Pump regular maintenance procedures
1.0 Purpose
The primary objective of this procedure is to ensure that all pumps remain in optimal working condition, either in operation or on standby, to guarantee reliable performance and safety at all times.
2.0 Scope of Application
This maintenance guideline applies to all buildings equipped with life support pumps, fire pumps, sprinkler pumps, booster pumps, sewage pumps, and air conditioning pumps.
3.0 Responsibilities
The management office is responsible for conducting regular maintenance on all pumps to ensure their continued functionality and compliance with safety standards.
4.0 Maintenance Content
4.1 Daily life pumps and air conditioning pumps should undergo routine inspections once a week and comprehensive maintenance every six months.
4.2 Fire pumps and sprinkler pumps must be tested monthly, while booster pumps should be tested once in February. Each test should last 10–15 minutes. During the fire pump test, the jet from the fire hydrant outlet should reach at least 6 meters. A full maintenance check should be conducted every six months.
4.3 Sewage pumps and submersible pumps require comprehensive maintenance every six months.
4.4 During pump maintenance, all related components within 2 meters of the pump body—such as valves, pressure gauges, and piping—should be inspected and maintained simultaneously.
4.5 Pump Body Care
4.5.1 Inspect the pump body for integrity, ensuring the nameplate is clear and the water flow direction is marked. The appearance should be clean, and the paint should be intact.
4.5.2 Check the lubrication oil; if it is discolored or contains impurities, replace it immediately.
4.5.3 Examine the packing seal for leaks. If found, add or replace the asbestos rope filler.
4.5.4 Replace damaged coupling bolts and rubber pads to ensure proper alignment and function.
4.5.5 Tighten the base screws and apply anti-corrosion treatment to prevent rusting.
4.5.6 For life and air conditioning pumps, which operate frequently, the bearings should be opened and cleaned or replaced annually.
4.6 Motor Maintenance
4.6.1 Inspect the motor's exterior for cleanliness, ensure the nameplate is intact, and confirm that the grounding wire is properly connected.
4.6.2 Disassemble the terminal connections inside the motor junction box and use a 500V megohmmeter to test the insulation resistance between phases. It should not be less than 0.5 megohms.
4.6.3 Ensure that the three-phase wires and connectors in the motor terminal box are secure and tightly fastened.
4.7 Valve, Pipe, and Accessory Maintenance
4.7.1 All valves should be checked for smooth and reliable operation, with no internal or external leakage.
4.7.2 Confirm that the valve action is flexible and free from any internal or external leakage.
4.7.3 Ensure the pressure gauge is accurate and its dial is clearly visible.
4.7.4 Check that the pipes and accessories are clean, without cracks, and that the paint remains intact.
4.7.5 Verify the correct pump rotation by using a jig. If incorrect, adjust it accordingly.
4.8 Control Cabinet Maintenance
4.8.1 Disconnect the main power supply to the control cabinet and test the transfer switch, start, and stop buttons for smooth and reliable operation.
4.8.2 Inspect the circuit breaker, contactor, and relay for damage. Tighten all electrical connections and wiring terminals.
4.8.3 Clean both the interior and exterior of the control cabinet to remove dust and debris.
4.8.4 Reconnect the main power and verify that the power indicator is functioning normally.
4.9 After completing the maintenance, start the pump and observe the ammeter and indicator lights for normal readings.
4.10 Monitor the pump during operation to ensure it runs smoothly, without excessive vibration or noise. The pressure gauge should show stable readings, and the control cabinet should have no unusual sounds.
5.0 Main Pump Maintenance Projects
5.1 SB Single Suction Centrifugal Pump Maintenance Projects and Requirements
1. Check the Stuffing Box: The pump uses a stuffing box for sealing. The packing must be neither too tight nor too loose. Under normal conditions, the leakage should be around 60 drops per minute. If the drip is too heavy or splashing occurs, it indicates an issue.
2. Check the Mechanical Seal: The mechanical seal should not run dry. Any debugging should be done briefly. In normal operation, a small amount of dripping from the retaining ring is acceptable. If excessive leakage occurs, inspect the friction rings and consider repair or replacement. The mechanical seal typically lasts about 8,000 hours and does not need full replacement unless necessary. Only the dynamic and static rings should be replaced as a pair.
3. Lubricate Bearings: The pump uses SKF series semi-enclosed bearings pre-filled with high-temperature grease, allowing continuous operation for up to two years. An annual top-up is required to maintain performance.
4. Check and Clean Impeller: In special cases where the impeller is damaged or foreign objects are present, the pump must be inspected and cleaned. This involves removing the bearing housing and tail cover, pulling out the shaft and impeller, without dismantling the pump body or inlet/outlet nozzles.
5. Check Wearing Parts: Key wearing parts include flexible couplings, mechanical seals, static and dynamic rings, O-rings, bearings, impeller nuts, and packing plates. These should be carefully inspected, and any damaged parts should be replaced promptly to avoid failure.
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