MOST RELIABLE CHECKLIST FOR PUMP MAINTENANCE

Pump maintenance is the process of keeping your pumps in good working condition. A thorough checklist that guides the maintenance engineer for pump maintenance can be very beneficial as pump maintenance is essential to keep your pumps running smoothly and prevent them from breaking down. This includes regularly checking and cleaning your pumps and replacing any parts that are worn out.

Modern pumps are essential equipment in the industrial and manufacturing sectors. These devices allow companies to move liquids and gases from one place to another, which can be crucial to operations. While modern pumps are reliable and rarely need maintenance, they require some attention over time.

What Are The Different Types Of Pump Maintenance?

The ideal way of classifying pump maintenance is through the method used for drawing out the maintenance plan. Based on this, the following are the four significant types of pump maintenance:

Corrective Maintenance:

Corrective maintenance is the most reactive type of pump maintenance, and it involves repairing or replacing parts as needed to keep a pump functioning properly. While this approach may be necessary for some situations, it is often not ideal due to its high cost and disruption of operations.

Preventive Maintenance:

Preventive maintenance is another common approach to pump maintenance that focuses on proactive measures such as regular inspections and adjustments. This can help avoid potential problems and keep pumps operating at peak efficiency. Using a reliable checklist for pump maintenance, engineers conduct a thorough checking and carry out the needful maintenance as and when needed. This approach is widely used in industries.

Predictive Maintenance: 

Predictive maintenance uses advanced sensors and equipment to monitor the condition of pumps and other components in real-time. This enables users to detect potential problems before they become serious issues that require extensive repairs or replacements. However, this type of maintenance is cost-intensive and unsuitable for small-scale pump systems.

Condition-Based Monitoring:

This type of pump maintenance is a newer type of pump maintenance that uses data collected from sensors to assess the condition of pumps and other equipment. This information is then used to develop a customized maintenance plan tailored to the equipment’s specific needs. This approach can be more effective than traditional pump preventive maintenance plans and can help to reduce downtime and costs. But setting up a CBM system can prove to be a costly affair.

Whether you are using one of these approaches or a combination of them, it is essential to ensure that your pump maintenance program is adequately designed and implemented to optimize the performance and longevity of your pumps. Pump maintenance plans are also created based on the system they target, including mechanical, electrical, and hydraulic. Mechanical maintenance typically involves replacing parts that have worn out or broken down due to normal wear and tear. Electrical pump maintenance requires checking the wiring for any signs of damage and replacing fuses if necessary. And hydraulic pump maintenance may involve changing fluid levels or upgrading the oil viscosity depending on the level of use.

Standard Checklist For Pump Maintenance:

The strength and effectiveness of your pump preventive maintenance plan depending on how robust your checklist is. While you would want to include all possible checks in the plan, it is impractical and inadvisable for all routine checks. Therefore the checklist is divided based on the frequency of checks making it more sustainable and effective:

Daily Check:

• Check pump exterior for any leaks
• Clean pump and nearby region to remove any debris
• Check for excessive pump vibration or unusual noises
• Check for foaming or oil discolouration
• Check bearing temperature for overheating
• Inspect all gaskets to ensure there are no oil leaks
• Inspect self flush pumps is applicable
• Clean bearing covers if needed
• Check pump cooling system

Monthly Check:

• Top up oil to bearing reservoirs if needed
• Clean oil bulbs and level windows
• Check the pump guards and replace them if needed
• Clear out dirt and debris from bearings and grease them
• If applicable, check that the hydraulic governors are working properly
• Check overall pump systems for leaks and clean the pumping system surroundings

Quarterly Check:

• Check pump and motor for any vibration damage
• Grease bearings as per need
• Change the oil in bearing systems
• Check suction, discharge and head pressure
• Check all hold down bolts for tightness to reduce vibration
• If needed, inspect shaft pump alignment
• Apply rust preventive coat to prevent corrosion

Annual Check:   

• Check axial float of the pump along with the driver shaft
• Remove mechanical cover and inspect the entire pump arrangement
• Check disc couplings for damage
• Inspect coupling alignment
• Perform the Overspeed test for the pump
• Inspect seal chamber for scoring and pitting
• Check oil levels and refill as per need
• Inspect impeller for erosion and replace if needed

Please note that the pump preventive maintenance schedule for each pump would depend on its design and application, and hence you should always consult the pump manufacturer for the same. However, the above checklist is a general checklist that can guide the process of pump preventive maintenance. A well-maintained pump will last longer and perform better than one not correctly cared for.

Key Aspects To Keep In Mind When Performing Pump Maintenance:

1. Check the manufacturer’s recommendation for service interval schedules. Depending on the type of pump, different servicing may be required at different intervals.
2. Always use the correct lubricant for your pump. This will help prolong the life of your pump and keep it running smoothly.
3. Keep an eye on the wear of your pump parts. Replacing worn-out parts before they break can save you time and money in the long run.
4. Keep your pump clean. A build-up of dirt and debris can cause your pump to work harder than necessary and shorten its lifespan.
5. When storing your Pump, make sure that it is stored in a clean, dry place. Moisture can damage your Pump and lead to Pump failure.
6. Maintain the proper records for all pump maintenance activity. Good data collection will give you the correct information about the pump’s health and operational condition.

5 Reasons Why A Qualified Expert Should Do Pump Maintenance:

Based on the checklist, pump maintenance may seem a simple task that needs to be done regularly. However, this is not true. Understanding the pump behaviour and performing suitable maintenance activities requires years of experience. Therefore, it is always advisable to hire a qualified expert to carry out pump maintenance due to the following reasons:

1. Safety – Pump maintenance through a qualified expert, ensures that all safety hazards are identified and eliminated. This keeps you, your equipment, and your employees safe from harm.
2. Efficiency – Qualified experts know how to service and maintain pumps to operate at peak efficiency. This can save you money on your energy bills and help prolong the life of your pump.
3. Peace of Mind – Pump maintenance can be a complex task. By entrusting it to a qualified expert, you can rest assured that the job will be done correctly and on time.
4. Avoid Downtime – Downtime is costly, both in terms of lost productivity and repair costs. Pump maintenance through a qualified expert can help minimize the risk of unexpected downtime.
5. Compliance – Pump maintenance through a qualified expert can help ensure that your pump complies with all relevant safety and environmental regulations. This can save you from costly fines or penalties.

The majority of reliable pump manufacturers offer pump maintenance as a part of their service. Therefore, it is always a good practice to hire them to execute the pump maintenance of your site. They will also be able to create an effective schedule and an exhaustive checklist that your site engineers can follow for pump inspection. Ensuring that pump preventive maintenance is done at the right time in the right way will make your overall system more reliable and efficient.