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....................................................... Pump Maintenance

An additional challenge in the financial aspect is the ability to persuade
senior management that the additional expenditure sometimes required
for a Reliability approach has quantifiable benefits. As most senior
managers are not always aware of the technicalities involved in pump
repair, or the ramifications of such repair, it becomes the responsibility
of the maintenance personnel to effect the translation from the
technicalities to the financial benefits. The ability to translate a
prevented failure into dollars saved is critical.
The most important number that must be learned is the cost of down-
time for the equipment (or system). This could involve the loss of sales
revenue from the product being produced and the loss of productivity
of the personnel involved. As this number is frequently in the tens of
thousands of dollars per hour of lost production, it become a critical
factor in the (financial) decision making process.
It is also important to know the difference in the cost of a repair
conducted in a planned and organized fashion as opposed to one
conducted in a reactive mode. The latter usually includes a lot of time
wasted while personnel, tools and spares are sourced and brought to
site. With a planned outage, all necessary personnel and equipment are
scheduled to be on site at the time the job is due to begin, thus
minimizing the risk of wastage. The difference in costs of such a repair
has been reported to be anywhere from 25% to 50% of the cost of an
unplanned reactive repair.
For Reliability strategy to be a success it is essential that support be
gained from those holding the purse strings. Consequently the
translation from technical benefits to dollar figures for each strategy
proposed must be undertaken by the maintenance staff in order secure
such support.

12.2 Preparation for pump dismantling
To ensure that each component of the pump is properly inspected, it is
recommended that standardized dismantling techniques be
implemented. This will ensure that every pump of the same type is
dismantled in the same way, with every step systematized and all
measurements recorded in the same way, for reference.

The first order of business in dismantling a pump for service is to lock
out the electrical power in order to prevent accidental startup of the
driving motor, and physical injury. In addition, all isolating valves on
both the pump suction and discharge side must be shut off.
If the pump has been operating at high temperature, allow sufficient
time for it to cool down before trying to dismantling the equipment. At
this point, all joints and piping should be match marked for accurate
reassembly.

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