General Maintenance Revised

Guyana Water Incorporated
Equipment Maintenance
Session 1
Training Content
1. Role of the operator in the maintenance.

2. General overview of items in the plant and
their function and importance to
maintenance.
3. Purpose of maintenance.
4. Benefits of maintenance
5. Setbacks to maintenance.
6. Preparing a maintenance plan
ENERGY LOSSES IN A PUMPING SYSTEM
Requirements For Sizing the Pump
Sizing of Pump
A Static Level
B Draw Down
C Height of Pressure Gauge From Ground

D Distance of Pressure Gauge From Well Head
Submersible Pump Level Measurement

Role of operator in maintenance
1. To carry out daily and routine maintenance

(applying grease to bearings, ois to
gearboxes, etc.).
2. To be the house keeper of the plant (clean
the building and equipment of any foreign
particles and objects).
3. To be the first person to detect a fault in an
equipment or a change in the operation.
4. Etc. (Operators to share others)
Role of operator in maintenance
Overview of testing and measuring equipment
Temperature gun
Multi function display meter
Flow meters
Pressure Gauge
Overview of items and measuring equipment
The human sensory system

Purpose for Maintenance
The main purpose of maintenance is

1. To have equipment available for use when
needed.
2. To have all equipment and systems
operating at 100% efficiency at all times.
3. To benefit from manufacture’s warranty.
4. Etc.
Benefits of Maintenance
1. Reduction in unplanned stoppages.
2. Slows the rate of replacement of a part or
the entire equipment.
3. Saves the company money long term.
4. Maintains the plant and or machine
efficiency.
5. Upkeep the useful life of the
plant/machine.
6. Maintains a safe working environment for
all.
Benefits of Maintenance
6.
7.
8.
9.
10.
Types of Maintenance
Types of Planned Maintenance Practices
Preventive maintenance
It is the regular and routine maintenance of

equipment and assets in order to keep them
running and prevent any costly unplanned
downtime from unexpected equipment failure
or stoppage.
Types of Maintenance Practices
Preventive maintenance
It is either
1. Conditional base - (a small leak on a valve, a
heated zone on a pump and is usual after an
inspection is done, etc.)
2. Mandatory or periodic base - (replacing the
oil and filters after every 6 months or 250
hours of operation in generators, lubricate a
part, etc. as indicated by the equipment
maintenance manual)
Corrective maintenance
Also called breakdown maintenance or

curative maintenance and often requires
troubleshooting to restore. It may even result
in the replacement of parts to make
operational again. E.g.
1. Cut cable on well motor
2. Burnt contactor or circuit board of a motor
starter.
Design out maintenance
This is also known as plant improvement
maintenance, and its object is to improve the
operation, reliability or capacity of the
equipment in place. This sort of work usually
involves studies, construction, installation,
start-up and tuning.
Design out maintenance
E.g. Inserting a sleeve around a
submersible motor to increase the speed
of water passing same in an effort to
increase cooling.
Predictive maintenance
Predictive maintenance is a technique that
uses data analysis tools and techniques to
detect anomalies in your operation and
possible defects in equipment and
processes so you can fix them before they
result in failure. E.g.
1. Using the plant’s log sheet data to
determine the state of an equipment.
2. Utilizing maintenance records to predict.
Cost of Assets Managed
Cost of Assets Managed
RURAL CUT OUT SWITCH (RCO)
Usually when the fuse

is damaged the fuse
holder releases the fuse
Fuse Holder
Fuse Wire
(fuse element)
3 POLE CIRCUIT BREAKER
Breaker Rating
Breaker Setting
(Adjustable
Rated Breaker)
OTHER CIRCUIT BREAKERS
Control Circuit Breaker

COMPONENTS IN ELECTRICAL PANEL
Load side of
Contactor
Temperature Line side of

Measurements are taken at Contactor
these points
3 POLE CIRCUIT BREAKER POSITIONS
Breaker Breaker
A B
What is the position
Breaker A ?
Breaker B ?
Breaker c ?
Breaker
C
COMPONENTS IN ELECTRICAL PANEL (THERMAL
OVERLOAD)
Reset Button
Overload trip point

COMPONENTS IN ELECTRICAL PANEL (MAGNETIC OVERLOAD)
Protects Against
• Under/Overload
• Under/Overvoltage
• Current Unbalance
• Overheated Motor
(if equipped with
Subtrol Heat Sensor)
• False Start
(Chattering)
• Phase Reversal
TYPICAL TRIP CURVE OF PROTECTION DEVICES
A motor overloaded 5
times its current will
take
1. Approx. 7 seconds
when set on class
1o overload
when set on class
20 overload
when set on class
30 overload
Transformer
3 Phase Voltage Monitor
High Voltage/Low Voltage Relay

1. Phase Voltage Balance Relay has a set

manufacturer voltage setting (415,
440, 460)
2. It has an over and under voltage
adjustment which operates on a % of
the set voltage
3. The over and under voltage setting
must be set as is specify by the motor
manufacturer.
4. Franklin electric motor well motor was
designed to work at +/- 10% of its rated
voltage
5. When the voltage is within range the
green R led is lit
6. When the >U led is lit then the voltage
is above the working range
7. When the U> led is lit then the voltage
is below the working range
Booster Motor – Parts Identification &
Purpose
Motor – Maintenance
A guide to when maintenance is performed
1. As per schedule – bearing life reached, etc.
2. Abnormal bearing sound – grease or
replace
3. Abnormal temperature rise from motor
windings.
Provide me with some other reasons

Motor – Understanding Booster Motor
Nameplate Data & Importance
Key Things to know
1. The motor has a maximum power rating of
100 Horse Power or 75 Kilo Watts.
2. It is rated to operate at 460 Volts with a
maximum current of 110 Amps. This current
must not be excessed during normal
operation.
3. It was designed to operate in an
environment of 40 0C and can have a
Key Things to know
4. The max temperature the motor winding can
withstand before damage is 0C.
5. The drive and non drive end motor bearing
is 6314 C3.
6. Motor bearings are to be greased every 4,000
hours with 27 grams of poly mobil EM grease.
Do’s and Don’ts with Booster Motor
1. Never operate without fan and fan guard.
2. Never hang/put anything on motor to dry.
(This will endanger you and the motor).
3. Never operate with an open terminal box
cover.
4. Replace all guards before operating
Franklin Electric Motor (Well Motor)
Operating Parameters
Key Things to know 1. Tolerance voltage is +/-
10% nominal voltage.
2. Unbalance current
should not exceed 10%
at full load current or 5
% at service factor
current
3. Service Factor current is
1.15 of full load current
4. Service factor current is
not to be continuous in
the operation
Booster Pump – Parts Identification & Type
Horizontal Split
Case Pump
Booster Pump – Parts Identification & Type
Horizontal End Suction Open Coupled Horizontal End Suction Closed

Pump Coupled Pump
Needs alignment but works with various It needs no alignment but needs a
motors compatible motor
Pump – Typical nameplate identification & curve
Pump – Maintenance
1. As per schedule – bearing life completed,
etc.
2. Abnormal sounds and vibration
3. Leaks on mechanical seal or gland packing
Do’s and Don’ts with Pump
1. Never operate without water. It will
damage the seal.
2. Never throttle valve on intake/suction
pipe.
3. Avoid throttling valve on outlet/discharge
pipe
4. Never close valve on lubrication line (line
cooling mechanical pump seal or gland
packing)
Gearbox – Checks & Lubrication
1
1. Oil levels in gearbox
must be checked daily
via the dipstick.
2. Oil level must not be
exceed full mark.
3. Only gear oil can be
used in gearbox.
4. A warp in shaft rotation
would indicate
something is wrong
with gearbox or its
coupling to stirrer
shaft.
Valve – Parts Identification
Valve – Maintenance
1. Whenever there is a leak
2. Routinely or as per schedule (valve must
be fully opened and fully closed from time
to time).
Daily Checks
Motor – Voltage, Current, Temperature,

Vibration, Abnormal sound, etc.
Pump – Flow, pressure, vibration, leaks,

abnormal sound, etc.
Equipment Maintenance
Session 2
POWER SUPPLY SYSTEMS

1. The need for alternative power source
2. The Automatic/manual transfer switch
3. Generator types and main components
The Prime Mover
The cooling system
The DC starting and charging system
The lubricating system
The fuel system
The alternating voltage system
The Need for Additional Power Supply Source
1. Power failure (Blackout) - It is the loss of
electrical power to the network.
2. Low voltage – Voltages supplied below the
nominal voltage on the equipment
nameplate and is below its tolerance.
3. High voltage – Voltages supplied above the
nominal voltage on the equipment
nameplate and is above its tolerance.
4. Phase loss - This occurs when one or more
fuse of a three-phase system is out.
5. Phase sequence - This is a change in the

sequence of the wiring
L1 L2 L3. L1 L3L2. L2L3L1
6. Unbalance voltages – The supply voltage on
the various lines varies significantly.
An example of an unbalanced voltages system
is a system provides the following voltage
360V, 385V, 400V.
This causes high current unbalances, results in
overheating of equipment
Typical Power Supply System
GP
L
Typical Generators in plants
Open generator
To be installed in a building
Outdoor generator
To be installed with adequate ventilation
Important Parts on a Generator
One part is the engine or the prime mover
The engine has many parts making up systems

Some Parts on a standby generator
The cooling system
Important Notes on Cooling System
1. Coolant must be visible at the gauge glass
of radiator.
2. Use approved coolant only in radiator.
3. There must be no leak in the cooling
system.
4. All fan drive belt must be in place with no
visible cracks
Some Parts of a Standby Generator
DC Starting & Charging System
Important Notes on DC Starting & Charging System
1. Battery must never be stored on a bare
concrete surface.
2. Battery must always have electrolyte inside
the cells. Only de-ionized water is to be
used tap up battery water.
3. Battery terminals must always be clean
and tight. Never start a generator when the
battery is slack.
4. Alternator fan drive belt must be in place
with no visible cracks and must not be
slack.
The Lubrication System
1. Use only the recommended oil in an engine. 15W40

2. Always check oil level before starting engine
3. Never add more oil than is needed in an engine
The Fuel & Combustion System
Fuel Water Separator Fuel Tank Air Filter

The Fuel & Combustion System
Red indicates water level in fuel Air Filter gauge

Important Notes on Fuel & Combustion System
1. Drain water from fuel filter regularly.
2. Daily check quality of fuel with fuel
marker.
3. Clean spillage on fuel tank base. Keep tank
base clean.
4. Regularly check the condition of the air
filter.
5. Change air filter if indicator guide is red.
The AC Alternator
How AC Voltage is Produced in the Generator
1. In the ac exciter field (stator) there is a residual
magnetic field that has magnetic properties.
2. When the prime mover (the engine) turns the exciter
rotor (amateur) in this magnetic field a voltage is
induced.
3. The induced voltage is then converted to a dc voltage
by a rectifier made of diodes.
4. The rectified voltage is then transferred to the main
field rotor via hard wire connection.
5. The magnetic field in the main field rotor then creates
a voltage in the main stator which operates the motors.
Daily Generator Check Sheet
Common Generator Faults Alarms & Possible
Solution
1. Engine fails to start
Emergency stop switch may be
engaged.
Battery may be dead
Battery lead may be slack
2. Engine cranks but fail to Start

Battery lead may be slack
Battery lead needs cleaning
Common Generator Faults Alarms & Possible Solution
3. Engine shuts down on overheat
Check coolant level in radiator.
Check for slack or burst fan belt.
Check for block radiator (external blockage
from oil accumulation, etc.).
Check for presence of radiator cap
4. Engine smokes excessively
Check condition of air filter.
5. Engine shuts down and backs down when
loading
Check for water in fuel.
Check condition of air filter.
Common Generator Faults Alarms & Possible
Solution
6. Generator shuts down on under-voltage
Faulty automatic voltage regulator
Damage diodes in exciter
(Call electrician for this fault)
Setback to maintenance
1. Equipment supplied without a
comprehensive service manual.
2. Lack of knowledge and skills to carry out
works.
3. Service tools unavailable and was not a part
of the purchase.
4. Lack of investment in maintenance
(spares).
Setback to maintenance
7. No maintenance plan
8. Poor attitude. Is not mine it’s the company.
9. Inadequate redundancies. If this is stopped
now so many persons will be affected.
10.
11.
Writing an Equipment Failure Report
Key Points in Report
1. Always state the measured operating
parameters (currents, voltages,
temperatures, etc.) at the time of the failure
2. Make mention of logged events like
shutdown, etc. before the equipment failed.
3. Always make mention of any documented
report of the equipment performance
4. State last service date, what was done and by
who.
Writing an Equipment Failure Report
Key Points in Report
5. State any valid recommendations
In Setting up a maintenance plan
Please note the following
1. Each equipment in the plant require some
amount of maintenance.
2. Maintenance must cater from the start to
the finish of a system. E.g. the well pump
starts at its power supply feed and ends at
the motor. All items related to the well must
therefore be catered for in a maintenance
plan.
In Setting up a maintenance plan
Please note the following
3. Equipment maintenance is specified by the
manufacturer’s manual firstly
4. Additional works can be added due to
operating environment, etc.
5. Spares must be catered for in any
maintenance work.
Maintenance Module Assignment
Please take note of the following
1. The assignment will be graded and will
form a part of the course work.
2. Operators operating out of the same plant
can work together to complete the
assignment. (Team effort would be
expected)
Maintenance Module Assignment
Prepare the schedule of a maintenance plan
for all the operating systems in your plant.
The plan must indicate the work that must be
done to each equipment and the materials
necessary to complete the task.
Note: The plan must follow the manufacturer’s

recommendation at minimum.
A table form would be appreciated.

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Guyana Water Incorporated

1. Role of the operator in the maintenance.

C Height of Pressure Gauge From Ground

Submersible Pump Level Measurement

1. To carry out daily and routine maintenance

The human sensory system

The main purpose of maintenance is

It is the regular and routine maintenance of

Also called breakdown maintenance or

Usually when the fuse

Control Circuit Breaker

Temperature Line side of

Overload trip point

3 Phase Voltage Monitor

High Voltage/Low Voltage Relay

1. Phase Voltage Balance Relay has a set

Provide me with some other reasons

Horizontal End Suction Open Coupled Horizontal End Suction Closed

Motor – Voltage, Current, Temperature,

Pump – Flow, pressure, vibration, leaks,

POWER SUPPLY SYSTEMS

5. Phase sequence - This is a change in the

One part is the engine or the prime mover

The engine has many parts making up systems

1. Use only the recommended oil in an engine. 15W40

Fuel Water Separator Fuel Tank Air Filter

Red indicates water level in fuel Air Filter gauge

2. Engine cranks but fail to Start

Note: The plan must follow the manufacturer’s

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