Preventive Maintenance Introduction
For Centrifugal Pump Systems
Prepared by: Eng. Amer Hamdan
General Maintenance Dept.
B...
Pump rooms, Pumps and their accessories, Valves, Pressure Gauges , Pipe works, Control Panels,
Pressure Tanks, Filters, Wa...
9- Discharge and suction valves are not positioned as per operation instruction on certain
throttling degree and end user ...
Main Failure Causes:
1-Manufacturers defects : Negligible, almost misalignment of the internal parts of the pump
2- System...
3- - Operational faults:
a-To keep the pump operation on manual mode until it pumps all water from tank and runs on dry
co...
Solutions:
1- Apply safety standards to all pump rooms including double sealing covers for all underground pump
rooms, and...
9- Check suction and discharge lines from blockage.
10- Check float switch position as per pump manufacturer recommendatio...
Preventive Maintenance System
CP
Preventive Maintenance CP:
The aim of this study is to activate PM routine check list to reduce pump failure and guarantee...
Technical Aspects to be monitored (PM):
1- Pump performance (Head H, Flow Q) and check if it is matching with manufacturer...
Benefits of PM for Centrifugal Pumps
If preventive maintenance considered as a major part of comprehensive maintenance wor...
Periodical PM testsPeriod
Monitoring Water level in TanksDaily
Monitoring Noise & VibrationDaily
Monitoring water leakageD...
Measure Motor performanceQuarterly
Measure Pump PerformanceQuarterly
Keep tanks cleanQuarterly
Check suction and discharge...
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Preventive Maintenance for CP by Eng. Amer Hamdan

Published on: Mar 4, 2016
Source: www.slideshare.net


Transcripts - Preventive Maintenance for CP by Eng. Amer Hamdan

  • 1. Preventive Maintenance Introduction For Centrifugal Pump Systems Prepared by: Eng. Amer Hamdan General Maintenance Dept. Building Maintenance and Facilities Section.
  • 2. Pump rooms, Pumps and their accessories, Valves, Pressure Gauges , Pipe works, Control Panels, Pressure Tanks, Filters, Waters Tanks, suction lines, Discharge lines , all of mentioned items have been tested and concluded the following: 1-Pump room covers are not sealed enough from dangerous insects, and same the concrete under the cover is broken, which is not safe of technicians and staff. 2- Vision is not clear at some pump rooms (Lights Missing). 3- Submersible pumps at pump rooms and other open areas are not covered and exposed to sediments and clay accumulation the thing that harms the submersible pump. 4- Some Pumps are leaking. 5- Some suction and discharge valves are leaking 6- Corrosion has been noticed in pump, base plate, pipes, valves and elbows 7-Some pumps are connected to operate directly on manual mode 8- In many cases there are a lot of tees and elbows and valves on suction lines. Overview:
  • 3. 9- Discharge and suction valves are not positioned as per operation instruction on certain throttling degree and end user staff changing it while pump operating, which harms the pump. 10- Pumps in some sites are over sized and are not matching system requirements, which results in poor duty point. ( pipes: type, length ,elevation, diameter) 11- float switch is not positioned to maintain recommended minimum fluid level at tanks 12-Noise and vibration are above normal levels in many pump sets. 13- Electrical motors need to be cleaned from sand and dust 14- Concrete base (Foundation) and base plate need renewing and leveling. 15- Pump are misaligned with respect to base plate and foundation. 16- There is no cautions lists describing DO’s and DON’T’s to be considered while dealing with the pump 17- In many sites pump name plate are painted ,so it is not possible to identify the pump specifications and serial number on the name plate.
  • 4. Main Failure Causes: 1-Manufacturers defects : Negligible, almost misalignment of the internal parts of the pump 2- System Design: a- Pump will be affected if the minimum liquid level makes NPSHa < NPSHr (NPSH: Net Positive Suction Head) b- Pipes level ( Suction, Discharge) is not matching pump level. c- Pump is oversized or smaller capacity pump has been selected. d- Pump selection is not matching system requirements : Pipe– size ,type ,length are not matching the system or the required duty point. e- Suction side full of tees and elbows and valves f- Submersible pump is exposed to clay accumulation and sediments without adding screen to protect the pump g- Using smaller size bolts for base plate. h- misalignment of pump ,motor ,Concrete Foundation and base plate.
  • 5. 3- - Operational faults: a-To keep the pump operation on manual mode until it pumps all water from tank and runs on dry conditions b- Pump to exceed daily recommended operational time c- To keep stand by pump without operation for long time d- In case of not cleaning tanks –especially- open tanks, then sands ,clay, solid contents and salt with accumulate at the tank and will harm pump internal parts e- Changing throttling degree of the discharge and suction valves f- Changing the float switch position below the minimum required liquid level g- Forget to grease pump for long time.
  • 6. Solutions: 1- Apply safety standards to all pump rooms including double sealing covers for all underground pump rooms, and contact pits control dept. for routine site visits. 2- Attach operation instruction by manufacturer to each pump set. 3- Routine cleaning for tanks. 4- Using special non-clogging impeller submersible pumps or cover the pit with a screen for pump protection. 5-Performing periodical fluid analysis and solid contents analysis 6- Changing mechanical seal in case of leakage 7- replacing bearing upon manufacturer recommendation or when noise and vibration exceed certain limits 8-Aligning the pump and motor to pump foundation and base plate.
  • 7. 9- Check suction and discharge lines from blockage. 10- Check float switch position as per pump manufacturer recommendations and project engineering design. 11- In charge staff to use instrumentation of flow meter, Pressure gauges, Vibration meter, noise meter, Volt and Amber meters. 12- Data base for all pumps including the following: a- Pump type, Manufacturer and Serial number; for correct spares request b- Hydraulic design specifications c- Data sheet (Manufacturer) d- Maintenance and operation manual e- Dimensional pump drawing including parts and its codes f- Spare Parts list g- Inspection and maintenance historical data book
  • 8. Preventive Maintenance System CP
  • 9. Preventive Maintenance CP: The aim of this study is to activate PM routine check list to reduce pump failure and guarantee that operate smoothly without any problem, the thing that will be reflected on maintenance costs. Actions to activate PM for CP: 1- Contractual agreement with specialized hydraulic works contractor to perform PM activities. 2-Location survey to all pumps at Municipality sites. 3-Establishing Pumps data base and update it with cooperation with the contractor 4- Performing PM inspection and services according to a periodic schedule, and record repeated pump failures 5- Provide PM schedule sheet near each pump set ,describes all test performed by contractor and inspection dates.
  • 10. Technical Aspects to be monitored (PM): 1- Pump performance (Head H, Flow Q) and check if it is matching with manufacturer data sheet: a- Suction pressure Ps b-Discharge pressure Pd c- Motor Speed rpm d- Power Hp, KW. 2- Vibration & Noise 3- System Characteristic analysis (Pipes + Suction & Discharge Valves) 4- Monitor pump leakage 5- Monitor the motor (Voltage, Amber, Temperature), and keep it clean, make sure motor speed is ok with pump performance and duty point 6- Check Pump parts temperature (Bearing) 7-Monitor oil or grease leakage 8-Check suction and discharge lines blockage 9-Check pressure gauges, pressure switch and pressure tank 10-Monitor float switch and float valve 12-Record fluid analysis results ,salinity and solid contents especially for open tanks 13- Check Automatic operation mode circuit ,operate stand by pump for 5 minutes
  • 11. Benefits of PM for Centrifugal Pumps If preventive maintenance considered as a major part of comprehensive maintenance works for centrifugal pumps within a time frame, so the results will be as following: 1- Protecting CP from the following: a-Pump performance problems (Head and pressure resulting) b- Motor malfunctions c-Bearing breakage d-Mechanical seal breakage e-Shaft problems f- Impeller problems g-Pump casing corrosion or pits h- System problems( Pipes + Valves) i- Float switch and float valve problems 2- Reduction of corrective maintenance actions 3-Reducing spare parts replacement requests 4-Reducing complains and service cut off 5-Saving 35%-40% of total maintenance cost for centrifugal pumps
  • 12. Periodical PM testsPeriod Monitoring Water level in TanksDaily Monitoring Noise & VibrationDaily Monitoring water leakageDaily Pets control serviceMonthly Check pressure gauges & Pressure TankMonthly Monitoring Pressure SwitchMonthly Check float valve and float switchMonthly Monitoring oil or grease leakage from bearing boxMonthly Monitoring pump parts temp. (Bearing temp.)Monthly Clean the pump and pump roomMonthly Make sure that motor performance is matching pump duty pointMonthly Monitoring electrical motor temp.Monthly Check automatic operating mode circuit +operate stand by pump 5 minutes. Monthly Check valves throttling position degreeMonthly Preventive Maintenance Check list
  • 13. Measure Motor performanceQuarterly Measure Pump PerformanceQuarterly Keep tanks cleanQuarterly Check suction and discharge line if blockedQuarterly System characteristic analysisHalf year Perform Fluid analysis, salinity and solid contentsYearly Greasing Pump OEM Recommendation Painting Pump ,base plate, valves and elbows and renew concrete foundation When needed Prepared by: Eng. Amer Ismail General Maintenance Dept. Building Maintenance and Facilities Section.

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