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close this book A training manual in conducting a workshop in the design, construction, operation, maintenance and repair of hydrams
close this folder Session 14: Repair and maintenance (2-4 hours)
View the document Handout 14A: Repair and maintenance chart
View the document Handout 14 B: Repair and maintenance worksheet
View the document Handout 14 C: Maintenance/service worksheet

Session 14: Repair and maintenance (2-4 hours)

Time: 2-4 hours

OBJECTIVES: By the end of this session the trainees will be able to:

· predict malfunctions and problems in the operation of a hydram over time;

· accurately diagnose malfunctions and causes; and

· develop skills and experience in repair and maintenance of hydram systems.

OVERVIEW: Participants identify potential malfunctions, describe symptoms and prescribe cures; practice repairing; and develop strategy for long term preventive maintenance and routine service. The activity described below can be adapted for actual installations, if available.

MATERIALS: Handouts 14A (3 pp), 14B, 14C

TOOLS: All basic plumbing tools used to date in workshop

Spare parts

Enough hydrams for each experimental station



1. State objectives of the session.


2. Ask participants to generate a list of possible malfunctions and symptoms based on their construction experience, inter-relationship experiments, and what they've learned so far to date.

List should include all items on '4A, trainer should add any that are not mentioned.

3. Divide participants into 3 groups, and assign each group approximate-1y 1/3 of the listed malfunctions. Distribute Handout 14B. Group Task: for each malfunction/ symptom listed, complete columns 2 and 3 of handout 14B, and write on flip chart for presentation.

Alternatively, groups work on all symptoms, after groups finish post flip charts on wall with each symptom. Individuals complete. Large group reviews, corrects, discusses. Trainers should be available if a group gets stuck. 1 hour.

4. Groups report out; check for accuracy and completeness of possible cures.

30 minutes.

5. Ask each group to select one malfunction, go to an experimental station, and simulate malfunction. Allow 20 minutes. Ask group to listen to the ram, write down the sound and record its deviation from a well functioning ram.

Trainers could also simulate to save time.

6. Each group moves to another station and listens to ram, records description of sound, diagnoses problem, determines solution and repairs it.


7. Each group will report on:


- sound


- diagnosis


- success in repairing


- implications for preventive maintenance.


8. Repeat steps 5-7, this time groups to combine 2 malfunctions/ symptoms.


9. Ask participants to complete worksheet, Handout 14B, columns 4 and 5.


10. In a large group, discuss implications for long term preventive maintenance. Have the group brainstorm a list of preventive maintenance tasks, routine servicing tasks. Individuals complete worksheet, handout 14C for their site.

Trainers will circulate to ensure that lists are complete, time frames accurate.