It is believed that pump industry professionals often encounter such situations: pumps that were manufactured at the same time are frequently requiring maintenance in some areas, while in other areas the pumps are operating well and even haven't suffered any damage for decades. Apart from possible quality differences in the pumps themselves, the daily maintenance and care of the pumps is actually very important. Although the structure of the pump is not very complex, it is prone to problems if not maintained and repaired regularly during long-term operation. Today, the pump experts from Shanghai Shen Yin Pump Industry will briefly introduce to you how to do a good job in the daily maintenance and repair of pumps, extend the lifespan of the pumps, save the costs of customers, and enhance the reputation of the company.
Types of daily maintenance and repair of pumps
Post-accident repair
The maintenance strategy after the water supply equipment has obvious faults is to remove the damaged equipment or components for repair or replacement.
Features:
① The cost of maintenance is high and time-consuming, causing delays in normal production.
② Reserve various spare parts for replacement; equip more maintenance workers to handle the repairs.
Daily Maintenance
Carry out routine maintenance at the designated time intervals at the site to repair or replace the equipment before major failures occur.
Features:
① The maintenance cost is lower than that of post-accident repairs.
② Improper arrangement of maintenance intervals can result in unnecessary excessive maintenance.
Condition Monitoring
Based on the actual working condition of the water supply equipment, it is implemented through the monitoring results of the equipment.
Specifically, whether to repair or maintain depends on abnormal phenomena such as mechanical vibration, bearing temperature, and running noise.
If a selected parameter reaches the predetermined critical value, the equipment must be shut down for maintenance to avoid more serious accidents.
Features:
① Clear maintenance objectives and high production efficiency.
② Corresponding detection equipment must be purchased, and personnel training is required.
Standard Daily Maintenance Procedure
Daily Inspection Contents
① Check if the pump discharge pressure is normal.
② Check the sound and vibration during pump operation, as well as the bearing temperature.
③ Check for any leakage in the pump body and associated pipelines.
④ Check if the coupling protective cover is loose.
⑤ Check the oil quantity and the cooling water volume for the seals.
⑥ Keep the equipment clean.
⑦ If any abnormalities are found, report to the dispatcher.
Monthly Maintenance Procedure
① Determine the monthly maintenance tasks.
② Conduct statistical analysis on the detection values of the machine pump status to analyze the trend of equipment operation.
③ Keep good maintenance and repair records.
Quarterly Maintenance Procedure
① Check the alignment between the pump and the motor. The axial alignment must be less than 0.05mm; the angular alignment must be less than 0.05mm.
② Collect and analyze the quarterly equipment operation status data to assess the equipment operation trend.
③ Prepare a report on equipment failure analysis.
④ Measure the thickness of the pump body.
Annual Maintenance Procedure
① Confirm that the annual preventive maintenance work for the centrifugal pump is carried out.
② Based on the quarterly equipment status data sheet, carry out maintenance on the planned maintenance equipment:
③ Disassemble and inspect the pump body, visually inspect the corrosion and mechanical damage of the pump casing, and decide whether to repair or replace based on the degree of corrosion or mechanical damage of the pump casing;
④ Check the corrosion and wear of the friction ring, measure the gap, and if the gap is excessive, it should be replaced;
⑤ Check the corrosion, wear and deformation of the pump shaft and key;
⑥ Check the bearings, check for any signs of metal fatigue in the inner and outer rings and rollers;
⑦ Check for corrosion and wear of the impeller, and check for cavitation;
⑧ Check the locking nut, carefully inspect the threads;
⑨ Replace the mechanical seal; inspect the shaft sleeve, if the fit clearance is too large or the surface is worn, replace it.
Maintenance of bearing lubricating grease
① Re-lubrication of the bearings should be carried out during planned equipment downtime and should be done regularly.
② Remove the old grease and clean the grease injection nozzle before adding new grease.
③ After cleaning, replenish with fresh grease of the same model.
④ The filling amount of the lubricating grease inside the casing: 1/3 - 2/3.
Maintenance of oil-lubricated bearings
1. Inspection of lubricating oil
1) Regularly check the oil level and quality of the lubricating oil.
2) Inspection of lubricating oil:
If the sample appears cloudy, it indicates oil emulsification.
If the sample changes to a darker color or becomes thicker, it may mean that the lubricating oil has begun to carbonize.
2. Lubricant Replacement
Replacement Requirements: Use fresh lubricant to flush the oil circuit. When replacing the lubricant, ensure that the new and old models of the lubricant are the same, and replenish it to the required oil level. The three-level filtration must be strictly followed.
Replacement cycle: With an oil bath type lubrication system, if the oil temperature is below 60℃ and the lubricating oil is not contaminated, it is sufficient to replace the lubricating oil once a year. If the oil temperature is between 60-100℃, then the lubricating oil needs to be replaced four times a year.
