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
 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.
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.
 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.
 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.
• ….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
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.
 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.
• …..cont.
• The low pressure on the pump’s inlet side causes the liquid to rise from a
particular depth and the high pressure on the outlet side pushes the liquid
to the desired head.
• A pump has similar working to a compressor.
• The main difference between them is that they use different working fluids
• ….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.
….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 multiple
types.
• The classification of the positive displacement pumps is given below:
1.Diaphragm pump
2. Gear pump
3. Peristaltic pump
4. Lobe pump
5. Piston Pump
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 the below-given types
• Centrifugal Pumps
• Radial Flow Pumps
• Axial Flow
• Mixed Flow
2.2) Vertical Centrifugal Pumps
1 Horizontal Pumps
2. Submersible Pumps
3. Line-shaft Pump
What Are the Symptoms of Water Pump Failure.
1. .Leaks:
2. Abnormal noise:
3. Excessive vibration:
4. . Corrosion:
5. Overheating:
6. . Clogging:
 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
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
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.
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.
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:
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 working of the heat tracing.
• 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 in normal
 • 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.
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
 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.
 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.
•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.
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
• 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