replace mud pump motor maintenance programs quotation

Everyone agrees that reactive maintenance is probably the worst pump reliability strategy. Maintaining equipment only after it breaks can mean unexpected downtime, emergencies, rush charges, overtime, and replacement of expensive parts.

The best pump reliability strategy is not either preventive or predictive maintenance, it’s a combination of the two, strategically applied. In this post, we’ll discuss the differences between predictive and preventive maintenance and when it’s best to use them.

Many operators rely heavily on “reactive” maintenance rather than preventing and planning for future repairs. As discussed in our eBook, 36 Ways to Kill Your Pump, “reactive” maintenance accounts for unplanned equipment downtime and increased costs.

Preventive and predictive maintenance programs extend the overall life of the equipment and result in fewer unplanned breakdowns. The choice is not one or the other, it’s a combination of the two.

Preventative maintenance is any variety of scheduled maintenance to a pump or other piece of equipment. Generally, it includes scheduled routine maintenance, such as equipment calibration, greasing, oil change, and analysis.

One of the biggest ways to prevent failures is to make sure your equipment is properly aligned and balanced. Misalignment and pump unbalance are the two most common reliability problems for rotating equipment. Laser alignment also fits within this category since its a service completed upon installation, setting the pump up for success.

These programs are designed to keep your maintenance costs low by preventing costly failures before they happen. If you need a preventative maintenance checklist, you can download one here.

Up to 50% of damage to rotating machinery is directly related to misalignment. Misalignment can cause increased vibration, premature seal and bearing failure, and increased power consumption. An unbalanced pump causes similar issues, such as vibration, which can be easily avoided with the right preventative maintenance measures.

Predictive maintenance services are used to monitor the condition of equipment over time. Vibration analysis, for example, measures the vibration of the equipment while it is still in service. This allows the technician to see the change in vibrations over time to predict when a problem may occur, and why.

Predictive maintenance should be part of routine maintenance for pumps and rotating equipment that absolutely can NOT go down. Operators and maintenance managers get a glimpse into the future life of the pump as it"s running today. This allows them to plan for repairs and avoid unexpected downtime.

Not all pumps are equally important in a manufacturing process, so not all pumps should receive the same maintenance plan. It wouldn’t make sense to spend time and money on vibration analysis for a pump in a non-essential application.

Before creating a maintenance plan, place the pumps into categories. This will help determine how much time and money to invest in each one. Use these categories to get started:

Regularly maintaining pumps will extend the life of your pump. When a pump is properly maintained, the parts that need replacing are usually the less expensive wear parts.

Check shaft alignment – believe it or not, shaft alignment can change! Thermal growth and machine movement due to load shifts can cause pumps to move out of alignment.

Up to 50% of damage to rotating machinery is directly related to misalignment. That’s huge. Machine vibration, bearing damage, premature seal wear, and coupling damage are all examples of issues pumps experience when misaligned.

For the most accurate alignment, we always recommend laser alignment. It’s the most accurate method available (to .0001), and once familiar, an operator can align a pump/motor very quickly. It is the most expensive method to get into if doing alignments in-house and can be difficult to learn at first. But when looking for long-term results, the laser align method is the better choice.

Precision rebuild or precision maintenance is the practice of rebuilding a pump as close to OEM specifications as possible. Attention to detail is required for precision rebuilds.

Precision rebuilds are proven to reduce failures and should be a central piece of a pump reliability strategy. If the team lacks capacity, tools, or expertise to rebuild pumps to OEM standards, look for a capable local shop.

Add taps with isolating ball valves into piping on the suction and discharge sides of the pump. Use these to mount pressure indicators to ensure the pump is performing properly.

Read the pump manual and follow each step in the procedure. The procedures therein give the best possible instruction for long and trouble-free life for the pump.

Upon start-up, record the pump performance baseline data – amps, suction pressure, discharge pressure. This is handy when troubleshooting issues, should they arise.

Vibration monitoring is a very helpful tool for predicting pump failures. Some manufacturing facilities have a vibration technician on staff to take readings on critical pumps. These technicians may read the results themselves or send them to a firm that can interpret the readings and provide a report.

Unfortunately, this is not a skill easily attained by a maintenance team. It requires expensive equipment and a great deal of training to be an effective vibration technician. Unless the facility has a large population of critical equipment, this is a service best hired out.

Arguably the most important piece of a preventative/predictive maintenance plan... The TRAINING! Training isn’t just for the maintenance team, it’s for everyone in contact with pumps, operators especially! Failure prevention is everyone’s responsibility.

The maintenance team is the keeper and protector of equipment in the facility. Train operators on the signs of failure so they can report it quickly. Show them how to properly start-up or shut down a pump and how their actions will affect other parts of the system.

If all these steps were do-able by a maintenance team alone, everyone’s reliability goals would be already met. Some of the steps we’ve laid out require specialized training, tools, or specialized training on tools to make them effective. It’s likely the team doesn’t possess all these as they’re expected to know how to fix every machine in the plant. Hire outside help where it makes sense.

Look to a preventative maintenance program and predictive maintenance measures to save on annual maintenance costs and unscheduled downtime. We recommend working with your local equipment supplier to schedule a preventative or predictive maintenance program for your pumps.

Need more information about our preventative and predictive maintenance services? We are happy to help businesses in Wisconsin and upper Michigan. Got a noisy, underperforming pump? Consider our FREE Bad Actor Pump Assessment!

Pump Solutions #1 Corporation is proud to offer the best prices, turnaround times, and customer service in the pump and pump accessories industry. Our superb services, combined with our massive selection of pumps, replacement pump parts, and pump motors from major manufacturers, ensure the success and productivity of any company who chooses to partner with our staff of highly trained pump experts.

Fill out our easy to use Request a Quote Form below or contact the pump system schematic inspection and repair team at Pump Solutions #1 Corp today for the best pump services and replacement pump components.

Pumps are often designed to operate at a single point known as the Best Efficiency Point (BEP). As components begin to wear, a pumps performance begins to decline, with operation away from this point leading to issues such as accelerated bearing or seal wear, vibration, excess temperature rise or cavitation. Quite often declining performance can start gradually, before quickly accelerating until failure if performance issues are not addressed in a timely fashion.

Corrective Maintenance is undertaken when failure has occurred. The unit may be leaking, efficiency reduced, pump stopped or motor tripped, leading to loss of production resulting in an urgent situation where parts must be sourced and fitted quicky.

Preventative Maintenance is inspection and repair scheduled at specific intervals (daily, weekly, monthly, yearly) or based on the number of hours run. Visual inspections are made externally and internally by dismantling the unit, replacing seals such as gaskets and mechanical seals, with pump parts checked for wear.

Differential Pressure:Check the operating pressure by calculating the difference between the inlet and outlet pressure of the pump ensuring it is operating on curve.

Excess Temperature – Check motor, bearing and casing temperature. Thermal imaging cameras can detect excess temperature quickly, without stoppage, dismantling or contact with the unit.

The “6 to 1 Rule” discovered by John Day Jr, (Manager of Engineering & Maintenance at Alumax South Carolina stated that the ideal ratio of Proactive Maintenance (PM) to Corrective Maintenance (CM) should be 6 to 1 - 6 PM checks to 1 RM check. If your ratio is below this then according to his theory it is being inspected too infrequently, above and inspections are too frequent.

Although Proactive Maintenance can seem to avoid the urgent costs and downtime associated with reactive maintenance, PM maintenance costs can be high due to the cost of labour in dismantling of complicated designs such as Progressing Cavity, or Triplex Plunger pumps which are often time consuming to maintain with more than one person required to undertake work.

On dismantling units, some seals require replacing regardless of condition, and excess spares can be required in case of gasket entrapment during assembly. Rental of specialist lifting equipment may be required and there can be situations where when inspected, pump parts do not require replacement.

MonitoringThe ideal situation is to ensure components are replaced before failure but not so far in advance that they have experienced little wear with valuable time spent on inspecting components which are otherwise fine.

This can be achieved through a monitoring device, where when the right data is collected, pump failure can be anticipated between 3 and 12 months in advance with an 80-95% accuracy.

With the average lead time on DN100 pumps, and units over 5 years old being 3 months or more, it is essential that spares are either on the shelf or failure is anticipated through advance ordering.

There are hazards during any maintenance activity. Always ensure the correct PPE is worn before attempting repair, that sufficient expertise is on hand and chemical data sheets of any fluid being pumped are checked prior to undertaking work. A full risk assessment should be completed in advance.

Hazardous FluidsIrritation, Chemical burns, ignitionEnsure when pump is opened the unit is cool, not pressurized, ignition sources are not present, and any fluids spilt are contained.

If inspection has been neglected for some time, then additional parts may require replacing than had the unit been inspected earlier, with some pump parts becoming beyond economical repair.

Enables planned work to be undertaken during lower activity levels and at lowest cost & risk.Pump has to be crucial within a process or above a certain size for monitoring to be cost effective

Thread Sealant –The use of semi-permanent thread sealant will ensure vitality important threaded fasteners such as bolts or screws on shafts, couplings or pump casings do not self-loosen due to vibration and become disengaged.

Interchangeable Spares –Our range of pumps are modular in design utilizing interchangeable spares, meaning on site stock holding of parts can be reduced by up to 80% further reducing slow moving stock.

Repair & Replace –Choosing to repair an existing pump within a process of vital importance, as well as replace, is a strategy we recommend for maximizing plant efficiencies and reducing downtime. Should unexpected pump failure occur, your process can be restored quickly.

Checklists & Logs –The use of checklists and logs ensures a fully repeatable process ensuring important maintenance intervals are not missed. Logs can provide valuable insight and reveal a pattern before failure occurs enabling easier troubleshooting.

indicates which areas should be checked, but note that a units maintenance routine is dependent on several factors such as hours of operation, duty, aggressiveness of pump medium, rpm of motor, temperature, inlet conditions and location of equipment.

Many things go into getting the most life out of your mud pump and its components — all important to extend the usage of this vital piece of equipment on an HDD jobsite. Some of the most important key points are covered below.

The most important thing you can do is service your pump, per the manufacturer’s requirements. We get plenty of pumps in the shop for service work that look like they have been abused for years without having basic maintenance,  such as regular oil changes. You wouldn’t dream of treating your personal vehicle like that, so why would you treat your pump like that.

Check the oil daily and change the oil regularly. If you find water or drilling mud contamination in the oil, change the oil as soon as possible. Failure to do so will most likely leave you a substantial bill to rebuild the gear end, which could have been avoided if proper maintenance procedures would have been followed. Water in the oil does not allow the oil to perform correctly, which will burn up your gear end. Drilling mud in your gear end will act as a lapping compound and will wear out all of the bearing surfaces in your pump. Either way it will be costly. The main reasons for having water or drilling mud in the gear end of your pump is because your pony rod packing is failing and/or you have let your liners and pistons get severely worn. Indication of this is fluid that should be contained inside the fluid end of your pump is now moving past your piston and spraying into the cradle of the pump, which forces its way past the pony rod packing. Pony rod packing is meant to keep the oil in the gear end and the liner wash fluid out of the gear end. Even with brand new packing, you can have water or drilling fluid enter the gear end if it is sprayed with sufficient force, because a piston or liner is worn out.

There is also usually a valve on the inlet of the spray bar. This valve should be closed enough so that liner wash fluid does not spray all over the top of the pump and other components.

Liner wash fluid can be comprised of different fluids, but we recommend just using clean water. In extremely cold conditions, you can use RV antifreeze. The liner wash or rod wash system is usually a closed loop type of system, consisting of a tank, a small pump and a spray bar. The pump will move fluid from the tank through the spray bar, and onto the inside of the liner to cool the liner, preventing scorching. The fluid will then collect in the bottom of the cradle of the pump and drain back down into the collection tank below the cradle and repeat the cycle. It is important to have clean fluid no matter what fluid you use. If your liners are leaking and the tank is full of drilling fluid, you will not cool the liners properly — which will just make the situation worse. There is also usually a valve on the inlet of the spray bar. This valve should be closed enough so that liner wash fluid does not spray all over the top of the pump and other components. Ensure that the water is spraying inside the liner and that any overspray is not traveling out of the pump onto the ground or onto the pony rod packing where it could be pulled into the gear end. If the fluid is spraying out of the cradle area and falling onto the ground, it won’t be long before your liner wash tank is empty. It only takes a minute without the cooling fluid being sprayed before the liners become scorched. You will then need to replace the pistons and liners, which is an avoidable costly repair. Make a point to check the liner wash fluid level several times a day.

Drilling fluid — whether pumping drilling mud, straight water or some combination of fluid — needs to be clean. Clean meaning free of solids. If you are recycling your fluid, make sure you are using a quality mud recycling system and check the solids content often throughout the day to make sure the system is doing its job. A quality mud system being run correctly should be able to keep your solids content down to one quarter of 1 percent or lower. When filling your mud recycling system, be sure to screen the fluid coming into the tanks. If it is a mud recycling system, simply make sure the fluid is going over the scalping shaker with screens in the shaker. If using some other type of tank, use an inline filter or some other method of filtering. Pumping out of creeks, rivers, lakes and ponds can introduce plenty of solids into your tanks if you are not filtering this fluid. When obtaining water out of a fire hydrant, there can be a lot of sand in the line, so don’t assume it’s clean and ensure it’s filtered before use.

Cavitation is a whole other detailed discussion, but all triplex pumps have a minimum amount of suction pressure that is required to run properly. Make sure this suction pressure is maintained at all times or your pump may cavitate. If you run a pump that is cavitating, it will shorten the life of all fluid end expendables and, in severe cases, can lead to gear end and fluid end destruction. If the pump is experiencing cavitation issues, the problem must be identified and corrected immediately.

The long and the short of it is to use clean drilling fluid and you will extend the life of your pumps expendables and downhole tooling, and keep up with your maintenance on the gear end of your pump. Avoid pump cavitation at all times. Taking a few minutes a day to inspect and maintain your pump can save you downtime and costly repair bills.

It is important to insulate the booms on your concrete pump with a material that does not absorb water, like neoprene. Wrapping your boom with saran wrap before you insulate it will help maintain the integrity of the paint job on your boom as well. If cost is a factor, you can get away with only insulating the last 2 sections of the boom. This is because a pipe full of concrete will not freeze as fast as an empty pipe. That frozen layer of concrete will peel off when you start pumping again and create a frozen slug of concrete that will plug in your elbows.

Also remember that hydraulic oil can be as thick as molasses on cold days. Give yourself lots of time so you can warm up your oil on site. Too much engine speed can cavitate pumps or blow lines. You will be certain to find the weak link in your system if you show up and throw the pump into gear simply because you are running late.

Keep brake line anti-freeze and fuel conditioner in your concrete pump at all times. It is good to keep your sponge balls in anti-freeze in the winter as well. It is not uncommon to see a concrete pump return to the yard because a ball is frozen within the boom. And don"t panic if you are frozen. Frozen concrete has to thaw out before it sets and you can still save the boom system.

An automatic greaser is a piece of equipment that saves you time and money in repairs. It takes the guess work out of regular greasing. However, just like the pump itself, the auto greaser is a piece of equipment that can malfunction.

It is becoming more and more common to use Wash Out Bags especially when pumping concrete in the city. As you all are aware, sometimes when setting up to clean out things just don"t go right, then you have a big mess on your hands.

In order to better serve our customers we have decided to add several parts for Putzmeister Pumps to our Pumps stock of inventory. So, now we have parts for both Putzmeister Big Mouth and Standard pumps. Among the items we are now stocking are: S-Tubes, Wear Plates, Cutting Rings, Thrust Rings, Front Housings, Suction Filters & Boom Filters. We also have access to a full line of OEM parts too!

Are you are looking to save a little money in the short run? Did you know you can replace the seals in your Augor Motor? You should always have on hand an Augor Motor Seal Kit, to help out in these areas (Part Number RB0400300).

Maintaining your Bearing Flange Assemblies versus replacing can save a little money at the right times as well. You can easily replace the O-Rings, Rubber Cones and Bushing.

There are many ways to save a little money here and there while still keeping your pump working. These just a few ideas. If you have any time or money saving maintenace tips fee free email them to us and we will share them online!

The accumulator bladder is one of the hardest working parts on a concrete pump. Therefore, it is critical that the nitrogen pressure is properly maintained the required 90 bar setting. This will prevent premature wear on the bladder and it will also prevent a lazy S-Tube shift which can cause a difficulty in pumping.

It is important to save money where you can in business. We would like to talk to you about how to stretch your dollar by extending the life of your S- Tube. Dry stroking the concrete pump when there is no concrete in the hopper can cause premature wear on the spline shaft of the S-Tube. Slowing your volume down and placing the concrete pump into a soft shift will help to prevent spline damage. Also, keeping the two bolts going through the yoke tight will help to extent the life of your S- Tube.

Distributor of heavy duty submersible mud, sand, sludge & slurry pumps. Specifications of pumps include 5 hp to 30 hp motor, three phase, 208 V to 575 V, 6.8 A to 39 A, 3 in. to 6 in. NPT sizes, 38 ft. to 134 ft. head size & 475 gpm to 1,690 gpm flow rate. Features include impellers, wear plates & agitators made from abrasive resistant 28 percent chrome iron, process hardened ductile iron volutes casted with thick walls, class H motor insulation, double silicon carbide mechanical seals, heavy duty lip seal & stainless steel shaft & shaft sleeve. Sand, sludge & slurry pumps are used in mines, quarries, dredging, coal & ore slurries, sewage treatment plants & steel mills. UL listed. CSA approved. Meets OSHA standards.

The PZ 2400 features a Y-shaped module design, meaning less stress is placed on the pumps internal components and higher flow rates can be achieved with improved fatigue life.

As it is the case with most equipment, pumps require regular maintenance to keep within peak performance benchmarks. The benefits of preventive maintenance in the HVAC industry have proven to improve asset life cycle, boost CRM, cut excessive repair costs and reduce unplanned equipment downtime.

When talking about pump failure the best remedy is having a great schedule and maintenance checklist in place. In a pump’s life cycle, environmental conditions can often be a major factor in its performance. Some other important maintenance tasks and factors to consider include:

All of these issues can be detrimental to a pump’s performance and cause defects if not resolved with regular maintenance. When considering what to include in your regular maintenance checklist a great place to start is the warranty and manufacturer standards as per pump type. Pump manufacturers often set requirements to follow to ensure the best life cycle for your equipment.

Pump efficiency point is the result of hydraulic, mechanical and volumetric parts to ensure performance is within a desired level. The level of efficiency in a pump is drawn from the units of energy that is required for performance.

However in centrifugal pumps, the inner workings of the pump will drive the motor. Essentially this means the mechanical energy is transformed to hydraulic energy and electrical energy is transformed to mechanical energy. This means that for a centrifugal pump you will find your level of efficiency sits at either 75% or higher in larger pumps and around 60% in smaller pumps.

As a part of your work order management for your pump maintenance schedule, you need to do some research behind what factors you need to consider that will be most detrimental to your pump’s health. When you create your ultimate guide to maintenance, your aim is to reduce your unplanned downtime and improve your standard of service by keeping a regular schedule.

When trying to determine the frequency of your maintenance checklist, you need to consider the factors that will impact your pump listed in the beginning of this article. If you have a higher quality pump that is used every day and is largely impacted by elemental factors, you will need to have more regular services in place. The warranty and safety standards will also have an impact here, depending on your pump type and according to the manufacturer’s instructions.

The more thorough your maintenance is, the better service you can provide. While a large maintenance schedule can seem daunting to your maintenance team, the assistance of checklists can ensure no step is missed no matter how big or small. Having a checklist in place will also provide consistency across your team and ensure each pump may receive the correct care it needs.

The main area for concern in centrifugal pumps is the lubrication. As centrifugal pumps rely heavily on correct lubrication to work, maintenance is important to ensure pumps aren’t under or over lubricated, which can cause damage. When you have over lubrication your pump will create too much heat and can result in frothing the oil.

Getting your maintenance plan right means you consider all these above factors and are able to incorporate them into your pump checklist and schedule.

For this checklist, you want to schedule a quick inspection of your pumps to avoid damage and wear. The main reason for having a daily checklist in your schedule is to catch those pesky issues that can turn into defects and pricey repairs if not caught early on.

Generally your quarterly maintenance will be done with the change of the season and can include varying tasks due to elemental factors. The severity of your pump environment will also affect the consistency and schedule of your pump maintenance program. Will your pump be exposed to extreme heat or extreme cold temperatures?

In your annual preventive plan, you will generally go into more detail and evaluate pump performance. Each year you should take a record of your annual operations and benchmarking data that might include:

For your routine maintenance schedule for your centrifugal pumps you need to make sure you have a solid system in place where you can reliably plan and train your team. Having a great software in place will also give you the ability to structure your maintenance program according to the manufacturer’s instructions and adhere to your customer contracts.

Job management software like FieldInsight gives you the ability to keep your centrifugal pump maintenance in perfect balance. With FieldInsight, you also gain access to the five primary automations in your business:

To reduce the stress in your scheduling system and improve your maintenance program, book a free demo today and find out what FieldInsight can do for your business.

A clean car not only makes for a happy driver, it helps the car run better, too. This is probably the simplest car maintenance advice, but it"s easily overlooked. With how busy life gets, car owners often don"t make time to clean out and wash a car. Here"s why you should be nice to your car.

The PZ 2400 features a Y-shaped module design, meaning less stress is placed on the pumps internal components and higher flow rates can be achieved with improved fatigue life.

Periodically we"ll inspect for wear, cracks and damage to critical components such as bearings, bull gear and pinion, conrods and crossheads. We"ll check the condition of your seals and other rubber goods and look for oil contamination. We"ll inspect your frame and ensure your pump is set up as per the manufacturer"s recommended tolerances, providing feedback and detailed reporting.

Emsco parts including the fluid end, power end, stuffing boxes, plungers, seals, bearings, diesel engines, and natural gas engines. We also have blasting and painting facilities as well as a machine shop. We have many years of experience rebuilding mud pumps

Where Emsco overhaul is required we"ll take care of complete disassembly, cleaning and NDT. Repairs will be made to machined components as necessary. Bearings, seals and other components will be replaced in line with our inspections. Motors will be overhauled, lube systems serviced and pulsation dampeners recertified. We"ll also check your fluid ends are in spec and can repair or replace. Your pump is then fully reassembled and commissioned.

SEEPEX metering and dosing pumps are a range of precision pumps that have a metering accuracy of +/- 1%. The pumps are found in a variety of industrial and municipal applications and are especially suited for low pulsation delivery of low to viscous media as well as chemically aggressive media and media containing solids.

Are you looking for a Pump Service Center in Burlington County, NJ? Pump Express is a Pump Service Center in Burlington County, NJ that has been serving customers in New Jersey, New York, Connecticut and surrounding areas since 1976. Backed by over 35 years of industry experience, our aim is to make it easier and easier to do business with us, while helping to improve your bottom line. We have listened to our customers" concerns about service quality, on-time delivery and elimination of errors.

Pump Express is the leading pump and electrical motor repair center in the tri-state area. With over three decades of experience, we are equipped to handle the most challenging demands.

We have a state of the art repair center with the industries most advance tools and machinery. Our facility is staffed with highly experienced factory trained pump engineers that are familiar with all the top brands. We serve many markets, including municipal, residential, commercial and industrial facilities. If you have a pump or repair problem that needs to be addressed, contact us now and we will get your pump back up and running in the least amount of time possible.

Our services range from simple seal replacements to complete pump overhauls. We provide diagnostic services for pumps and pump related equipment . We test all of our repairs before returning them to field operation. We offer free repair pick-up and delivery. Most services are completed the same day.

Our Bergen County Authorized Pump and Electric Motor Service Center can perform normal and expected wear service and help you resolve warrantee issues. From your heating circulator and chilled water split case pump to your pressure boosting and irrigation pump, we can handle them all. We also specialize in pedestal and submersible pumps of all types and sizes. Since we have one of the largest parts inventories in the country, you can be assured of a quick turn around time, so that your systems are up and running in the shortest time possible.

Pump Express has been delivering on its commitment to achieve excellence through continuous improvement. This means constantly monitoring our product offerings, customer service, delivery and inventory to ensure we are consistently meeting the needs, desires, and expectations of our customers.

We provide 24/7 emergency pump service. We also offer a variety of pump maintenance plans and programs to keep you covered. Get a Pump Service Estimate in Burlington County, NJ.

Backed by highly accomplished personnel in this arena, we are offering Hydraulic Pump Repairing Services . A team of dexterous personnel works in close coordination with our patrons to impart these services as per their needs. Provided services are largely valued amid our patrons for their on-time execution.

With the initiation of advanced technology, we provide PE Inline Pump Repairing Serviceto the clients. Our rendered services are quality verified and rendered according to the precise preferences of our customers. Our offered services are authentic and reliable in nature and are delivered with custom-made and standardized solutions to our valued customers.read more...