Suggested Maintenance Plan

TECHNICIAN REQUIREMENTS

        Only skilled, trained, and safety conscious persons will service or repair pump stations.  All persons including helpers will be trained in electrical and mechanical safety procedures before working on any equipment.

        All technicians repairing or maintaining pump stations will be trained and equipped to work under “Lock Out” procedures.  Workers will practice lock out procedures at all times.  The standard lock-out procedures to be used are those published by the U.S. Department of Health and Human Services (DHHS) National Institute of Occupational Safety and Health (NIOSH) Publication Number 83-125.

        Determine the frequency of maintenance required based on site conditions and specific problems due to site conditions.  Some equipment can be safely maintained once every two months.  Some equipment must be maintained once per month or even more frequently.       

GOALS

1.      Maintain all equipment in proper working order.

2.      Maintain all pump stations and equipment rooms in a safe condition.

3.      Reduce long term operating expenses by preventative and predictive maintenance.

4.      Record operating parameters to assist in future assessments and diagnostics. 

DOCUMENTATION AND INVOICING

        Maintenance records will be the forms attached to this specification.  The forms will be filled out and signed by the technician in charge of and actually performing the routine maintenance on each visit, one form for each pump station.  The forms will be filled out, signed by the technician, and then copies of the original signed forms will be attached to the invoice sent to the customer for each routine maintenance or repair call.

 MAINTENANCE START UP AND PREPARATION

        It is assumed that the equipment has not been maintained to the level described in this document.  Therefore the first visit will require spending additional time at each pump station to prepare for service, to bring each station into full compliance with these standards, and to perform all services for the first year including the monthly, bi-monthly, six month, and annual services.

Prepare the equipment for future maintenance operations as follows:

1.      Determine and document the Standard Zone for each pump station.  The Standard Zone should have the highest flow rate within visual range of the pump station.

2.      On all pumps located above ground install a vacuum port for obtaining a vacuum reading from each pump.  This vacuum port should be at or as near as possible to the pump inlet connection.  The port shall consist of a ball valve with a pipe plug.  The port shall be closed off by the ball valve and pipe plug after readings are taken.  The port will be installed so that connection of the vacuum gauge is easy and fast.

3.      Determine and record which motors require bearing lubrication and which bearing greases each motor requires following the procedures described in this document.

4.      Install grease vents on each motor bearing case containing a non-sealed bearing that requires lubrication.  It is assumed that a zerk fitting is in place for any bearings that require lubrication, if not then install a zerk fitting.

5.      Any other preparations required to enable future maintenance operations to be performed in an efficient, safe, and suitable manner. 

MONTHLY or BI-MONTHLY MAINTENANCE

1. Determine if the pumping equipment and controls should be examined once per month, or once per every two months.  Experience will determine the frequency required.  Systems with low usage and systems that exhibit very few problems may only require examination once every two months.  Some systems may require every month, perhaps more.  Irrigation Craft does not recommend that a station be left unexamined for more than 2 months even in the best of circumstances.
2. On surface water sources visually check if possible the pump intake screens for weed growth and debris.  Check for audible pump cavitation (sounds like gravel in pump).  Clean or replace intake screens as required.  If screens require replacement use only permanent type intake screens constructed of HDPE, PVC, and type 316 stainless steel.  If growth on screens is rapid apply coat of marine anti-fouling paint such as Marlin CF bottom paint.
3. If water source is a well, and if the well has iron bacteria problems, perform a monthly service as required to clean out iron bacteria deposits from affected components.
4. Clean station and the area adjacent to the station.  Remove all dust, dirt, debris, vegetative growth, or any other items that may be harmful to the equipment.
5. Visually inspect all equipment for signs of infestation by insects, rodents, wildlife, or any other living infestation.  Clean and remove any unwanted intrusions.  If necessary maintain fresh poison in stations that have problems with vermin.  Use dry poisons only, do not use liquids or aerosols.  Use only poisons that are commonly available to the general public.  In the case of stinging flying insects such as bees, wasps, hornets, etc., use a liquid or aerosol spray if required but never allow the spray to land on electrical equipment.  If the infestation is inside an electrical component or enclosure then the equipment must first be disconnected from all electrical sources before spraying the area.
6. Lubricate locks and lock cylinders with graphite lock lubricant only.
7. Maintain all painted and corrosion prone equipment.  Apply touch up paint as required.  If severe corrosion is already present then treat with a rust treatment first, then paint with an appropriate coating to prevent further damage.  Pay particular attention to the pump (cast iron), pump motor (steel), some check valves (cast iron) and cooling blower (steel), and any painted steel electrical boxes.  Turn off all electrical power during and at least for 1 hour after painting.  If any painting was done near high voltage equipment (over 24 volts) ensure that all areas are fully dry and vented sufficiently before re-energizing the equipment.
8. Check for proper operation of any cooling blowers or fans, vents are clean.
9. Visually inspect station for and correct any water leaks.  After correcting the leak clean the area stained by the leak.
10. Clean pressure control pilot filter as required, but at least one time per month.
11. Check Pressure Control Valve for proper operation.
12. Check and record pressure on the Standard Zone.
13. Check and record flow rate (if possible) on the Standard Zone.
14. Inspect electrical equipment and wiring for signs of overheating, cracking, or damage.

15. Check the air tank for proper air pre-charge pressure if a bag or bladder type tank.  Follow the directions below to check and maintain the pre-charge pressure.

a)     Determine pump start pressure by observing at what pressure the pump starts.

b)     Remove all SYSTEM pressure from the pressure tank.

c)      Check tank pre-charge pressure at the Schraeder valve with pressure gauge.

d)     Air pre-charge pressure should be set to 2 psi below the pump start pressure.

e)     Add or remove air as required through the Schraeder valve.

f)        Re-start station.  Once station is pressurized and stopped, test station by opening the Standard Zone.  If air tank makes noise just before the pump starts then lower air pressure until noise stops when repeating this test.

16. If the pressure tank is not a captive air type tank, then verify that the following components are working properly and correct as needed:

a)      If tank receives air from a line shaft turbine direct into the pressure tank then verify that the vacuum release valve on the turbine pump is operating correctly, and that the air level maintenance valve is working properly.

b)      If tank receives air from an air maintenance valve (knick-named “snifter” valve), then make sure that this valve is actually maintaining a correct level of air inside the pressure tank.

17. If the system is a pressure demand (constant pressure on mainline), with no water flowing, determine and record how often the pump must start to maintain pressure on the mainline, and also how long the pump must run each time.  Compare with past recordings and notify owners of field leakage if a problem is suspected.
18. If the system is clock demand, manually operate pump until mainline pressure reaches maximum pressure and steady, then turn the pump off.  Time how long it takes the pressure to drop to zero or the lowest static head pressure.  Record this time and notify owner if system leakage is a problem.

 SIX MONTH MAINTENANCE

1. Perform the following procedures in addition to all monthly procedures.
2. Check that all pilot lights function properly.  Replace as necessary with LED bulbs only.
3. Test each feature and alarm for proper operation.  Adjust and repair as needed.
4. Check & Calibrate all pressure switch adjustments.
5. Check and record static voltage at the incoming power connection to each control panel.
6. Check and record the vacuum reading for each pump while the Standard Zone is operating.
7. Check and record dynamic voltage at the incoming power connection to each control panel with the Standard Zone operating.
8. Check and record amperage draw on each pole of each motor during operation of the Standard Zone.

 YEARLY MAINTENANCE

1.      Perform the following procedures in addition to all monthly and six month procedures.

2.      MAIN ELECTRICAL LUG TORQUE VALUES - Check each power connection on the incoming service connection and the entire motor power circuit once per year for tightness according to chart A below.  While tightening the lugs inspect for signs of corrosion and overheating, correct as necessary.

CHART A

TORQUE IN INCH POUNDS

3.      Grounding – Check all ground connections for signs of corrosion, clean or replace wiring and connectors as required.  Tighten all ground connections according to the values shown in Chart A.

4.      Check Pressure Control Valve for proper operation.  On all pump stations capable of developing more than 80 psi overhaul the pressure control valve and pilot system.  Replace all soft parts on the valve and pilot control system.  Start pump and bleed air from pilots and valve cover chamber, calibrate valve.

5.      Motor Lubrication

        Irrigation pump motors may or may not require lubrication depending on whether or not they have sealed bearings.  If a motor has sealed bearings then no lubrication is required.  Do not attempt to lubricate sealed bearings.

        Investigate the type of bearings which each motor has and lubricate as required by the motor and bearing manufacturer.  Establish a lubrication procedure as follows:

B.     SEALED OR OPEN - Determine if the bearing is a sealed or open type bearing.  If sealed then do not lubricate.  If open then follow the directions below.  Assume that any motor less than 3 horsepower has sealed bearings, do not lubricate the bearings.

C.    WHAT KIND OF GREASE ? - Determine what type of grease was originally installed in the bearing.  You must use the same type of grease or risk incompatibility and rapid failure of the bearing.  If you do not know what type of grease was used then consult the motor manufacturer, bearing manufacturer, or some other authority and select your own brand and type of grease.  If you are changing the type of grease then remove the bearings and clean all the existing grease off the bearings.  To assist you in finding a compatible grease we have listed the grease types used by the different manufacturers.

1.      BALDOR MOTORS – Mobile Polyrex EM or Chevron SRI No. 2.

2.      US ELECTRIC MOTORS– Mobile Polyrex EM or Chevron SRI No. 2.

3.      WEG MOTORS – Frames 143T up to 215T use Alvania R3 (Shell Oil).  Frames 254T and larger use Esso Unirex N2.  WEG states that Exxon-Mobile Polyrex EM is compatible.

4.      AO SMITH MOTORS – These are typically small 1-2 horsepower motors with sealed bearings, DO NOT LUBRICATE.

D.    VENT PLUG – No bearing should ever be lubricated without first opening a vent to allow the escape of old grease.  If no vent tube is in place install one as follows.  Remove vent plug, permanently install a copper “U” shaped tube with the open end aimed up and away from the ground.  If exposed to rain or falling water then aim the open end of the tube parallel to the ground in such a manner that rain cannot directly fall onto the open end.

E.     FREQUENCY OF LUBRICATION -  For all irrigation pumps located on Fort Lauderdale International Airport property lubricate one time per year.

F.     AMOUNT OF GREASE –  Inject sufficient grease into the bearing to expel the old grease.  Stop injecting grease when new grease exits the vent tube.

Specifications, Pricing, and all other information on this website are subject to change without notice.