Purpose: This procedure is formulated to ensure that
flood control pumps are in good condition and operate reliably during critical flood seasons, extending their service life and maximizing their flood control and drainage effectiveness.
Scope of Application: This procedure applies to the daily maintenance, scheduled maintenance, and special inspections of all fixed or mobile water pumps (including centrifugal pumps, submersible pumps, diesel pumps, gasoline pumps, etc.) used for flood control and drainage within this unit/department, as well as their associated power units (motor, diesel engine, gasoline engine), control systems, and piping.
Responsibilities:
Equipment Manager: Responsible for developing maintenance plans, overseeing their implementation, managing spare parts, and organizing training.
Operation and Maintenance Personnel: Carefully perform daily maintenance, scheduled maintenance, test runs, and troubleshooting in accordance with this procedure and plan, and maintain relevant records.
Safety Officer: Responsible for overseeing safety procedures during maintenance and repair.
1. Daily Maintenance (After each use or at least once a week)
Cleaning:
After shutting down the machine, turning off the power, or shutting down the engine, immediately rinse the pump body, impeller, filter screen, and the outer walls of the pipes with clean water to remove any sand, dirt, and weeds. Ensure there are no blockages or rust.
Wipe away any water stains on the equipment surface and keep it dry and clean to prevent rust and electrical shorts.
Tidy up the work area and ensure it is clean and tidy.
Inspection:
Visual Inspection: Inspect the pump body, flanges, and fittings for obvious cracks, deformation, or severe rust.
Fastener Inspection: Inspect key fasteners such as anchor bolts, flange bolts, coupling bolts, and protective covers to ensure they are not loose. Retighten if necessary.
Seal: Inspect the shaft seal (stuffing box or mechanical seal), pipe joints, flange gaskets, etc. for leaks.
Lubrication:
Oil Level: Check the oil (or grease) level or oil window to ensure it is within the normal range (applicable to bearing housings, gearboxes, and diesel engine oil that require lubrication). Oil quality: Observe the color and viscosity of the lubricating oil. Replace it promptly if it is emulsified, blackened, or contains excessive impurities.
Lubrication points: For manual lubrication points (such as grease fittings), add an appropriate amount of grease as needed (do not overfill).
Filter (water inlet): Thoroughly clean or replace the water inlet filter to ensure it is unobstructed.
Cooling system (if applicable): Check the cooling water tank level and leaks for water-cooled diesel engines/pumps; check the radiator (air-cooled) for cleanliness and unobstructed conditions.
Fuel system (diesel/gasoline engines): Check the fuel tank level and oil lines for leaks; check the condition of the fuel filter (depending on the age of the engine or the instructions).
Electrical system (electric pump):
Inspect cables for damage, aging, loose connectors, or oxidation.
Inspect components in the control cabinet/starter for overheating, burn marks, or looseness.
Check the grounding wire for a secure connection. Drive System: Check coupling alignment (visually or with a simple tool) and elastic elements for damage; check belt tension and wear (if applicable).
Instruments: Check pressure gauges, vacuum gauges, temperature gauges, etc. for integrity and normal indications.
Cranking (Non-Operating): For non-submersible pumps, manually crank the pump shaft (with the power off/engine shut off) to check for smooth, free rotation, without binding or unusual grinding noises. Report any abnormalities immediately.
Records: Record inspection results, maintenance details, and any issues found in the Equipment Maintenance Record Form.
II. Regular Maintenance (according to the equipment manual, operating hours, or monthly/quarterly/annual schedule)
Monthly Maintenance:
Perform all routine maintenance tasks.
Replace the oil-water separator filter (diesel engines).
Check and refill the battery electrolyte (if applicable). Clean the electrode terminals.
Test the functions of the manual/automatic control systems (start/stop, protection, etc.) to ensure accurate and reliable operation. Perform a short (5-10 minute) no-load test run to observe vibration, noise, temperature rise, and instrument indications for normal operation.
Quarterly Maintenance:
Complete monthly maintenance items.
Lubricant/Grease Replacement: Completely replace the lubricant in the bearing housing and gearbox according to the equipment manual or operating hours (generally 200 hours after the first run, and every 500 hours or six months thereafter). Fill all lubrication points with fresh, qualified grease (old grease squeezed out).
Seal Inspection/Replacement: Inspect shaft seals (including packing and mechanical seals) for wear. If stuffing box leakage exceeds the standard or mechanical seals are leaking, adjust or replace them promptly. Inspect seals such as O-rings and gaskets.
Filter Cleaning/Replacement: Replace the diesel engine's oil and fuel filters (according to the manual or operating hours). Clean the air filter regularly (more frequent cleaning is required in dusty environments). Impeller Inspection: Open the pump casing (if structurally feasible and necessary) and inspect the impeller for wear, cavitation, blockage, or foreign matter. Clean it thoroughly. Severe wear requires repair or replacement.
Bearing Inspection: Check the bearings for operating noise and temperature rise. Disassemble and inspect for wear and replace if necessary.
Electrical Inspection: Tighten all electrical terminals; measure the motor insulation resistance (using a megohmmeter; the cold-to-ground insulation resistance should be ≥1MΩ); and check the settings of protective components such as thermal relays.
Annual Maintenance / Pre-Flood Comprehensive Maintenance (Critical!):
Complete quarterly maintenance items.
Comprehensive Disassembly Inspection (based on equipment condition and importance): For critical water pumps (such as fixed-station main pumps), a comprehensive disassembly inspection, cleaning, measurement, and evaluation of worn parts (such as bearings, seals, impellers, and rings) are recommended, and replacement is recommended as necessary.
Instrument Calibration: Calibrate or inspect pressure gauges and vacuum gauges.
Diesel Engine Special Maintenance (if applicable):
Replace the coolant (antifreeze and rust preventative).
Check and adjust valve clearance. Check the atomization of the fuel injectors (if necessary).
Check the starter motor and generator.
Pipeline system inspection: Check the inlet and outlet pipe brackets and hangers for security; check that the valves open and close freely and leak-free; and check that the check valves operate normally.
Control system inspection: Thoroughly inspect the condition and tightness of the components, terminal blocks, PLC (if equipped), sensors, relays, etc. within the control cabinet; simulate and test all protection functions (overload, phase loss, overtemperature, low water level, etc.).
Performance testing: Conduct a load test run (simulating actual operating conditions as much as possible), recording key parameters such as inlet and outlet pressure, flow, current/power, voltage, speed, vibration, noise, and bearing temperature. Compare these parameters with rated values or historical data to evaluate performance.
Anti-corrosion treatment: Remove rust and repaint any rusted areas on the pump body and non-flow-through surfaces of the piping.
Maintenance during extended outages:
Completely drain any accumulated water from the pump casing, cooling system, and piping system (especially in winter to prevent freezing and cracking).
Clean the pump cavity and impeller. Apply anti-rust grease to metal surfaces such as the pump shaft.
Remove wearing parts (such as V-belts) and store them properly.
Disconnect the power supply (for electric pumps) and remove the battery (for internal combustion engine pumps) and store it separately, charged.
Store the equipment in a dry, ventilated, and corrosive-free indoor environment, covered with a waterproof sheet.
Rotate the wheels regularly (monthly) to prevent bearing seizure.
III. Special Inspection and Maintenance During the Flood Season
Pre-flood Preparation (Key Points):
Complete annual/pre-flood comprehensive maintenance.
Ensure that all water pumps (including backup pumps) have completed a trial run and are in good condition.
Inventory and maintain a sufficient supply of key spare parts (seals, bearings, belts, filters, fuel, lubricants, fuses, etc.).
Inspect and test the switching function of all backup power sources (generators, UPS).
Inspect the tires, trailer, and signal lights of the mobile pump truck.
Familyize yourself with emergency start-up and operation procedures. During flood season operation:
Enhance inspections: Increase inspection frequency (e.g., hourly or per shift), focusing on monitoring:
Checking for normal operating sound and vibration.
Checking for bearing and motor/engine housing temperatures exceeding standards.
Checking for current, voltage, and frequency within normal ranges.
Checking for normal inlet and outlet pressures and flows.
Checking for serious seal leaks.
Checking for normal cooling system (water temperature, heat dissipation) (internal combustion engines).
Checking for fuel, oil, and grease levels and conditions.
Ensuring cleanliness: Promptly clean debris from the water inlet filter to prevent clogging.
Avoiding overloads: Monitor current flow and avoid running the pump for extended periods with the outlet valve closed or at very low flow (for centrifugal pumps).
Rotational operation: If multiple spare pumps are available, their operating times should be rationally scheduled and rotated to prevent excessive fatigue on individual pumps.
Post-flood maintenance:
Strictly perform "routine maintenance" after each use. After the flood season ends, perform a comprehensive "quarterly maintenance" inspection and maintenance on all operating pumps as soon as possible, focusing on the wear of impellers, seals, bearings, and other equipment after intensive operation.
Thoroughly clean the equipment inside and out.
Repair any problems found.
Update maintenance records and summarize experience.
IV. Safety Precautions
Power Off/Shutdown and Lockout: Before beginning any maintenance work, ensure the pump is completely stopped and the power source is disconnected (disconnect the power switch and lock it out, shut off the internal combustion engine, and remove the key). Verify that the system is depressurized (close valves and exhaust).
Prevent burns: The engine, exhaust pipe, and pump body can be very hot after operation; allow them to cool before touching them.
Prevent rotating parts: Do not perform maintenance operations while the pump is running. Exercise caution when turning the engine.
Prevent chemical contact: Wear protective gloves and glasses when handling chemicals such as lubricants, fuel, antifreeze, and cleaning agents.
Prevent electric shock: Electrical maintenance must be performed by a qualified electrician and in accordance with electrical safety regulations. Ensure the equipment is fully de-energized and discharged before using a megohmmeter. Preventing Suffocation/Poisoning: When operating an internal combustion engine pump in a confined space, ensure adequate ventilation to prevent carbon monoxide poisoning.
Preventing Slips and Falls: Keep the work area dry and clean, and be mindful of your feet.
Using Tools Correctly: Use appropriate tools for disassembly and installation to prevent damage.
Wearing Labor Protection Equipment: Wear personal protective equipment such as a hard hat, safety glasses, work clothes, and safety shoes during operation.
Preventing Fire and Explosion on Gasoline Pumps: When operating a gasoline engine pump, smoking and working near open flames are strictly prohibited. Refueling must be performed when the pump is cold.
V. Common Troubleshooting (Quick Reference)
Water Pump Not Flowing/Low Water Flow: Check if the water inlet is submerged? Is the inlet strainer/bottom valve clogged? Is the pump full of water (for centrifugal pumps)? Is the impeller clogged/worn? Is the speed too low? Is the pump head too high?
Excessive vibration or noise: Check for loose anchor bolts, bearing wear or oil shortage, impeller wear, imbalance, or blockage, coupling misalignment, and cavitation (a sound similar to gravel).
Bearing overheating: Check for oil shortage or oil deterioration, bearing damage, misalignment, or belt overtightening (if applicable).
Severe seal leakage: Check the gland properly for packing seals (a small amount of dripping is acceptable). Mechanical seals that leak should be replaced.
Motor overload tripping: Check for overload (low head, excessive flow), impeller sticking, motor bearing damage, low voltage, or phase loss.
Diesel engine will not start/is having difficulty starting: Check the battery charge, starter motor, fuel supply (is there oil? Is the filter clogged? Is there air blockage in the oil line?), air filter clogged, preheater (in cold weather), or ambient temperature too low. During operation, check for protective devices (overload, overheating, phase loss, low water level) and fuel depletion. Is there a control system malfunction?
This article provides an understanding of flood control pump maintenance. For more information, visit:
http://www.uhhjr.com/
