Why Service Your Drum Pump? The Importance of Pump Maintenance
Reliable equipment is crucial in manufacturing. Pumps are used in many different industries, from cosmetics and pharmaceuticals, through to advanced manufacturing and chemical production. Any production process that involves fluids usually requires a pump. Taking care of your pump through regular pump maintenance is vital to ensure optimal performance and to prevent costly downtime and repairs. This article explores drum pump maintenance; including how and why you should take care of your pump.
Firstly, let’s explore the difference between corrective and preventative pump maintenance. Corrective maintenance occurs once a pump failure has already taken place. This requires you to conduct essential industrial pump maintenance swiftly, to get the pump working efficiently again with minimal lost manufacturing or process downtime.
Focussing only on corrective pump maintenance poses a concern, as it solely addresses issues after they occur, rather than being proactive in preventing them. It’s perhaps more important to reduce pressure and downtime stemming from unforeseen pump failures. Therefore, the implementation of a preventative pump maintenance schedule becomes useful for a business.
Preventative pump maintenance
Preventative pump maintenance is less costly overall. This is because repairing a complete failure often requires more parts than performing routine maintenance. Businesses can also plan and prepare for down-time, rather than have a failure occur at an unwelcome moment.
A perfect example of this is replacement of the mechanical seal in the Flux F 430 pump. This wear part should be replaced every 3 years or after approximately 800 hours of operation. If the seal is not replaced and subsequently fails, liquid will enter the inner tube, contaminating the bearings, o-rings and driveshaft. These parts are not designed to be immersed in the pumped fluid and may be corroded or degraded. Liquid may begin to leak from the top of the pump tube below the motor, causing further damage and possibly creating a risk to the operator. The repair cost will be at least double the cost of a replacement mechanical seal.
Importance of pump repair and maintenance
Whole-Life Cost Savings
Implementing pump maintenance procedures reduces the risk of unexpected breakdowns and costly repairs. Regular inspections and preventive pump maintenance will identify potential issues before they escalate, saving you money in the long run.
Increased Efficiency
Well-maintained pumps operate more efficiently, resulting in energy savings and reduced operational costs.
Extended Lifespan
By following proper pump maintenance practices, you can significantly extend the lifespan of your drum pump. This means avoiding premature replacement costs and maximising return on investment.
Enhanced Safety
A well-maintained pump is less likely to pose safety risks, such as leaks, overheating, or sudden failures. Protecting the integrity of the process ensures a safe working environment.
Regulatory Compliance
Depending on the industry, there may be specific regulations or standards regarding equipment maintenance. Properly maintaining your pump helps meet these requirements and avoid potential legal or regulatory issues.
How to implement a Preventive Maintenance Program
If you currently lack a maintenance program for your pump, assign this responsibility to a team member. Follow a preventive pump maintenance schedule, e.g. annual servicing. This may include tasks such as replacing seals and o-rings, checking motor shaft alignment, testing safety devices such as pressure switches and verifying pump efficiency.
Identifying and addressing issues early can significantly contribute towards avoiding breakdowns. By implementing a structured maintenance routine, you can ensure optimal performance, whilst avoiding downtime.
Pump maintenance checklist:
Visual inspection
Conduct routine visual inspections to check for signs of impeller wear, shaft leaks, corrosion, or loose connections. Check the motor coupling cage for wear and damage. Rough handling can damage the motor connection union nut. If cracked, replace it immediately. Otherwise there is a risk of the motor becoming detached from the pump which can destroy the coupling cage. Ingress of large solid particles, or dropping the pump, can damage foot pieces and impellers.
During visual inspection, you may notice corrosion of the pump body. Corrosion can lead to failure through weakening of welds and other essential components. Addressing this early can help you avoid unwelcome centrifugal pump repair. Consider if the liquid is compatible with the materials of construction.
Monitor Vibration and Noise
Unusual vibrations or excessive noise can indicate driveshaft or bearing wear. Regularly monitor and investigate any abnormal vibrations or noises and address the root cause promptly. If liquid, sludge or solid particles have entered the inner tube of the F 430 pump, this can cause friction and excessive heat, leading to a squealing noise.
The driveshaft in F 424 pumps and certain F 430 models is reversible – if shaft wear is noted, reverse the driveshaft to double its lifespan. You should avoid pumping abrasive particles with seal-less pumps – this leads to excessive impeller, bearing and shaft wear, causing vibrations and eventually premature failure. Excessive motor noise can be attributed to worn bearings or carbon brushes.
Cleaning
Avoid letting debris, dirt, or contaminants enter the liquid container whenever possible. Use a compression gland, or fume gland to minimise this risk. Regularly check filters and strainers, ensuring they remain free from any blockages. Pumps used to transfer adhesive, or crystallising liquids, should be flushed before being left idle for any length of time, to avoid damage to seals.
Check Seals and Stators
Examine elastomers, seal faces and o-rings carefully, checking for signs of wear, delamination or physical damage. Replace these items if needed, to proactively avoid leaks. Leaks could result in operator injury, plus further damage to the pump, nearby equipment or the environment, and potentially delay your production processes. Worn progressive cavity pump stators will greatly reduce pumping efficiency.
It’s essential to remember that mechanical seals are a wearing part. Regularly replacing them will extend pump life. Centrifugal pump bearing replacement will increase the longevity of your pump.
Overheating
Excessive heat generation in the motor, motor coupling or pump bearings must be avoided. Potential causes could be due to lack of lubrication, mechanical seal failure, misconnection of the pump and motor, or overload from pumping viscous or adhesive liquid. In addition, using the incorrect power input, dry running, or running the pump against a closed valve for long periods will generate excess heat.
If overheating is left unchecked, rapid failure can occur. This is a particular concern when pumping flammable liquids, or working in a Zoned area. Diagnose the root cause and take appropriate corrective measures.
Clogging
It is vital to ensure there is not an accumulation of solids in your pump, as this can lead to impeller or driveshaft clogging. Signs of clogging include decreased flow rate, excess noise and eventually a destroyed motor coupling if total blockage occurs.
Parts availability
Although we endeavour to stock a wide range of parts in our UK warehouse, we recommend keeping typical wear parts such as mechanical seals, stators, o-rings, coupling cages and union nuts readily available at your site. Having these components on hand facilities quick and efficient repairs. You can download our spare parts lists here.
Embracing a proactive pump maintenance strategy and maintaining local stock of critical parts will significantly reduce downtime and optimise overall pump performance. If you need further assistance with pump maintenance or repairs, contact us at sales@flux-pumps.co.uk today!
