Operation and Maintenance of Pump

WASA Tube well/Disposal Station

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Operation and Maintenance of Pump
• Operation of system
• Ensuring effective routine running of system timely and daily.
• Stability
• Efficient
• Safely

• Maintenance
• Keep of structures/system including planned
• Preventive or Corrective maintenance
• Repair
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Operation and Maintenance plan

Operation Record and • Keep a operational record continuously.

Manual • Prepare a O&M Manual (SOP).

Improvement of • Understand / follow the O&M Manual (SOP).

Operational Control • Detect any abnormalities and take measures.

Control of Water Amount • Establish a proper control method of equipment.

and Pressure • Prevent from water leakage.

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Operation and Maintenance Plan
• Preparation of O&M Plan
• Preparation of a plan involves list of routine tasks, specific tasks at
regular intervals including inspection of system (Daily, Weekly,
Quarterly, Annually etc.)

• Plan also involves a checklist for operation, supervision and

maintenance.

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 Standard Operating Procedure for Pump
• 1.Check on the panel door the 3 indicator lights are illuminated. If the indicator lights are
off check the position of Main breaker. Turning the main breaker On will illuminate the
indicator lights. But if the situation remains the same then there will be shut off from
Wapda’s side.
• 1.‫ں اگر اشارے ک یال ئٹسب ند ہ یںت و مین‬
‫ انڈیکیٹر ال ئٹسروشنہ ی ۔‬3 ‫پ ینل ک ے دروازے پ ر چیکک ریںک ہ‬
‫ب ریکر ک یپ وزیشنچیکک ری ۔ں مینب ریکر ک و آنک رنے س ے اشارے ک یروشنیاںروشنہو جائیںگ ۔ی ل یکن‬
‫ئی‬
‫اگر ص ورتحا لی ہیرہیت و واپڈا ک یطرفس ے س پالئیب ند ک ر دیگ ۔‬

• 2.Check the indicator light status of (Over Load Trip).

‫پ‬
( ‫ک ے اشارے ک یروشنیک و چیک)اوور ل وڈ ٹ ر‬
2. ‫ریں‬
‫ک ۔‬

• 3. Check the indicator light status of(Dry Running trip).

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) ‫ ک ے اشارے ک یروشنیک و چیکک ریں۔‬Dry Running trip)
Standard operating procedure
• 4.Check the indicator light status of (Earth leakage trip).

‫(اشارے کی روشنی کو چیک کریں۔‬Earth Leakage Trip)

• 5.You can only start the pump if all the above four indicator lights are in off state.In case
anyone of above light is in on state do inform the respective operation supervisor.

• ‫آپ پمپ کو صرف اس صورت میں شروع کر سکتے ہیں جب اوپر دی گئی چاروں اشارے کی الئٹس بند ہوں۔‬
‫اگر اوپر کی کوئی روشنی چل رہی ہو تو متعلقہ آپریشن سپروائزر کو مطلع کریں۔‬

• 6. Before Pump start check main braker on or not?

‫مین بریکر آن یا نہیں؟‬

• 7.The (Duty selector switch) is in ON position.

‫ڈیوٹی سلیکٹر سوئچ آن ہو۔‬ 6

Standard operating procedure

• 8.Power Factor switch should be on Auto position.

8.‫پاور فیکٹر سوئچ آٹوپوزیشن پر ہونا چاہئے۔‬

• 9.Before Starting the pump open valve of water lubrication tank and close it after
it goes empty.

‫پمپ کو چالنے سے پہلے باکس سے پانی لیں اور خالی ہونے کے بعد اسے بند کر دیں۔‬

• 10.Press ON(Green) button pump will start.

‫ )سبز) بٹن کو دبائیں پمپ چلنا شروع ہو جائے گا۔‬ON

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Standard operating procedure
• 11.After starting the pump, ON the Chlorine dosing pump to start the dosing of
Chlorine.

‫پمپ چالنے کے بعد کلورین پمپ چالئیں۔‬

• 12.After starting the main pump make sure the complete absence of abnormal noise
or vibration in motor and pump. In occurrence of any such behavior immediately
inform the respective site supervisor.

‫پمپ شروع کرنے کے بعد موٹر اور پمپ میں غیر معمولی شور یا وائبریشن چیک کریں۔ ایسے‬
‫کسی بھی رویے کی صورت میں فوری طور پر متعلقہ سائٹ سپروائزر کو مطلع کریں۔‬
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 Daily operation Record
• Daily operation record Parameters
• Pump capacity
• Total Head
• Discharge pressure
• Chlorinator setting
• Motor heating, Noise
• Voltage(V),Ampere(A),Motor Output(KW)
• Leakage

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 Daily Operation Record Sheet (Tube Well Pumping Station) 10
Pump Capacity: cusec Rated Ampere: A Location / Code:  
Total Head: m Rated Rotation Speed: rpm Submission Date: / /
Approved by (Engineer)  
Rated Motor Output: kW Chlorinator Capacity: L/hr
Rated Voltage: V Chlorinator Setting: % Prepared by (Operator)  
S-No. Items Unit Results Total
1 Date -                  
2 Start Time - : : : : : : : :  
3 Stop Time - : : : : : : : :  
4 Operating Hours hour                  
5 Flow Meter Reading (Start) m3  
               
6 Flow Meter Reading (Stop) m3  
               
7 Flow Amount (No.6 - No.5) m3
                 
8 Pressure Gauge Reading Bar / MPa  
               
9 Voltage V                  
10 Ampere A                  

11 Operation of Chlorinator Done / Not  

               
Normal /
12 Motor Heating  
High                
13 Abnormal Sound/Noise Yes / No                  
14 Leakage Yes / No                  

15 Remarks  
 Daily Operation Record Sheet (Disposal Pumping Station) 11
Pump Capacity: cusec Rated Ampere: A Location / Code:  
Total Head: m Rated Rotation Speed: rpm Submission Date: / /
Rated Motor Approved by (Engineer)  
Output: kW    
Rated Voltage: V     Prepared by (Operator)  
S-
Items Unit Results Total
No.
1 Date -                  
2 Start Time - : : : : : : : :  
3 Stop Time - : : : : : : : :  
4 Operating Hours hour                  
5 Suction Pressure Bar / MPa                  
6 Discharge Pressure Bar / MPa                  
7 Voltage V                  
8 Ampere A                  
Normal /
9 Motor Heating  
High                
10 Abnormal Sound/Noise Yes / No                  
11 Leakage (except pump) Yes / No                  

12 Cleaning of Screen Done /  

Not                

13 Remarks  
Maintenance Management of Pump 12

• Maintenance Management is categorized into the following

items;

Maintenance
Management

Preventive Corrective Improvement of

Maintenance Maintenance Reliability
Parameters for Monthly/Yearly inspection(Preventive maintenance) 13

• Pump capacity
• Total Head
• Chlorinator capacity/setting
• Gland packing leakage
• Voltage(V),Ampere(A),Motor Output(KW)
• Oil Level/Grease
• Operation of discharge valve
• Vibration
• Insulation
• Connections
• Overhaul
 Monthly Inspection Record Sheet (Vertical Pump)
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Pump Capacity: cusec Rated Ampere: A Location / Code:  

Total Head: m Rated Rotation Speed: rpm Inspection Date: / /

Chlorinator Capacity: Approved by  
Rated Motor Output: kW (only for Tube Well) L/hr (signature)
Chlorinator Setting: Prepared by  
Rated Voltage: V (only for Tube Well) % (signature)
S-
Measurement Items Unit Result Standard Remarks
No.
1 Leakage Amount at Grand Packing mL/min Proper / Not q = 0.5×d (mm, shaft dia.)  
According to the caluculation
2 Dosing Amount of Chlorine Solution L/hr Proper / Not Only for Tube Well
sheet
           
S-
Check / Maintenance Items Unit Result Remarks
No.
4 Retightening of Grand Packing - Done / Not In case that leakage amount is excess.

7 Operation of Discharge Valve - Functioning / Not

 
< Comments / Findings>
 Yearly Inspection Record Sheet (Vertical Pump)
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Pump Capacity: cusec Rated Ampere: A Location / Code:  

Total Head: m Rated Rotation Speed: rpm Inspection Date: / /

Chlorinator Capacity: Approved by  
Rated Motor Output: kW (only for Tube Well) L/hr (signature)
Chlorinator Setting:  
Rated Voltage: V (only for Tube Well) %Prepared by (signature)
S-No. Measurement Items Unit Measurement Location/Direction* Measured Value Standard Value* Remarks
Axial (A)    
1 Upper Limit:
(Drive Mounting Orthogonal (X)   8.5 (less than 200kW),  
Surface/Lower Motor
Bearing) 9.5 (above 200kW)
Orthogonal (Y)    
1 Vibration mm/s
Axial (A)    
2 Upper Limit:
(Pump Bearing/Lower Orthogonal (X)   8.5 (less than 200kW),  
Motor Bearing) 9.5 (above 200kW)
Orthogonal (Y)    

2 Insulation MΩ ** According to the electrical inspection sheet * Figure (Reference: ISO10816-7)

S-No. Maintenance Items Result Remarks

3 Retightening of Anchor Bolts Done / Not

 
4 Replace of Grand Packing Done / Not every 1 to 4 years (depending on the condition)

5 Replace of Oil/Grease Done / Not every 1 to 4 years (depending on the condition)

6 Overhaul Done / Not every 1 to 4 years (depending on the condition)

< Comments / Findings>
Instruments use for Inspection
• Vibration meter
• Clamp meter
• Insulation meter

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Troubleshooting of Pump

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