Work Efficient with a Pump Maintenance Checklist

What Is a Pump Maintenance Checklist?

A pump maintenance checklist is a comprehensive list of maintenance tasks created by pump manufacturers. The checklist guides owners, pump technicians, or engineers on how to take care of their equipment. It also shows them when to perform each of these maintenance tasks — whether it is daily, quarterly, or annually.

The checklist also shows how to repair components if they malfunction or are broken. Through the guide, it is easier to locate and determine what part needs repair or check-up. Most of all, it serves as a guide for creating an effective maintenance program.

Proper maintenance results in efficient operation. A well-maintained pump will save up to 25 percent on energy consumption.

This article covers the following topics:

1. What an effective pump maintenance makes

2. Preventive and predictive maintenance for pumps

3. Digital tool for effective pump maintenance

What Makes an Effective Pump Maintenance?

The only solution to have an efficient and reliable pump is to have a robust maintenance program that incorporates these five elements:

1. Pump performance monitoring

There are five parameters to inspect when monitoring pump performance:

• Power
  Current transducers are the most basic and cost effective tools in measuring the pump power. Take note, however, that motor amps are disproportionate to load. So you also need to consider the pump’s motor efficiency, input voltage, and power factor. It allows you to get a more accurate reading of the actual shaft horsepower transmitted to the pump.
• Suction and discharge pressures
  The suction and discharge pressures indicate whether the pump is running close to its Best Efficiency Point (BEP), the flow rate where the pump runs at its highest efficiency.
• Pump speed
  Pump speed is a factor in determining pump wear, especially if using a variable speed device. Internal clearances and the normal wear and tear will affect how the pump generates pressure. A lack of information can lead to a wrong diagnosis.
• Flow
  Most pumps have a flow meter that makes monitoring easier. Make sure that these features are functioning properly and calibrated regularly.

2. System monitoring

Monitoring the pump system is often overlooked. The common mistake comes from the notion that the system was created with the installed pump in mind. Remember that pumps are not part of the overall design of the system. They are, however, added as components to complete the pump system.

3. Vibration monitoring

Vibration monitoring is the foundation of any pump maintenance program. Although there is not an absolute amplitude level, pump vibration is indicative of its condition. Some guidelines are created as target values that allow engineers and technicians to set the alarm level.

4. Bearing temperature

Using a device to contact the outer race of the bearing is the most effective method to monitor bearing temperature. Installing a temperature sensor on the bearing housing is another way of monitoring if the bearing lacks or needs lubrication.

5. Visual inspection

Visual monitoring should be included in your heat pump maintenance checklist. It ensures early detection of pump failures, such as leaking, cracking, or corrosion. By including “walkarounds”as part of a sump pump maintenance checklist, action can be taken immediately and prevent any serious problems from happening.

Preventive and Predictive Maintenance for Pumps

Pump checklist for preventive maintenance includes scheduled maintenance — weekly, monthly, quarterly, or annually — to a pump.

Some of the tasks included are vibration analysis, greasing, calibration, and oil change.

Two of the biggest problems of pumps are unbalance and misalignment. Almost 50 percent of the damage to pumps is related to misalignment. If not addressed early on, it can cause bearing failure and increased vibration. So the only thing that can help you avoid this problem is to prevent it from happening.

Predictive maintenance, on the other hand, includes system and visual monitoring of the equipment. Monitoring bearing temperature and vibration analysis are part of predictive maintenance. These processes allow you to anticipate when problems might happen.

When creating a preventive and predictive maintenance program, remember that each pump is different. Each has different features and parts, so their maintenance needs are also different.

With that in mind, a centrifugal pump maintenance program looks very different from a sump pump maintenance checklist. To be able to create an effective program, categorise the pumps.

It will help create an effective checklist and help determine the time and money needed for the type of pump you have.

There are basically three types of pump problems: critical, essential, and non-essential.

1. Critical
   If a pump will have catastrophic results when it gets damaged, it belongs to this category. More so, there is no backup for this type of pump.
2. Essential
   Essential pumps impact productivity. If a pump that belongs to this category fails, operation might cease for a while until a replacement is found.
3. Non-Essential
   Non-essentials, as the name suggests, does not impact the tasks of the people who use them. More so, there’s a backup which is readily available when it breaks down.

Digital Tool for Effective Pump Maintenance

Paper-based inspections and documentation is unreliable and costly. A digital and mobile tool, like Lumiform's Audits and Inspections app, helps technicians and engineers conduct effective pump inspections by performing inspections according to all specified steps. It also makes it easier to identify defects and take immediate action to correct problems. Lumiform offers the following innovative options for pump inspections and maintenance - all without paper:

• Enforce a paperless pump maintenance process using digital pum maintenance checklist - that saves time and money.
• Schedule routine inspections using the app to maintain good pump operating conditions. Receive automatic notifications when scheduled pump inspections are missed.
• Take photos of issues using your mobile device and make notes to better describe the nature of the issue.
• Automatically generate pump inspection reports and share them immediately with costumers and management.
• Use customized scoring to measure inspection results and watch out for recurring issues.