Preventative maintenance Videos
 
If you have a pump on site and you don’t already have a maintenance programme in place, then your first step should be to make someone responsible for this, maybe your in-house engineer or operations team. Most pump engineers offer servicing contracts and can carry out any required maintenance then and there. However, it’s good practice to be able to inspect your pump yourself more regularly to catch any issues in between your services.

A pump maintenance programme would generally involve a periodic check of the pump performance, an inspection of the wearing parts and lubrication of bearings and joints. It is good practice to carry out a visual inspection of the pump installation on a daily basis. Spotting an issue early is one of the best methods of trouble shooting and preventing pump breakdown. Most of the things to look out for should be easily visible, these include:
 
  • Leaks - Check the pump and pipe work for any leaks that need to be dealt with, as they will result in reduced performance and loss of pump output as well as mess. Common leaking points are from the stuffing box or the mechanical seals. Mechanical seals are a wearing part and need to be routinely replaced.
  • Unusual noise - One of the first signs of a problem with your pump is noise. Like anything with a motor, a consistent hum when the pump is running is quite normal. However, abnormally loud noises or a clunking or crunching sound is likely to indicate an issue e.g. worn bearings. A popping sound, particularly if it is near the impeller, could mean the pump is experiencing cavitation which can cause a lot of damage.
  • Extreme vibration - A properly installed, well working pump should not overly vibrate, and therefore any level of vibration deemed excessive should be investigated. Common causes include impeller imbalance, damage and misalignment of the pump and motor.
  • Corrosion - Rusting, cracking or discoloration of the pump casing or pipe work need to be acted on immediately as these are all signs of corrosion. Corrosion can not only result in pump failure through a weakening of the casing and components, but also contamination of the fluid being pumped.
  • Overheating - The pump, motor or bearings getting really hot is not something that should be ignored as it always indicates some form of problem. Some explanations may be internal rubbing/wearing of parts, that the wrong power has been put into the pump, the pump has been running against a dead head or that it has been running at a duty it cannot efficiently maintain.
  • Clogging - The presence of solids can result in the clogging of impellers or valves if the pump is not capable of handling the size of the solids that have attempted to pass through. You will usually notice clogging quite quickly as the pump will not be delivery the same quantities of fluid.
         
         
Whilst these are examples of typical daily checks, other checks however are required less regularly. One of the largest causes of pump downtime is pump owners not routinely replacing wearing parts and instead waiting for them to fail before changing them. It is recommended to replace certain components such as the mechanical seals and impellers every 1-2 years to prevent leaking and other issues. Best practice is to hold stock of typical wearing parts on site to prevent any delay in being able to maintain your pump if any components fail.
 
Make things easier with a Pump Maintenance Schedule
Just like the below, preventive pump maintenance should to be planned into a periodic maintenance schedule. By setting out when certain tasks should be carried out, maintenance becomes a smoother more efficient process and tasks don't get "forgotten" about. Not only does it reduce the likelihood of unexpected pump failures and downtime, it also helps to reduce the cost of ownership as replacing wearing parts for example is a much cheaper process than replacing an entire pump.
 
Frequency Staff Needed Time Task
DAILY 1 10-15 minutes
  • Check for overheating
  • Check for cavitation & bearing noise
  • Check for motor current & voltage
WEEKLY 1 20-30 minutes
  • Check for suction & discharge pressures
  • Check for vibration & noise
  • Visual check for sealing and pipe work leakage
  • Check for signs of corrosion or discolouration
MONTHLY 1 20-30 minutes
  • Remove safety guards & check for shaft & auxiliary devices
  • Check for coupling alignment
  • Fill lubrication oil (if necessary)
ANNUALLY 2 2-3 hours
  • If you have a back up pump, run the pump & check for maintainability
  • Check for axial movement of motor shaft
  • Remove & clean all auxiliary devices (valves, manometers, piping’s, sight glasses, etc)
  • Remove coupling halves & check for wear at rubber part (renew if necessary)
2 YEARS OR 10000 HOURS

2

 6-8 hours
  • Dismantle the pump from the piping & disassemble
  • Make inspection on parts, replace if necessary:
    - Impellers
    - Wear Rings/Wear Plates
    - O-rings
    - Shaft
  • Apply coating on un-machined surfaces