Preventive Maintenance Introduction

For Centrifugal Pump Systems

Prepared by: Eng. Amer Hamdan

General Maintenance Dept.
Building Maintenance and Facilities Section.
Overview:

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.
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.
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.
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.
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.
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
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
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.
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
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 2- Reduction of corrective maintenance actions
d-Mechanical seal breakage 3-Reducing spare parts replacement requests
e-Shaft problems 4-Reducing complains and service cut off
f- Impeller problems 5-Saving 35%-40% of total maintenance cost for
g-Pump casing corrosion or pits centrifugal pumps
h- System problems( Pipes + Valves)
i- Float switch and float valve problems
 Preventive Maintenance Check list

Period Periodical PM tests

Daily Monitoring Water level in Tanks
Daily Monitoring Noise & Vibration
Daily Monitoring water leakage
Monthly Pets control service
Monthly Check pressure gauges & Pressure Tank
Monthly Monitoring Pressure Switch
Monthly Check float valve and float switch
Monthly Monitoring oil or grease leakage from bearing box
Monthly Monitoring pump parts temp. (Bearing temp.)
Monthly Clean the pump and pump room
Monthly Make sure that motor performance is matching pump duty point
Monthly Monitoring electrical motor temp.
Monthly Check automatic operating mode circuit +operate stand by pump 5
minutes.
Monthly Check valves throttling position degree
 Quarterly Measure Motor performance
Quarterly Measure Pump Performance
Quarterly Keep tanks clean
Quarterly Check suction and discharge line if blocked
Half year System characteristic analysis
Yearly Perform Fluid analysis, salinity and solid contents
OEM
Greasing Pump
Recommendation
When needed Painting Pump ,base plate, valves and elbows and renew concrete
foundation

Prepared by: Eng. Amer Ismail

General Maintenance Dept.
Building Maintenance and Facilities Section.