LESSON

4
LECTURE
COMMON PUMP PROBLEMS
SUB-OBJECTIVE
At the end of this Lesson the Trainee wi !e a!e to des"ri!e "o##on $%#$
$ro!e#s witho%t error&
'&( T)PES AN* S)MPTOMS O+ COMMON PROBLEMS
During operation a pump can face a variety of problems. These can
develop suddenly or gradually. They can be classified into two
varieties hydraulic and mechanical.
Examples of hydraulic problems.
* Insufficient discharge pressure
* No delivery of fluid
* Loss of priming after startup
Examples of mechanical problems
* !verheating
* "ibration
* Lea#s
'&' TROUBLE-S,OOTIN- A PUMP
The process of identifying problems that develop in any e$uipment is
#now as troubleshooting% usually begins with a report from the
e$uipment operator or other personal that there is something wrong
with the e$uipment. In most cases the causes of the malfunction is not
#nown and it is the duty of the maintenance mechanic to inspect the
pump and find the problem. The technician can find out the following
information from operator.
&. 'hat were the original unusual operating symptoms(
). 'hen did the symptoms first appear.
*. 'hether the symptoms developed suddenly or over a period of
time.
+. 'ere any other unusual things happening at the time(
'&. T)PES O+ S)MPTOMS
,nless the pump has had a complete brea#down and cannot be run at
all% the technician should inspect the pump whilst it is still running.
MECHANICAL MAINTENANCE COURSE MODULE 10
LESSON 4 PAGE 1 PUMP AND PUMP MAINTENANCE
'&.&' T,REE T)PES O+ S)MPTOMS CAN BE I*ENTI+IE*
&. -ymptoms that can be heard .excessive or unusual noise/.
). -ymptoms that can be seen .lea#age or unusual readings on
gauges/.
*. -ymptoms that can be felt .excessive vibration or heat/
N!TE0
Excessive heat can also produce an unusual smell.
1. N!I-E
,nusual noises can be divided into four groups0
&. Loud 2attling or 3langing noises% .which can often be a
bro#en part of foreign ob4ect loose in the casing/.
). 5rowling or 6owling% .which is usually worn or damaged
bearings/.
*. 6ighpitched -creeching .often caused by metal to metal
contact or overspeed/.
+. 1 loud 2attling that sounds li#e marbles% .often a sign of
3avitation/.
If one of these loud noises are heard the next step is to pinpoint
the exact place. This can be done with a stethoscope or
sounding rod such as a long screw driver.
S/#$to#s that "an !e seen in"%de0
&. 1bnormal gauge readings.
). Too much or too little lea#off from pac#ing glands.
*. Lea#age from pump casing and flanges.
+. Lubrication lea#age from bearing housing7pipe wor# .also
a 8I2E ris#/.
B& -a%1e readin1s 2%s%a/ ow readin1s3 are often the !est
indi"ator or $%#$ $ro!e#s&
Note0
9efore rushing off to strip the pump down% chec# that the gauges
are functioning correctly:
MODULE 10 MECHANICAL MAINTENANCE COURSE
PUMP AND PUMP MAINTENANCE LESSON 4 PAGE 2
Loss of pump discharge pressure is usually the most important
parameter.
Low dis"har1e $ress%re "o%d #ean one or #ore of the foowin1
"a%ses0
&. 9loc#ed suction strainers
). Loss of priming .usually caused by air lea#ing INT! the system/
*. Damage caused to impeller by foreign ob4ects.
+. -uction valves not correctly opened.
;. Incorrect assembly after maintenance i.e. motor may be
incorrectly wired up causing impeller to rotate bac#wards.
+i1& '(-4-'& Pro$er *ire"tion of I#$eer Rotation&
C& -and Lea4-off
&. The technician gets to #now through experience how
much lea#off is normal for a particular type of pump.
). Too much lea#off could mean that the gland follower
needs tightening.
*. If this does not wor# then the pac#ing has become worn
and will re$uire replacing.
+. Too little lea#off could mean that the gland follower is too
tight% or that the lantern ring is bloc#ed for instance.
MECHANICAL MAINTENANCE COURSE MODULE 10
LESSON 4 PAGE 3 PUMP AND PUMP MAINTENANCE
*& Lea4in1 +an1es
9olts need to be chec#ed for tightness% and gas#ets may need
to be replaced.
E& L%!ri"ant Lea4a1e
This could by caused by crac#ed housings or faulty seals% and
could cause severe damage such as sei<ed bearings through
loss of lubrication or even a fire.
.&( S)MPTOMS T,AT CAN BE +ELT
&. Excessive vibration.
). !verheated bearings.
*. !verheated -tuffing box
Excessive vibration can be felt by hand.
It can also be more accurately detected and diagnosed by a "ibration
meter which can detect shaft7coupling misalignment% bent shaft%
imbalance of rotating parts% worn bearings and mechanical looseness.
!verheating can be detected by hand% by thermometer7thermocouple%
or in extreme cases.
!/ a !%rnin1 s#e&
MODULE 10 MECHANICAL MAINTENANCE COURSE
PUMP AND PUMP MAINTENANCE LESSON 4 PAGE 4
S)MPTOM 5 CAUSE SOLUTION
N! LI=,ID DELI"E2ED
Lac# of prime.
-uction lift too high.
Discharge head too high.
Impeller plugged.
8ill pump and suction pipe completely with li$uid.
If no obstruction at inlet% chec# for pipe friction losses. If static lift is too high% li$uid to be
pumped must be raised or pump lowered.
3hec# pipe friction losses. 3hec# that valves are wide open.
Dismantle pump and clean impeller.
N!T EN!,56 LI=,ID DELI"E2ED
1ir lea#s in suction piping.
1ir lea#s in stuffing box.
Impeller partially plugged.
Defective impeller.
Defective pac#ing or seal.
-uction not immersed enough.
Test flanges for lea#age. -uction line can be tested by plugging inlet and putting line
under pressure.
Increase seal li$uid pressure to above atmosphere.
Dismantle pump and clean impeller.
Inspect impeller and shaft. 2eplace if damaged or vane sections badly eroded.
2eplace pac#ing or mechanical seal.
Lower inlet.
N!T EN!,56 >2E--,2E
-peed too low.
1ir lea#s in suction piping.
?echanical defects.
!bstruction in li$uid passages.
1ir or gases in li$uid. .'atch for bubbles/
3hec# whether motor is receiving full voltage.
Test flanges for lea#age. -uction line can be tested by plugging inlet and putting line
under pressure.
Inspect impeller and shaft. 2eplace if damaged or vane sections badly eroded. 2eplace
pac#ing or mechanical seal.
Dismantle pump% inspect passages% and remove obstruction.
>ossibility of overrated pump. >eriodically exhaust accumulated air.
>,?> !>E21TE- 8!2 -6!2T TI?E T6EN -T!>-
Incomplete priming.
1ir lea#s in suction piping.
1ir lea#s in stuffing box.
8ree pump% piping% and valves of all air. 3orrect any high points in suction line.
Test flanges for lea#age. -uction line can be tested by plugging inlet and putting line
under pressure.
Increase seal li$uid pressure to above atmosphere.
>,?> T1@E- T!! ?,36 >!'E2
?echanical defects.
-uction not immersed enough.
-tuffing box too tight.
-haft bent or damaged.
8ailure of pump parts.
Inspect impeller and shaft. 2eplaced if damaged or vane sections badly eroded.
2eplace pac#ing or mechanical seal.
Lower inlet.
2elease gland pressure.
3hec# deflection of rotor by turning on bearing 4ournals.
3hec# bearings and impeller for damage.
MECHANICAL MAINTENANCE COURSE MODULE 10
LESSON 4 PAGE 5 PUMP AND PUMP MAINTENANCE