PUMP MAINTENANCEAND TROUBLESHOOTING

Brian GongolDJ Gongol & Associates, Inc.

January 27, 2016

NWOD Snowball ConferenceKearney, Nebraska

Not all maintenance is worth doing!

Maintenance is about one thing

Getting the full life-cycle value from a product

Extending life means actively saving money

Think of operational savings in pretax dollars

$1.25 to $1.33 in pretax incometo the ordinary taxpayer

So let's save some money!

Types of maintenance

Fix on failure Scheduled Preventive Predictive

Each approach has its place

Fix on failure

When it's cheap, simple, and in-stock, like a pen

Scheduled maintenance

When there is lots of data from prior experience

Preventive maintenance

When a failure puts you at serious riskof long-term downtime

Predictive maintenance

When the signals of trouble are well-knownand surveillance is cheap

In the context of your health...

Fix on failure

Bandage on a papercut

Scheduled maintenance

Getting your annual physical(prostate exams, colonoscopies, cholesterol tests...)

Preventive maintenance

Regular exercise

Predictive maintenance

Blood pressure checks Body-composition bathroom scales Blood-sugar tests

We rely too heavily on fix-on-failure

(Not a recommended maintenance strategy.)

You would never fly Fix-On-Failure Airlines

Avoid the curse of Shary Bobbins

Always put safety first

You are the most valuable piece of equipment

Lock out, tag out

Check for gases

Seriously. Check for gases.

Prevent slips, trips, and falls

Carpet pattern designed as if to maximize disorientationCenturyLink Center, Omaha

Prevent muscle strain

Keep safety equipment in good repair

Guards Belts Sensors Handrails

Measurement means control

Everyone knows quantitative measurements

Pump run times

Energy consumption

Flows

Pressure readings

Oil temperatures

Motor casing temperatures

But qualitative measurements matter, too

Vibration

Smells/scents/odors

Smells/scents/odors

bitter burnt citrusy fermented fishy fresh fruity grassy hot moldy musty

oily oppressive organic pungent rotten sharp smoky sour sulfuric sweet

Sounds

Sounds

bassy buzz chirp clack clap click crescendo dissonant echo grind growl harmonic hum knock loud muffled

piercing ping quiet rattle rhythmic ringing rumble screech sharp squeak squeal staccato tap whinny whoosh

Why take measurements?

And keep qualitative records?

From fix-on-failure to anticipation

Making the change meanscollecting and using data

Not appropriate to everything

Litmus test

If downtime would wake you in the middle of the nightand a replacement isn't on your own shelf,

use some kind of predictive/preventive measurement

Make it easy to measure and record

Make it easy to review performance

Take the time to review

I-35W: Calculations were "too much work"

Take records straight to a tablet or netbook Eliminates handwriting errors Eliminates copying errors Promotes rapid visualization

Prices are so low, it's highly justifiable

Use free resources

E-mail

Calendars

Charts and task lists

7x7

Make them easy to digest at a glance

People like to keep up unbroken chains

"X" days without a safety incident

Know your indicators

Problem indicators Smoke from under the hood

Planned indicators Squeaking brakes

Conduct a post-mortem on failures and incidents

What did it cost you? What signals were missed?

Primary predictive-maintenance indicators

Temperatures Oil/lubricant conditions Ultrasonic analysis Vibration Performance trends

Nobody wants to do the dirtiest job

Create a culture that encourages maintenance

Starting with ownership of the process

Wax/paint/clean the equipment

Broken window effect

A baseline for what's right...

...makes it easier to see when something's wrong

A hidden payback

When you practice regular maintenance,you get to know the equipment

on an expert level

Expert-level understanding makestrouble resolution much faster

What you have in common with machines

Some of the things thatmake your life more pleasant

help equipment, too

Winter heating

Proper heating in winter prevents freezing

Summer cooling

Well-ventilated motorsare more reliable and more efficient

Turn better maintenance into a game

Rival departments (or shifts)

Rival communities

Leverage your efforts & improve motivation

Friendly rivalries withsomething on the line

(pride or a small wager)raise the level of performance

all around

Make it a measurable goal with a small wager

Doughnuts?Lunch?

A round of beers?

Buddy system aids information-sharing

Create your own "peer group"

Valuable for comparisons in reports

If you're doing well

The peer group helps you take credit

If you're doing badly

Peer pressure can motivate improvement

If you need more resources

The peer group helps you make the case

Reward good maintenance ideas

Multi-thousand-dollar ideas go un-sharedbecause people don't think they'll be rewarded

Rewards beget buy-in

"You can achieve amazing progressif you set a clear goal and find a measurethat will drive progress toward that goal

in a feedback loop."- Bill Gates

Use mental tricks to help yourself

Make maintenance automatic

Conserve mental energy

Don't make more choices than necessary

Color-coded tools

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

Add a third choice to make

Add a third choice to make

Batches of three

Just clustering tasks and choicesin groups of three

reduces the mental taxof decision-making

Conserve mental energy for what matters

"What do you want for dinner?"

"I don't know. What do you want?"

"I don't know."

Tools under $25 to improve maintenance

Kneepad

Graph pads

Fold-out two-wheeler

Lock-out, tag-out devices

Pilot's kneeboard

Custom toolkits for frequent tasks

Foam roller

Reach extender

Zip ties (cable ties)

Carabiners

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

Play hurt sometimes

Figure out what is adding extra strain,then eliminate it

Caring for assets makes you a:

Guardian Conservator Trustee

Custodian Steward Fiduciary

"Cheap" isn't always cheap

"Cheap" up-frontmay cost you a fortune

Doing maintenance right saves you grief

AVOID PAIN!

Good maintenance saves customers money

PLEASE THE PEOPLE!

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

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.

PUMP TROUBLESHOOTING

Brian GongolDJ Gongol & Associates, Inc.

January 27, 2016

NWOD Snowball ConferenceKearney, Nebraska

Sir Arthur Conan Doyle (as Sherlock Holmes)

"Once you eliminate the impossible,whatever remains, no matter how improbable,

must be the truth."

All pump problems are either mechanical...

...or hydraulic

Secondarily, they are either internal...

...or external to the pump

How to tell a mechanical problem

Take away the water

How to tell a hydraulic problem

Take measurements

Mechanical problems - internal to the pump

Bearings

Seals

Packing

Tightness of fit

Suction flap valves

Debris

Internal rubbing

Friction

Mechanical problems - external to the pump

Motors

Controls

Alignment

Balance

Transmission

Belts

Sheaves

Couplings

Valves (throttling)

Valves (isolation)

Valves (air-release)

Piping

Rotation

Jay-Z had 99 problems

We've come up with about 50...and this is halftime

Hydraulic problems - internal to the pump

Recirculation

Clearances

Wearplate wear

Wear ring wear

Volute wear

Impeller wear

In at least three flavors...

Chemical attack

Abrasion

Cavitation*

Cavitation damage happens inside the pump...but it's almost always caused outside the pump

Hydraulic problems - external to the pump

Suction side or discharge side

The two flavors of external hydraulic issues

Hydraulic problems - external - suction

NPSH

NPSHa (net) = Atmospheric pressure- vapor pressure- safety factor- total dynamic suction lift- NPSHr for the pump

Atmospheric pressure

Heat/vapor pressure

Air entrainment

Air in high spot

Turbulence

Vortexing

Minimum submergence

Plugged suction

Debris

Never underestimate what a storm can do...and deposit in your wetwells

Horizontal runs

Valves

Leaks

Not water getting out,but air getting in

Changes to fluid properties

For instance...

Gases in solution

Surfactants

Viscosity

Specific gravity

Froth/foam/bubbles

Hydraulic problems - external - discharge

Valves

Leaks/breaks

Sediment

Debris

Changes to effective pipe diameter

Caused by...

Air

Ice

Corrosion

Scaling

Buildup

Tools to assist in your investigation

Impeller condition: Excess wear

Impeller condition: Suction cavitation

Impeller condition: Discharge cavitation

Shaft breakage

Seal failure

Strange or unwelcome noises

Strange or unwelcome noises

Suction cavitation

Discharge cavitation

Surges

The scream

Use all of your available senses (minus taste)

Record performance

Keep pump curves handy

Gauge readings make a huge difference

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

Gauge case studies

Gauge case studies

The prime that took forever

Gauge case studies

Gauge case studies

The prime that took forever The hole in the suction line

Gauge case studies

Gauge case studies

The prime that took forever The hole in the suction line The plugged suction

Gauge case studies

Gauge case studies

The prime that took forever The hole in the suction line The plugged suction

The forcemain failure

Gauge case studies

Gauge case studies

The prime that took forever The hole in the suction line The plugged suction

The forcemain failure The sedimentation

inclination

Gauge case studies

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

Gauge case studies

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

Gauge case studies

Always divide and conquer

Questions?

Thank you for coming!

Thank you for your attention!

Contact us anytime with questions

Brian Gongol DJ Gongol & Associates 515-223-4144 info@djgongol.com

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