pump maintenance in the water industry

PUMP MAINTENANCE IN THE WATER INDUSTRY

TIM HEBERT A&W ELECTRIC, INC. (704) 363-3144 [email protected]

WHAT WILL WE DISCUSS TODAY?• Main Components

• Principles of Operation

• Key Failure Points

• Inspection

• Maintenance

• Troubleshooting


MAIN COMPONENT PARTS -CENTRIFUGAL• Impellor

• Wear Rings/Efficiency Rings

• Cooling Jacket

• Volute

• Suction

• Discharge

• Coupling


IMPELLOR / WEAR RING• Impellor

• Wear Rings/Efficiency Rings

• Cooling Jacket

• Volute

• Suction

• Discharge

• Coupling


COOLING JACKET

• With radiant Coolant used in pump

• Cooled with pumpage only


PROTECTIVE DEVICES• Seal Fail Detector

• Overtemp

• Usually in the motor side

• Vibration switches

• Protective Relays

• Phase Loss

• Over/Under Voltage

• Low Suction Pressure


WHAT MAKES A PUMP WORK?• Driver – Electric Motor

• Volute

• Suction size vs. discharge size

• Shape of Volute “forces” pumpage to discharge

• Impellor

• Shape and Style “Slings” pumpage

• Gap between wear and efficiency rings


KEY FAILURE POINTS• Bearings

• Ball and Thrust Bearings

• Sealing Components• Lip Seals

• O-Rings

• Mechanical Seals

• Impellor damage usually caused by one or more above


PUMP STATION INSPECTIONVisual

Electrical

Mechanical

Operation / Performance


Organization: Mfg: HPLift Station: Model PhasePump ID # Serial # Voltage

GPM RPMFthd FLA

Visual InspectionControl Panel ExteriorExposed SOW/SEOW CordStrain Relief on CableVisible Portion of RailWetwell LidConnection to Generator

Electrical TestingMegger Test Ph1Megger test Ph 2Megger test Ph3Milliohm Test A-BMilliohm Test A-CMilliohm Test B-CVolts to Mtr Ph1Volts to Mtr Ph2Volts to Mtr Ph 3Amps Ph1Amps Ph2Amps Ph 3

System TestingRun HoursFlow testVolute Inspection Transfer Switch

ControlsFloat Test - Invert float manually to see if pumps cycle properlyFloat test - Disconnect electrically, raise float and test for continuitySeal Failure - Test for open circuitTemp Devices / RTD's test for open circuitLead/Lag Cycle

NAMEPLATE INFO

A&W ELECTRIC, INC.LIFT STATION INSPECTION REPORT

DATE

PUMP STATION INSPECTION & MAINTENANCEInspection

Testing

Maintenance

Next Steps

We need to think about

Frequency – Based on age & condition of station as well as influent

Scope – How often do we want to do each test?

Maintenance – How can we prevent problems, extend life?

What happens when we run into an issue – Seal Fail, overamping, etc.


INSPECTION PROCESS -ELECTRICALElectrical

• Is voltage to the control panel within 3% of nominal

• Is voltage balanced across all three phases

• What is the amp draw of each of the motors? Trend of amp draw?

• What is the condition of wire and starters inside the panel?

• Contactor coils burnt and dark

• Loose connections?

• Is SO cord rotted and cracking? Swollen?


INSPECTION - OPERATION• Do pumps cycle adequately?

• Are all alarms and control lights working?

• Is an alarm condition communicating back to Scada/Mission?

• Are contactors pulling in when control asks them to?

• If alternating relay, are pumps cycling properly?


INSPECTION MECHANICAL• Are floats clean? Are they operating?

• How do we test floats?

• Is well excessively dirty:

• Trash and debris in well

• Sand and grit?

• Flow test – are we flowing to the curve? What is the trend? • GPM

• PSI

• Drawdown

• Have we inspected volute for blockage?


CAUSES OF PROBLEMS – ELECTRICAL AND MECHANICAL

• Poor voltage delivery

• Bad/Loose connections

• Loss of phase

• Weak/ Dirty contactors

• Bad cable in pump

• Bad windings in electric motor

• Blockage in Well

• Blockage in pump

• Cavitation

• Worn impellor

• Bad mechanics in pump causing extra load


PUMPS IN THE WASTEWATER INDUSTRY


Thank you for your attendance !For more information contact:Tim Hebert – A&W Electric(704) 333-4986 (O)[email protected]

mailto:[email protected]

pump maintenance in the water industry

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