s design
performance range. You can search it on the manufacturer’s
website or in the operating instructions.

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2) Annual maintenance of Pumps
• Record the performance of the pump at least once a year.
• The bench marking data should contain at least motor amp
draw, flow rate, head pressure, and vibration for bearings.
• Before the maintenance of your pump, you must
disconnect the power source.
• Following are major parts of the pump that you should
inspect compulsory during the annual maintenance:
• Bearing Frame and Foot:
• Bearing Frame:
• Shaft and Sleeve:
• Casing:

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3) Daily Maintenance Checklist
• Daily inspect your pump for cavitation and noisy bearing
problems.
• Inspect the gaskets and casing for pressure leakage.
• Check the glands and packing for any steam leaks. There
should be no leakage of steam.
• Inspect the oil of the bearings for discoloration and water.
• Check the temperature of all bearings.
• Inspect the water-cooling system for efficient working.
• Check the temperature of the heat exchanger, jacket, and
cooler by touching them. Check oil ring and bearing via a
filling port. Wash covers of the bearings clean.
• Check the condition of the mechanical seal, and it should
be 01/10/2024
in normal 20
 • Maintenance issues of the Pump
• Problem found in the pump . Their solutions
• leak was found in the seal. .Broken seals should be
replaced.
• Rings & gaskets were torn. . Rings & gaskets needed to
be -replaced.
• Vibrations and noises. . Check for the bearing,
lubrication and shaft alignment.
• Water back flow due valve failure. . Check for the
condition of one-way valve.
• High power consumption . Electric components of motor
should be -repaired or the motor itself can be replaced.
• Increase in Temperature of motor. . Proper fan should be
used and - replaced if broken.
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Applications of Pumps
• These use to transmit water from one place to another
place.
• They use for fuel injection in different vehicles.
• Uses for cooling water purposes.
• For pumping gas or oil.
• It uses in the paper industry.
• Uses in the chemical industry

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 What is the function of pump?
• A pump uses to transfer the fluids from one location to
other.
• It just produces the fluid flow; it doesn’t produce pressure.
• A pump just generates the necessary fluid flow to develop
the pressure, which helps the pump transfer fluid from one
location to another.
• Why do water pumps fail?
• A water pump fails because of an imbalanced pump shaft
or erosion inside the cooling system.
• But in maximum cases, water pumps damage due to the
leakage of the shaft.

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 4. Pump Maintenance Schedule
• 4.1.Routine maintenance (Can be made during pump operation)
• Perform the following tasks whenever you perform routine
maintenance:
• Clean bearing bracket from any oil if found.
• Check oil drain plug.
• Lubricate the bearings.
• Inspect suction and discharge flanges for any leak.
• Inspect pump casing for any unusual damage signs.
• Inspect the seal.
• If the pump is offline check the coupling and its shims for
any damage.
• Make sure that the coupling guard s well tightened to
pump base plate.
• Check that motor alignment bolts are all in place.
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• Pump Maintenance in 7 Easy Steps
• Lubricants are the “Product of Choice” for Pump,
Hose & Seal Maintenance, Repair and Assembly
• When things are running smoothly it’s easy to
overlook common maintenance chores and
rationalize that it’s not worth the time to regularly
inspect and replace parts.
• But nothing could be farther from the truth.
• The reality is that most facilities have several
pumps performing a variety of functions that are
integral to the successful operation of the plant.
• If a pump malfunctions it can be the cause of an
entire plant shut down.
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To keep pumps running properly, a regular maintenance schedule
should be implemented and followed

1. Determine maintenance frequency

2 observation is key
3. Safety first
4. Mechanical inspection
 Check that mounting points are secure
 Inspect the mechanical seal and
packing
 Inspect the pump flanges for leaks
 Inspect the couplings
 Inspect and clean filters
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• 5 LUBRICATION.
• 6. ELECTRICAL/MOTOR INSPECTION
i. Check that all terminations are tight
ii. Inspect motor vents and windings for dust/dirt
build-up and clean according to manufacturer’s
guidelines
iii. Inspect starter/contractor for arcing,
overheating, etc.
iv. Use a me ohmmeter on the windings to check
for insulation failure
• 7. REPLACE DAMAGED SEALS AND HOSES

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