This document provides guidance on pump maintenance and troubleshooting. It discusses different types of maintenance including fix-on-failure, scheduled, preventive, and predictive maintenance. The document then covers mechanical and hydraulic pump problems, whether internal or external to the pump. Specific issues that could cause problems are identified. The importance of qualitative measurements like sounds and smells is emphasized. Case studies using gauge readings to troubleshoot issues are presented. Maintaining pumps is important to avoid downtime and costs.
46. Litmus test
If downtime would wake you in the middle of the night
and a replacement isn't on your own shelf,
use some kind of predictive/preventive measurement
68. A baseline for what's right...
...makes it easier to see when something's wrong
69. A hidden payback
When you practice regular maintenance,
you get to know the equipment
on an expert level
Expert-level understanding makes
trouble resolution much faster
70. What you have in common with machines
Some of the things that
make your life more pleasant
help equipment, too
76. Leverage your efforts & improve motivation
Friendly rivalries with
something on the line
(pride or a small wager)
raise the level of performance
all around
77. Make it a measurable goal with a small wager
Doughnuts?
Lunch?
A round of beers?
81. If you're doing badly
Peer pressure can motivate improvement
82. If you need more resources
The peer group helps you make the case
83. Reward good maintenance ideas
Multi-thousand-dollar ideas go un-shared
because people don't think they'll be rewarded
84. Rewards beget buy-in
"You can achieve amazing progress
if you set a clear goal and find a measure
that will drive progress toward that goal
in a feedback loop."
- Bill Gates
88. Opt-in versus opt-out
๎ When the default option is participation, one-third of people
stick with retirement plans who wouldn't have signed up on
their own
104. It is not wasteful to duplicate tools
๎ If it's the difference between doing the maintenance and not
๎ If it saves time on a quick payback period
110. First-Half Summary
๎ Do the right maintenance for the right equipment
๎ Fix-on-failure, scheduled, preventive, predictive
๎ Use your brain as often as your hands
๎ Place a real value on maintenance and communicate it
111. References:
๎ Cost of anti-terrorism:
๎ http://www.pewresearch.org/fact-tank/2013/09/11/u-s-spends-over-16-billion-annually-on-counter-
terrorism/
๎ Cost of deferred maintenance:
๎ http://www.infrastructurereportcard.org/news/
๎ Retirement opt-in participation:
๎ http://www.nber.org/bah/summer06/w12009.html
๎ Airport security photo (public domain):
๎ https://twitter.com/TSAMedia_RossF/status/375424954600157185/photo/1
๎ I-35W "too much work":
๎ http://www.startribune.com/local/minneapolis/52124637.html
๎ I-35W photo (public domain):
๎ http://en.wikipedia.org/wiki/File:I35W_Collapse_-_Day_4_-_Operations_%26_Scene_(95).jpg
๎ Osama bin Laden screen capture:
๎ http://www.fbi.gov/wanted/topten/usama-bin-laden
๎ Aircraft boneyard photo (public domain):
๎ http://research.archives.gov/description/6505216
๎ All other photos and illustrations are original work by Brian Gongol. Copyright and all other rights are reserved.
199. Gauge readings make a huge difference
Look in the direction of change
Was the change gradual or abrupt?
Some are dead giveaways,
others just point in the right direction
209. Gauge case studies
๎ The prime that took forever
๎ The hole in the suction line
๎ The plugged suction
๎ The forcemain failure
๎ The sedimentation
inclination
211. Gauge case studies
๎ The prime that took forever
๎ The hole in the suction line
๎ The plugged suction
๎ The forcemain failure
๎ The sedimentation
inclination
๎ The bubble, bubble, toil,
and trouble
213. Gauge case studies
๎ The prime that took forever
๎ The hole in the suction line
๎ The plugged suction
๎ The forcemain failure
๎ The sedimentation
inclination
๎ The bubble, bubble, toil,
and trouble
๎ The surge-and-slam
217. Thank you for your attention!
๎ Contact us anytime with
questions
๎ Brian Gongol
๎ DJ Gongol & Associates
๎ 515-223-4144
๎ info@djgongol.com
218. References:
๎ Photo: Mechanic tightening nut (public domain)
๎ http://loc.gov/pictures/resource/fsac.1a35263/
๎ All other photos are original work by and copyright reserved
to Brian Gongol