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Trouble Shooting Problems in Chemical Industry

A DISSERTATION

Submitted in partial fulfilment of the requirement

for the award of degree
of
BACHELOR OF TECHNOLOGY
in
CHEMICAL ENGINEERING
by
SUSHANT DHIR SAJAL AGGARWAL
Roll No.-11112085 Roll No.-11112073

Under the supervision of

DR. NEETU DIVYA
Assistant Professor

Department of Chemical Engineering

Dr. B. R. Ambedkar National Institute of Technology
Jalandhar, India 144011
May, 2015
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CANDIDATE’S DECLARATION

We hereby declare that the work which is being presented in dissertation entitled “Troubleshooting Problems
in Chemical Industry”, submitted towards the partial fulfilment of the requirements for the award of the degree
of Bachelor of Technology in Chemical Engineering, Dr. B. R. Ambedkar National Institute of Technology,
Jalandhar is an authentic record of our own work carried out under the supervision of Dr. Neetu Divya,
Assistant Professor, Department of Chemical Engineering, National Institute of Technology, Jalandhar.

The matter embodied in this dissertation report has not been submitted by us for any other degree or
diploma.

Place: NIT Jalandhar (Sushant Dhir)

Roll No. 11112085

(Sajal Agarwal)
Roll No.11112073

CERTIFICATE
This is to certify that the above statement made by the candidate is correct to the best of my knowledge.

Date: (Dr. Neetu Divya)

Dissertation Guide Head of Department
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Acknowledgement

We express our deep sense of gratitude to our project supervisors Dr. Neetu Divya, Assistant Professor,
Department of Chemical Engineering, National Institute of Technology, Jalandhar, for his invaluable guidance,
persistent encouragement and constructive supervision during the course of our study. We are indebted to her for
having spared their valuable time in giving concrete suggestions and increasing our knowledge through fruitful
discussions.
We are thankful to the members of our evaluation committee Mr. Abhishek Verma, Assistant Professor,
Department of Chemical Engineering, Dr. B. R. Ambedkar National Institute of Technology, Jalandhar his
valuable suggestions and critical comments during the course of our work. The cooperation we received from
other faculty members of this department is gratefully acknowledged.
Finally, we would like to thank everybody whose direct or indirect support has helped us.

NIT Jalandhar (Sushant Dhir)

(Sajal Agarwal)
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List of Contents Page No.

List of figures 6
List of Tables 7
Abstract 8

Chapter-1 Introduction 9
Chapter-2 Literature review- Pumps 10
2.1Introduction to Pumps 10
2.1.1 Pump Stations
2.1.2 Types of Pumps
2.2 Introduction to Problems in Pumps 17
2.3 Hydraulic Failures 17
2.2.1 Cavitation
2.2.2 Pressure Pulsations
2.2.3 Radial Thrust
2.2.4 Axial Thrust
2.2.5 Suction and Discharge Recirculation
2.3 Mechanical Failure 23
2.3.1 Bearing Failure
2.3.2 Seal Failure
2.3.3 Lubrication Failure
2.3.4 Excessive Vibrations
2.3.5 Fatigue
2.4 Other Modes of Failure 28
2.4.1 Erosion
2.4.2 Corrosion
2.4.3 Excessive Power Consumption
2.5 Vacuum Pumps Common Problems and Troubleshooting 30
2.5.1 Problems in Liquid Ring Vacuum Pump
2.5.1.1 Leakage
2.5.1.2 Noisy Pump Operations
2.5.1.3 Vacuum Problems
2.5.1.4 Vibration Problems
2.5.2 Problems in Rotary Piston Vacuum Pump
2.5.2.1 Excessively High System/Pump Ultimate Pressure
2.5.2.2 Excessive Pump Noise
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2.5.2.3 Pump Stalls

2.5.2.4 Dry Screw Vacuum Pump Insufficient Pumping Capacity
2.5.2.5 Over heat
Objective 34

Chapter 3 Material and method study 35

3.1. Materials required 35
3.1.1 Flow sheets
3.1.2 Pump specifications
3.1.3 Troubleshooting charts
3.1.3.1 Troubleshooting Chart-1
3.1.3.2 Troubleshooting Chart-2
3.1.4 Designing tool
3.2. Methodology used 44
Chapter 4 Result and discussions 45
4.1 Problem Description 45
4.2 Reasons of Problem 46
4.3 Possible Solutions 47
4.3.1 Theoretical aspect
4.3.2 Design engineering aspect
4.3.2.1 Designing and Engineering
4.3.2.2 Manual of Line Sizing (Pump Lines)
4.4 Cost estimation of different possible solutions (Theoretical) 54
of problem
4.5 Cost estimation of different possible solutions (Design) of problem 58
Conclusion 62
References 63
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List of Figures

Serial No. Title

Figure – 1.1 Gear Pump Internal
Figure – 1.2 Screw Internal Pump
Figure – 1.3 Rotary Vein Pump
Figure – 1.4 Plunger Pump compared to Piston Pump
Figure – 1.5 Centrifugal Pumps
Figure – 1.6 The Forces effect on a mass going
Along an impeller vanes
Figure - 1.7 Troubleshooting-1
Figure- 1.8 Troubleshooting-2
Figure - 1.9 Troubleshooting-3
Figure – 2.0 Troubleshooting-4
Figure – 2.1 Troubleshooting-5
Figure – 2.2 Troubleshooting-6
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List of Tables

Serial No. Title

Table – 2.1 Troubleshooting Chart-1
Table – 2.2 Troubleshooting Chart-2
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Abstract

Chemical Industries play an important role in the economy of any Nation. Chemical Industries include Chemical
Plants, Pharmaceutical Industries, Oil & Energy sector, Nuclear Power Plants, Thermal Power Plants,
Cement/Ceramic Industries and many more. These Industries face lots of problems, failures, breakdowns during
its operation which leads to production loss, energy loss and undesired quality of products and sometimes could
lead us to Hazards. Lots of research and development has been done in this field but it is required as world is
facing Hazards in Chemical Industries very often which shows the importance of this study. We will focus on
Pumps, pumping system Exchangers and will try to figure out what are the problems we face in these equipment,
how we can resolve this problem, what could be the suggested new technique. We will discuss the
troubleshooting of pumps and line system associated with it by designing aspect and finally will come up with
an efficient and optimized technique.

Keywords: Chemical Industries, Pumps, Lines, Mitigation Techniques, pumping system, designing,
optimization.
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Chapter 1
Introduction

An industry operates by the help of its manpower, equipment’s and resources. If any of the one goes off the
route for even a single day then the productions and the output become paralyzed. The project we are working
on focuses on the pump. Pump is one of the most important functioning equipment with in an industry. Over the
past few yes, as the demands in the markets areincreasing the industries works towards meeting the demandsand
earning the profits. Now if a breakdown occurs inside a plant, then the number of hours taken to make the plant
run again is the ultimate production loss of the company. Through this project we have developed systematics
procedure for the troubleshooting of the pump. The project focus on the theoretical aspect of the pumps, but it on
one hand is providing us an enormous amount of knowledge to be used further in future. We carried out the
troubleshooting at even the smallest scale, observing every possible causes of the problems encountered while
operating the pumps, the number and the types of solutions valuable to us after the troubleshooting of the pump,
analyzing the feasibility of the solution obtained, understanding the concept of cost estimations, calculating
various types of the cost expenses and the profits loss per day.
Through this project we want to focus on the type of problems associated with a working industry and
developing an approach towards the basic ideas and methods of troubleshooting any problem in pump. Though
in market today high technological alternatives are available, but they somewhere lag at the point of decision
making. In this project our basic aim will be headed for the achievement of a proper troubleshooting procedure
with some idea of the feasibility either by the theoretical aspect available with dealing the problems or with the
designing approach. We will develop a tool to calculate the pressure losses inside the line to provide solutions to
problems using the designing aspect.
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Chapter 2
Literature review-pumps

2.1 Introduction to Pumps:

A pump is a device that moves fluids, or sometimes slurries, by mechanical action. Pumps can be classified into
three major groups according to the method they use to move the fluid: direct lift, displacement,
and gravity pumps.
Pumps operate by some mechanism (typically reciprocating or rotary), and consume energy to
perform mechanical work by moving the fluid. Pumps operate via many energy sources, including manual
operation, electricity, engines, or wind power, come in many sizes, from microscopic for use in medical
applications to large industrial pumps.
Mechanical pumps serve in a wide range of applications such as pumping water from wells, aquarium
filtering, pond filtering and aeration, in the car industry for water-cooling and fuel injection, in the energy
industry for pumping oil and natural gas or for operating cooling towers. In the medical industry, pumps are used
for biochemical processes in developing and manufacturing medicine, and as artificial replacements for body
parts, in particular the artificial heart and penile prosthesis.
In biology, many different types of chemical and bio-mechanical pumps have evolved, and bio mimicry is
sometimes used in developing new types of mechanical pumps.
2.1.1 Pump Stations:
Functions:
Pump Stations are small communities used for following purposes-
i. Remove water from a source, such as river, lake, reservoir, well, spring, or pond.
ii. Move water from treatment plant to distribution system or reservoir.
iii. Circulate water through distribution channel.
iv. Maintain distribution in the distribution system.
v. Circulate glycol through the heat exchanger or heating loop.
vi. Pump chemicals into the system.
Major components:
Pump system is composed of four types of components-
i. The building
ii. The hydraulic system: pump and related piping.
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iii. The electric system: the motor and its related components.
iv. The control system: pressure, flow and level switches.

2.1.2 Types of Pumps:

A. Positive displacement pump
A positive displacement pump makes a fluid move by trapping a fixed amount and forcing (displacing) that
trapped volume into the discharge pipe.
Some positive displacement pumps use an expanding cavity on the suction side and a decreasing cavity on the
discharge side. Liquid flows into the pump as the cavity on the suction side expands and the liquid flows out of
the discharge as the cavity collapses. The volume is constant through each cycle of operation.
Positive displacement pump behavior and safety
Positive displacement pumps, unlike centrifugal or roto-dynamic pumps, theoretically can produce the same
flow at a given speed (RPM) no matter what the discharge pressure. Thus, positive displacement pumps
are constant flow machines. However, a slight increase in internal leakage as the pressure increases prevents a
truly constant flow rate.
A positive displacement pump must not operate against a closed valve on the discharge side of the pump,
because it has no shutoff head like centrifugal pumps. A positive displacement pump operating against a closed
discharge valve continues to produce flow and the pressure in the discharge line increases until the line bursts,
the pump is severely damaged, or both.
A relief or safety valve on the discharge side of the positive displacement pump is therefore necessary. The relief
valve can be internal or external. The pump manufacturer normally has the option to supply internal relief or
safety valves. The internal valve is usually only used as a safety precaution. An external relief valve in the
discharge line, with a return line back to the suction line or supply tank provides increased safety.
Positive displacement types
A positive displacement pump can be further classified according to the mechanism used to move the fluid:

 Rotary-type positive displacement: internal gear, screw, shuttle block, flexible vane or sliding vane,
circumferential piston, flexible impeller, helical twisted roots (e.g. the Wendelkolben pump) or liquid
ring vacuum pumps
 Reciprocating-type positive displacement: piston or diaphragm pumps
 Linear-type positive displacement: rope pumps and chain pumps
Rotary positive displacement pumps
Positive displacement rotary pumps move fluid using a rotating mechanism that creates a vacuum that captures
and draws in the liquid.
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Advantages: Rotary pumps are very efficient because they naturally remove air from the lines, eliminating the
need to bleed the air from the lines manually.
Drawbacks: The nature of the pump demands very close clearances between the rotating pump and the outer
edge, making it rotate at a slow, steady speed. If rotary pumps are operated at high speeds, the fluids causes
erosion, which eventually causes enlarged clearances that liquid can pass through, which reduces efficiency.
Rotary positive displacement pumps fall into three main types:

 Gear pumps - a simple type of rotary pump where the liquid is pushed between two gears.

Figure – 1.1

(Gear Pump Internal)

 Screw pumps - the shape of the internals of this pump is usually two screws turning against each other to
pump the liquid

Figure – 1.2
(Screw Pump Internal)

 Rotary vane pumps - similar to scroll compressors, these have a cylindrical rotor encased in a similarly
shaped housing. As the rotor orbits, the vanes trap fluid between the rotor and the casing, drawing the fluid
through the pump.
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Figure – 1.3

(Rotary Vein Pump)

Reciprocating positive displacement pumps

Reciprocating pumps move the fluid using one or more oscillating pistons, plungers, or membranes
(diaphragms), while valves restrict fluid motion to the desired direction.
Pumps in this category range from simplex, with one cylinder, to in some cases quad (four) cylinders, or more.
Many reciprocating-type pumps are duplex (two) or triplex (three) cylinder. They can be either single-
acting with suction during one direction of piston motion and discharge on the other, or double-acting with
suction and discharge in both directions. The pumps can be powered manually, by air or steam, or by a belt
driven by an engine. This type of pump was used extensively in the 19th century—in the early days of steam
propulsion—as boiler feed water pumps. Now reciprocating pumps typically pump highly viscous fluids like
concrete and heavy oils, and serve in special applications that demand low flow rates against high resistance.
Reciprocating hand pumps were widely used to pump water from wells. Common bicycle pumps and foot
pumps for inflation use reciprocating action.
These positive displacement pumps have an expanding cavity on the suction side and a decreasing cavity on the
discharge side. Liquid flows into the pumps as the cavity on the suction side expands and the liquid flows out of
the discharge as the cavity collapses. The volume is constant given each cycle of operation.
Typical reciprocating pumps are:

 Plunger pumps - a reciprocating plunger pushes the fluid through one or two open valves, closed by suction
on the way back.
 Diaphragm pumps - similar to plunger pumps, where the plunger pressurizes hydraulic oil which is used to
flex a diaphragm in the pumping cylinder. Diaphragm valves are used to pump hazardous and toxic fluids.
 Piston pumps displacement pumps - usually simple devices for pumping small amounts of liquid or gel
manually. The common hand soap dispenser is such a pump.
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 Radial piston pumps

Figure – 1.4

(Plunger Pump compared to Piston Pump)

B. Centrifugal Pumps:
Centrifugal pumps are a sub-class of dynamic axisymmetric work-absorbing turbomachinery. Centrifugal
pumps are used to transport fluids by the conversion of rotational kinetic energy to the hydrodynamic energy of
the fluid flow. The rotational energy typically comes from an engine or electric motor. The fluid enters the pump
impeller along or near to the rotating axis and is accelerated by the impeller, flowing radially outward into a
diffuser or volute chamber (casing), from where it exits.
Common uses include water, sewage, petroleum and petrochemical pumping. The reverse function of the
centrifugal pump is a water turbine converting potential energy of water pressure into mechanical rotational
energy.

Figure – 1.5
(Centrifugal Pump)
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Working: General explanation: Like most pumps, a centrifugal pump converts mechanical energy from a motor
to energy of a moving fluid. A portion of the energy goes into kinetic energy of the fluid. Fluid enters axially
through eye of the casing is caught up in the impeller blades and is whirled tangentially and radially outward
until it leaves through all circumferential parts of the impeller into the diffuser part of the casing. The fluid gains
both velocity and pressure while passing through the impeller. The doughnut-shaped diffuser or scroll,section of
the casing decelerates the flow and further increase the pressure
Observe a mass going along a straight vane impeller (the oldest and simplest impeller), there are these forces
impact on it:
1- The impeller vane push on it a force Fc, it reflect an anti-force F' on the vane
2- The centrifugal force Fc pull it fly out (follow centrifugal direction)
Dynamic head pressure
Applying Bernoulli principle: The first force cause the absolute velocity of the object as circumferential speed
which means dynamic head pressure

Static head pressure

The second force create the static pressure. If a mass moves radially outward along a vein of the impeller its
orbit will be a spiral-shaped curve. We can easily calculate its angular speed in two dimensions the angular
velocity ω is given by

So during it movement the centrifugal force Fc always present as

The centrifugal acceleration increase linearity on the radius of rotary R(variable) In constant
gravitational acceleration g, static pressure of a column of water h is

In the centrifugal acceleration increase linearity from R1 position to R2 position static pressure of a
column of water R2 -R1 is
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In the case the discharge of the pump is 0 static pressure save it’s original value In the outlet of the pump is open
air of static pressure created by the impeller drop to 0 static pressure transfer all to the dynamic pressure in
vector which is highest value.

Figure 1.6

(The forces effect on a mass going along an impeller vane)

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2.2 INTRODUCTION TO PROBLEMS IN PUMPS

Pumps and their associated systems are essential in a wide variety of industrial applications for the efficient
transportation of fluids, from clean water to sewage. Centrifugal pumps, which are a common pump used in
industry, are known to fail as a result of problems that arise within the fluid, such as cavitation, and mechanical
faults, such as found in bearings and seals. Vibration monitoring has been found to be suitable in determining
faults within pumps. Permanently fixed condition monitoring sensors are well suited for applications where the
pump is submerged in inaccessible environments as commonly occurs in water supply and sewerage industries.
It is becoming increasing common for pump manufacturers to provide onboard sensors on their equipment;
however end user interpretation and analysis of this data is not being used to its full potential. In the following
sections it will be outlined that the use of multiple sensor readings and the synthesis of these measurements with
the information of the fault and failure modes within centrifugal pump use still needs to be utilized for
condition monitoring to create a more efficient maintenance strategy in the water supply and sewerage
industries.

Pump failures result in operational changes that reduce efficiency or result in a breakdown of the pump. There
are 13 main problems that afflict centrifugal pumps when in use. These problems, which include both
mechanical and hydraulic problems, have been discussed in the literature over a number of years in a wide
variety of industries. The problems that will be addressed here will be hydraulic failures (cavitation, pressure
pulsations, radial thrust, axial thrust, suction and discharge recirculation), mechanical failures (bearing failure,
seal failure, lubrication, excessive vibrations, fatigue), and other types of failure (erosion, corrosion, excessive
power consumption). Each problem will be outlined including its cause and effect, symptoms, and pertinent
mechanical corrective procedures.

2.3 HYDRAULIC FAILURES

Hydraulic failures arise from changes in pressure either in the volute or the pipes leading to the pump due to
changes in factors such as temperature, velocity of the fluid flow, and volumetric flow rate of the fluid. This
section will cover the main hydraulic problems, reasons behind them, and solutions, if any.
2.3.1 Cavitation
Cavitation is the formation of vapor bubbles in a moving fluid where the pressure of the fluid falls beneath its
vapor pressure. In essence, cavitation results from a reduction in suction pressure, an increase in suction
temperature, or an increase in the flow rate above that for which the pump has been designed. Designers of
pumps attempt to take into consideration the fact that pumps do not always run at peak efficiency, and try to take
into account the operating range of the system. A centrifugal pump is usually operated comfortably within the
range of 85% to 110% of its best efficiency point (BEP). However, many pumps are forced to operate outside of
this range. As a result, designers go to great lengths to ensure that cavitation bubbles do not collapse in the
pump, but rather in the main piping system, far away from the impeller vanes .
There are several causes for cavitation in a pump and piping system, such as: high volumetric flow; a large
decrease in the amount of fluid in the system which results in an abnormal increase in the temperature of the
fluid; decrease in suction pressure due to changed conditions on the suction side of the pump; heating the fluid in
the suction system, which leads to a higher fluid vapor pressure at the pump inlet; flow instability within the
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pump, which normally occurs at flow rates well below the pump’s best efficiency point (BEP) flow rate; flow
close to zero which results in rapid fluid heating in the pump casing, and quickly results in vapor-locking in the
system; poor distribution of the fluid in pumps operating in parallel; oversized pumps operating at high capacity;
pumping warm water with high vapor pressure; it is also hypothesized that cavities formed between the fluid and
the vibrating parts of the pump that are in contact with the fluid; and a high percentage of leakage flows may
lead to an increase in the temperature at the eye of the impeller, which would then possibly cause localized
flashing.
High flow cavitation occurs more frequently when the Net Positive Suction Head (NPSH) margin (actual NPSH
– required NPSH) is small, possibly due to design constraints, and there is a reduction in the normal pump
suction pressure as a result of an increase in the amount of suction piping pressure losses, or when the pump is
operated well above its normal or rated flow. The Actual Net Positive Suction Head (NPSHA) is calculated
using characteristics found at the pump’s suction nozzle and is thus independent of the pump or the pump’s
characteristics. The Required Net Positive Suction Head (NPSHR) is the amount of net positive suction head
that is required to avoid cavitation. It is independent of the system characteristics, and remains the same
regardless of which system the pump is installed in. Excessive cavitation may lead to “vapor locking”, a
phenomenon where the fluid within the pump becomes mostly vapor, due to extreme vaporization of the fluid, or
the pump being run for a long period of time at zero or near zero flow rate. Recovery from this phenomenon
requires stopping the pump and allowing liquid to re-enter the pump.
Cavitation damage, which occurs on the low-pressure or visible surface of the impeller inlet vane, is
accompanied by four symptoms:
A. Erosion
The collapse of the cavities in areas of higher pressure can exert enormous local stresses on the surfaces against
which they are collapsing, causing damage to the pump surfaces. Signs of erosion will appear as pitting due to
the water- hammering action of the collapsing vapor bubbles. Damage occurs because when the cavities
collapse, the jet of liquid that is released hits the surface of the pump at the local speed of sound, which results in
a local high surface pressure that can be higher than the ultimate strength of the material. It has been found that
cavitation damage rates increase rapidly with the increase in the volume of the fluid. Erosion rates increase by a
factor of 4 when the capacity is raised from 100% to 120% of the shock less flow. If the capacity of the fluid
continues to increase, and the head decreases, past the shock less flow point, then the NPSHA will inevitably
become less than the NPSHR, and cavitation will set in.
B. Noise
The sound of the cavities collapsing under higher pressure is a sharp crackling sound. Some refer to it as if it
was pumping stones. The level of the noise that results from cavitation is a measure of the severity of the
cavitation. The noise can be found in and around the pump suction. If the crackling noise seems to be random,
and is accompanied with high- intensity knocks, then this indicates cavitation in the suction recirculation.
However, this does not indicate a reduction in the performance of the pump if the NPSHA is greater than the
NPSHR. There are actually three main types of cavitation, classified based on the location of the cavities
inception and the location of implosion of the vapor bubbles, and each is accompanied with its own range of
acoustic radiation. Sheet cavitation, which is the first type, forms cavities across the vane surface when pumps
operate close to their design flow with low suction pressure. It creates a broad band noise, with low amplitude,
in the range of 2 kHz to 40 kHz. Cloud cavitation, the second type, forms cavities downstream of the cavity
sheet when the pump operates away from its design flow at low suction pressure. This is the loudest of the three
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types of cavitation. It generally appears at high frequencies, such as 20 kHz to 40 kHz, and gives the familiar
sound of “pumping gravel”. Vortex cavitation, the third type, is a highly unstable form of cavitation when pumps
operate at very low flows and in the inlet backflow regime. Although it is a bubble collapse phenomena, like the
previous two, it is less damaging because the collapse of the vapor bubbles occur well away from solid surfaces.
This type of cavitation is characterized by random bursts of noise accompanied by the typical cavitation sound.
When NPSHA gets very close to the 3% head decay line and the pump operates in the back flow regimes
simultaneously, vortex cavitation generates a low frequency beat in the region of 1Hz to 4 Hz. This is known as
cavitating surge.
C. Vibration
Pump vibrations due to cavitation are characteristically high amplitude and low frequency, usually found in the 0
to 10 Hz range.
D. Reduction in pumping efficiency
Vapor bubbles created in the passages around the impeller impede the flow of the fluid being pumped, thus
resulting in a reduction in output. A drop in efficiency of the pump is a more reliable sign of cavitation
occurring, since noise is not prominent until cavitation has progressed to the point where the efficiency of the
pump is poor. On some occasions it has been found that the pump’s efficiency may slightly increase moments
before cavitation begins. This may be due to a reduction of friction at the beginning of the separation in the
flow, just before the cavities start to implode.
Cavitation can be detected using a suction gauge or manometer to help determine if the NPSHA is equal to or
less than the NPSHR by the manufacturer or detected by microphones capturing the acoustic radiation associated
with the cavitation damage. Since cavitation is a common phenomenon, corrective procedures have been devised
in order to avoid or control the damage. Some of these corrective procedures are: replacing the impeller in the
pump with one made of a more cavitation resistant material, such as stainless steel; reducing the flow of the
pump so that the NPSHR will be equal to or less than the NPSHA; completely redesigning or altering the design
of the impeller by reworking its geometry or surface finish to reduce losses, improve flow characteristics, or
increase the flow inlet area, which would decrease the impeller inlet velocity; throttling the pump discharge so as
to reduce pump flow and possibly restore pump operation back into the allowable range for NPSHA; placing an
inducer on the suction side of the pump to increase the pressure in the pump before the fluid reaches the
impeller; admitting small amounts of air into the pump suction will reduce the noise associated with cavitation,
although it is not commonly used with centrifugal pumps; and providing low flow protection by placing a
recycling line from the pump discharge back to the suction source.

2.3.2. Pressure Pulsations

Pressure pulsations are only of concern in high pressure pumps, where the head of water is more than around
300 m. For high-heat pumps, suction and discharge pressure pulsations may cause instability of pump controls,
vibration of suction and discharge piping, and high levels of pump noise. In addition any failure of internal
pressure-containing members should be investigated with consideration given to the possibility that the fatigue
failures are from internal pressure pulsations. If the fatigue failure shows microscopic striations, which are due
to cyclic stress, then pressure pulsations may be a root cause of the problem.
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Pressure pulsations are found in both the suction and discharge of centrifugal pumps. The magnitude and
frequencies of these pulsations are dependent on several factors: the design of the pump, the total head produced
by the pump, the response of the suction and discharge piping, and the point of operation on the pump’s
characteristic curve. The frequency of the pulsation may come from known sources, such as the running
frequency or the vane passing frequency or multiples of each, or it may seem random since it may come from
sources such as the system’s resonance, acoustic behavior, eddies from valves or poor upstream piping.
Regardless of the source, the pulsations should not be discarded as being irrelevant, since the pulsations carry
information about the system. The observed frequencies in the pump suction are much lower than in the
discharge. Typical frequencies in the pump suction are in the order of 5 to 25 cycles/s, and do not appear to
have any direct relation to the rotational speed of the pump or the vane passing frequency. Pressure pulsations
may be amplified acoustically in a piping system or its elements, which may lead to alternating stresses and
excessive vibration beyond the endurance limit of the system. The wake flow found at the impeller’s outlet is
one of the strongest sources of pulsation. This is caused by the interaction between the fluid flow at the impeller
vanes and the volute, which results in a pressure pulsation at the blade passing frequency and its harmonics.
Water hammer is another major cause of pressure pulsations in the piping system. Water hammer is essentially
caused by the rapid closing of a valve or by a pump failure with a subsequent abrupt closure of the check valve
or by a sudden switch over and the pump start procedure. This sudden flow variation in the pipe produces a
pressure surge that travels at the speed of sound through the system. To prevent water hammer happening in the
piping system, a storage tank can be placed in the system to absorb the pressure pulsation, rather than other parts
of the system. In this case, water hammer generated at the check valve/failed pump would travel with the speed
of sound through the piping system. At the storage tank, the pressure wave is absorbed, then reflected back to
the check valve/failed pump. Once at the check valve/failed pump, the wave is reflected again back to the
storage tank. This procedure repeats until the energy of the wave is dissipated due to dynamic friction and fluid-
structure interaction. The damping of the reflected water hammer is controlled by the speed of the pump. Low
pump speeds have no influence, but higher pump speeds can reduce the pressure pulsation. Pumps are also able
to create pressure pulsations. The maximum of a pulsation is generated when the pump is running part load, and
the minimum occurs when the pump is running at its design point. Pulsations also change when the pump speed
shifts, where in this case, high pump speeds generate high pulsations and low pump speeds are a minor source
for pressure pulsations.
Research has shown that the pump acts like a non-moving valve for the pressure wave, producing a low
resistance, which is very small in comparison to the wave’s pressure amplitude. About 80 percent of the
pressure wave passes through the pump, while the remaining 20 percent is dissipated by the pump. This number
varies depending on whether an impeller’s vane is found directly in front of the pump’s outlet.
Since water has low acoustical absorption, pressure pulsations are easily sustained. Pipe lengths of odd
multiples of one-quarter wave lengths and multiples of half wave lengths may resonate and amplify pressure
pulsations by five or six times. Piping supports, particularly for feed water systems in power plants, have failed
due to extreme amplification of pressure pulsations. In the suction system, resonant conditions in the intake
structures or in the suction piping systems can aggravate sufficiently to cause incipient cavitation with vibration,
erosion, and in some cases, failures. Resonance can be avoided by changing the number of vanes or by inserting
expansion chambers or venture sections in the piping system to break up the resonance.
Pressure pulsations are normally measured with piezoelectric pressure transducers and recorded as peak to peak
pressure pulses over a broad frequency band. After the information is recorded, spectral analysis may then be
performed on the data to retrieve information, and be used to devise a strategy to handle the situation. Three
 Page-21

main problems arise from the pressure pulsations: vibration of suction or discharge piping, instability of pump
controls, and fatigue failure of internal pressure-containing components of the pump from pressure pulsations.
If the pressure pulsation causes a vibration in the suction or discharge piping, vibration measurement on the
piping structure could be more appropriate than the use of piezoelectric pressure transducers. The following
strategy can be used to alleviate pressure pulsations in suction or discharge piping:: shift the resonant
frequencies in the piping or supports that respond to any pressure pulsations; increase the output of the pump by
either installing a bypass that would run from the discharge to the suction of the pump or change the mode of
operation; replace impellers with ones containing more or less vanes if the piping responds to the vane passing
frequency of the pump; increase the output of the pump by either installing a bypass that would run from the
discharge to the suction of the pump or change the mode of operation; install acoustical filters to reduce the
magnitude of the pressure pulsations.
2.3.3. Radial Thrust
Radial thrust is thrust imposed on the pump rotor that is directed toward the centre of rotation. Forces on the
pump’s rotor are usually comprised of a dynamic cyclic component, which is superimposed onto a steady state
load. The dynamic component increases rapidly when the pump is operating in its recirculation state, during low
flow in the system. The static load increases with both low and high flow operation, having its minimum value
at or near the best efficiency point (BEP) flow rate. This effect is often found in pumps of a single volute
design, less in pumps of a double volute design, and rarely in pumps with a diffuser design. The geometry of the
volute may also change the amount of radial thrust found in the system.
High radial thrust that results in excessive shaft deflections may lead to persistent packing or mechanical seal
problems, and possibly, shaft failure. Shaft failures usually occur in the middle of the shaft span in the double-
suction or multi-stage pump. End suction pumps usually have shaft failures at the shoulder of the shaft, where
the impeller joins the shaft sleeve, or at the location of the highest stress concentration. High radial loads may
also produce high temperatures in the bearings, which may also reduce the life of the bearing. Sleeve bearings
will have bearing metal worn only in one direction and the journal will be worn uniformly. However, if the
reverse is present, which is the bearing is worn uniformly and the journal is worn excessively in one direction,
then the cause is not excessive bearing loads but instead most likely an unbalance or a bent shaft.
It is difficult to detect high radial thrusts in a pump. Temperature rises in the bearing may or may not be a
symptom of excessive radial loading. High bearing temperatures may be a result of misalignment, lack of
lubrication, or excessive axial loading of the thrust for bearing. As a result, further investigation should be done
to eliminate other causes before concluding that the radial loads are excessive.
Most failures that are a result of excessive radial thrust occur when the pump is operating at low flow rates. As a
result, radial loads can be reduced by operating the pump at higher capacities or by installing a bypass from the
pump discharge back to the pump suction or suction source.
2.3.4. Axial Thrust
Axial thrust is imposed along the shaft axis, either in the inboard or outboard direction. The thrust is usually a
result of a dynamic cyclic component, which is superimposed on a steady-state load in either direction.
Increasing the dynamic load on the shaft may impose excessive stresses, which could ultimately lead to metal
fatigue. The static, steady-state load may impose an excessive load on the bearing, which may increase the
temperature to an unacceptable state and lead to a short bearing life. The majority of thrust bearing failures are
fatigue failures due to the dynamic cyclic axial loads on the bearing components.
 Page-22

Bearing damage is caused by both static and dynamic axial thrust. Heavy static thrust will cause cracking in the
balls or rollers, and in the race of the rolling element bearings, and in the metal scoring of the shoes in the tilting-
pad bearings. Excessive dynamic loads which surpass the bearing ratings will result in fatigue failures of the
balls or rollers, and raceways in the rolling element bearings. In order to determine which of the two types of
loads caused the failure, one would have a close examination under the microscope. Fatigue failure from
dynamic loading will show a hammering effect caused by the points of impact. Fatigue failure from static
loading will show metal fatigue without the hammering effect of the impact loading. Rolling element bearing
failures can be addressed in large, between bearing pumps by substituting a tilting-shoe type of thrust bearing.
The high cyclic axial forces are better absorbed in the oil film of the tilting-shoe bearing than in the rolling
element bearing.
Shaft failure is mainly due to the high cyclic loading induced on the shaft when the pump is partially
recirculating its output. In this case, axial cyclic stresses can be reduced by increasing the pump output, or by
installing a recirculation line to bypass sufficient flow to move the pump total flow rate beyond the critical point.
If this is not possible, then the shaft failures can be reduced by substituting a shaft material of higher endurance
limit.
Depending on the location of the axial thrust, different instrumentation would be used to determine its
magnitude. Proximity-type sensors should be used to determine the axial movement of the shaft relative to the
bearing housing. Deflection of the thrust-bearing housing can be obtained using seismic instruments. Finally,
axial loading of the tilting-shoe type of thrust bearing can be monitored by a load cell permanently installed in
the leveling plate.
2.3.5. Suction and Discharge Recirculation
Recirculation usually occurs during reduced flows, and is the flow of some fluid around the impeller to the
suction side. If this is found in the inlet of the impeller, then it is known as suction recirculation. If this is found
at the outlet of the impeller, then it is known as discharge recirculation. Recirculation is inevitable in every
impeller design. The discharge recirculation can be reduced in design, but this would result in a reduction in the
rated efficiency of the pump. The suction recirculation can likewise be reduced, which would result in an
increase in NPSHR.
In order to avoid recirculation, the recommendation is not to exceed certain suction specific speeds (a
dimensionless ratio describing operating conditions in a pump). Although useful, this advice cannot be applied
blindly to all cases. During recirculation, heat is added to the fluid being pumped due to the pump losses. As a
result, if the pump operates in this mode for an extensive period of time, temperatures may increase leading to
vaporization and potentially an explosive and dangerous condition may exist. This may result in a limiting the
flow through the pump.
During suction recirculation, a loud crackling noise is produced around the suction of the pump, for discharge
recirculation, at the discharge volute or diffuser. Noise produced by recirculation has a greater intensity than
that produced by cavitation, and is normally characterized by a random, knocking sound.
Suction or discharge recirculation can be determined by monitoring the pressure pulsations found in the suction
and discharge of the pump. Piezoelectric transducers are normally placed close to the impeller on either the
suction or discharge side of the pump. Data obtained may be analyzed using a spectrum analyzer to generate a
plot of the pressure pulsations versus the frequency of selected flows. On this plot, a sudden increase in the
magnitude of the pressure pulsations would represent the beginnings of recirculation. Pitot tubes installed at the
eye of the impeller can also help determine the onset of suction recirculation. With the pitot tube directed into
 Page-23

the impeller eye, suction recirculation will occur when the flow reversal from the eye impinges on the pitot tube
with a rapid rise in the gauge reading.
In order to correct recirculation in the system, the following steps are suggested: increase the output flow of the
pump; install a bypass between the discharge and the suction of the pump; substitute an improved material for
the impeller that is more resistant to cavitation damage; increase the output capacity of the pump; or modify the
impeller design.

2.4 MECHANICAL FAILURE

Mechanical failures can arise from a number of different parts of the pump, including bearing, seals, lubrication
in the pump, and other miscellaneous problems. This section will cover the main mechanical problems, reasons
behind them, and solutions, if any.
2.4.1 Bearing Failure
Bearings fail, in general, either through contamination of the bearing oil by water, another liquid, or solid
particles or because of high heat, which is often caused by an overload on the bearing or by excessive
lubrication. These faults can have various root causes.
Moisture contamination in the bearings comes from multiple sources: packing leakage flows back to the
bearings, and seeps into the bearing housing; using a water hose to clean a packing leakage, which would allow
water to splash into the bearing case and into the housing through the vent or grease seal area; replacing the
heated air through the bearing casing vent with cooler atmospheric air when the bearing case cools down; or the
leakage of steam, condensate or cooling water from a mechanical seal quench gland and directed at the radial
bearing.
When the pump is operating at its BEP, the only bearing loads are due to the weight of rotating assembly, the
stress caused by the interference fit on the shaft, and any bearing preload that has been specified by the
manufacturer. However, most pumps do not work continuously at their BEP, and thus overloading is possible.
Overloading of bearings can be a result of many different conditions: an unbalanced rotating element; a bent
rotating shaft ; blocked impeller balance holes; cavitation; excessive axial thrust; excessive radial load caused by
low flow operation or some mechanical failure inside the pump; excessive heating of bearings due to improper
dissipation of heat; improper cooling of the bearings such as cooling the bearing housing with a water hose or
some other similar system; increased pump internal running clearances around the wear rings; increasing the
speed of the bearing; misalignment between the pump and its driver; operating the pump away from its best
efficiency point (BEP), which may create excessive radial forces on the impeller that would felt by the bearing;
pipe work exerting strain; pulley driven pump drivers; pumping a high specific gravity fluid such as sulphuric
acid, which can almost double the radial load on a bearing; pushing the bearing too far up a tapered sleeve;
rusting of antifriction bearings because of water in the bearing housing; having the thermal expansion of the
shaft greater than the thermal expansion of the bearing; causing the bearing housing to be out of round; having
the impeller located too far away from the bearing; having the wrong interference fit between the bearing and the
shaft (the shaft was out of tolerance causing the bearings to be too tight); having the vane passing frequency
coincident with the resonance of the pump assembly; having the vibration of almost any form from other parts of
the piping system or within the pump; or producing water hammer in the lines.
 Page-24

Causes of overheating may be due to a lubrication problem in the bearing. In this case, this may be due to
having: the oil level too low or too high; the wrong grade of oil; moisture in the oil; too much grease inside the
bearing; lack of lubrication, in general; or foreign matter inside the lubricant, often due to shaft seal leakage.
Moisture in bearings can also cause failure due to such problems as pitting and corrosion of the bearing races
and rolling elements that increases the fatigue of the metal components, hydrogen embrittlement due to the free
atomic hydrogen in the water which leads to an acceleration of the fatigue in the bearing metal, and the lack of a
good lubricating film due to the non-mixing of water and oil. Ball bearings generate vibrations that cover a wide
range of high frequencies that may not be a multiple of the shaft running speed. Vibration caused from bearing
faults can often by relatively subtle in the early stages of the bearing degradation, and will not be noticed in the
overall vibration signal and more sophisticated signal processing of the vibration signal is often needed. Stress
waves and shock pulses on the pump bearing housing will show failure trends that prelude an increase in the
level of mechanical vibrations. Monitoring these waves or pulses falls under the category of acoustic high-
frequency monitoring or incipient-failure detection (IFD), or narrow band envelope analysis. Definitive early
detection of bearing faults would be unlikely to be detected outside of vibration or acoustic emission
measurements.
Over the course of the years of using bearings, procedures have been used to keep water, moisture and dirt out of
the bearing housing, and overcoming bearing overheating and wear. There are many different methods used by
pump companies to keep moisture and water out of the bearing housing.
2.4.2 Seal Failure
Mechanical seals may fail due to the pump running dry. Many applications are best protected by using dual
pressurized mechanical seals, which remain lubricated even through periods of complete dry running. In non-
hazardous applications, a pump sealed with packing that is lubricated from an external source will survive dry
running better, given that the source is compatible with the fluid being pumped.
Mechanical seals, in general, fail for two reasons: the lapped faces open up, or one of the seal components
becomes damaged. When a seal face opens, it allows solids to penetrate between the lapped surfaces. The
solids embed themselves into the softer carbon / graphite face causing it to act like a grinding wheel, which then
causes severe wear on the hard face. This type of failure accounts for the majority of mechanical seal failures.
Temperature gauges help assist in the diagnosis of a failed seal. Many fluids are affected by a change in their
temperature, which may eventually lead to seal failure. This can happen, especially in the stuffing box, when one
of the seal components (such as the elastomer, the seal faces or the metal parts) becomes destroyed, or the coated
hard faces crack. This can be prevented by keeping the stuffing box temperature within the specified limits. In
addition, by controlling the pressure in the stuffing box, one can control the temperature and prevent the fluid
from vaporizing in the stuffing box or across the seal faces.
2.4.3 Lubrication Failure
The purpose of lubrication is to decrease the friction between two moving parts, thus decreasing their wear, and
prolonging the life of the parts of the system. Non-contaminated oil cannot wear out and has a useful life of
about thirty years at 30oC. This life span is halved for every 10o C rise in the temperature of the oil.
Overloading bearings can cause excessive heat to be generated within the bearings. The temperature rise will
result in a decrease in the viscosity of the lubricant, which then leads to generation of more heat as it loses its
ability to support the load. A varnish residue forms which then cokes at the elevated temperature. This coking
 Page-25

will destroy the ability of the oil or grease to lubricate the bearing, as well as introduce solid particles into the
lubricant. Infrared thermography can be used to determine whether or not the bearing is overloaded by the
amount of heat that is produced.
2.4.4 Excessive Vibrations
Excessive vibrations, or otherwise unsatisfactory or unacceptable vibrations, are classified, according to ISO
10816, to have amplitudes larger than 2.80 mm/s for small machines, 4.50 mm/s for medium machines, 7.10
mm/s for large machines with rigid foundations, and 11.2 mm/s for large machines with soft foundations.
Vibrations result from unbalanced moving parts found within the pump system, interactions of the fluid and its
particles with the pump and the connecting pipes, and movements of the pipelines themselves. There are
numerous reasons that can lead to unwanted vibrations in a pump system, such as impeller unbalance, hydraulic
imbalance, problems in the bearings, movement in the baseplate, component run-out, cavitation, air or vapour
lock, and hydraulic excitation.
Impeller imbalance usually appears in the vibration signature as a 1x running speed frequency vibration, and
may result from either a mechanical problem, such as a mechanical seal or bearing failure, or a hydraulic
problem. Mostly, inspections to determine if an impeller is balanced are not performed until heavy pitting is
found on the impeller. The degree of etching or pitting is usually used as an indicator that the impeller needs
balancing. Unbalanced forces which result from loose fit impellers could results in large amplitude vibrations.
Impellers may shift due to the decrease in residual stresses that are created when the impeller is cooled and
contracted around the shaft. Shaft vibrations and flexing tend to result in the impeller cocking or bowing the
shaft, which removes it from its original balance along its centerline. Hence, when balancing an impeller, it is
imperative that it must be balanced at the operating speed so as to evaluate the importance of shaft deflection
due to the previously mentioned factors and due to possible modal resonance components.
Hydraulic imbalance is mainly due to an uneven flow distribution within all the vane passages, which causes a
1x running speed frequency vibration. Unsteady flow into the impeller may result in axial thrust and high axial
vibrations. In double suction impellers, the nonsymmetrical positioning of the impeller or the offset of the upper
or lower case half will result in a 1x unbalance due to nonsymmetrical flow. In addition, recirculation forces and
pulsation recirculation, which are present in a pump when the flow is less than that for which the pump and the
piping system were designed, may result in noise and/or vibration with random frequencies, and an increase in
pressure. Increasing the NPSHA has been found to help alleviate this problem by using a bypass.
Baseplates have also been known to produce unwanted vibrations. Trends in pump and pipeline construction
have moved from low rotating speeds and cast iron baseplates to higher rotating speeds with less rigid fabricated
steel baseplates. These higher rotating speeds, with higher operating temperatures, coupled with larger
impellers have greatly increased the probability of baseplate vibrations, distortions, and decreased stiffness for
the rotor dynamics occurring within the operating range for the system. As a result, baseplate vibration
problems must be resolved at the design stage or during construction of the system. Alterations to the design to
alleviate these problems may include leveling screws, grout filling holes, venting holes, and corrosion
protection.
Insufficiently stiff bearing housings, or improperly designed baseplates, may cause bearing housings or casings
to vibrate at resonance. Even though the shaft vibration amplitude may not be excessive, and even almost
constant with speed, the bearing housing may show distinct resonance peaks with significant amplitudes. This
can be determined by impact or modal testing. By changing masses or the stiffness of components in the system,
the natural frequencies can be moved outside of the operating frequency range.
 Page-26

Shafts also produce unwanted vibrations due to a mass imbalance, or a natural bow in the shaft. Mass
imbalances and bows produce a 1x running speed frequency, depending on whether there is only one defect in
the shaft. Multiple defects produce more complex vibrations. Component run out, or a misalignment between
components, especially annular seals, produces unwanted vibration. Shafts that produce a component run-out,
which is separate from the shaft bow, produce a radial force. Other sources of excessive vibrations may be due
to: air or vapor lock in suction; inlet of suction pipe insufficiently submerged; pump and driving unit incorrectly
aligned; worn or loose bearings; impeller choked or damaged; foundation not rigid; coupling damaged; or
pipework exerting strain on the pump.
An area of controversy in the topic of vibrations for a centrifugal pump is the cause of a sub synchronous
vibration at 0.7 – 0.9 of the running speed. One theory says that it is a result of destabilizing forces developed
by the angular rotation of liquid in the internal running clearances. Another theory is that the excitation is due to
the rotating stall at the inlet of the impeller, which is a phenomenon that is widely discussed in the literature.
Field experience shows that in variable speed pumps, a sub synchronous vibration is seen to exist over a part of
the pump’s operating range that ceases as the pump approached the design flow.
Several authors have published a list of vibration frequencies that can be found in a centrifugal pump, and the
possible causes of each vibration. In addition, published a table that contains the stages of bearing degradation
and the vibrations associated with each stage. Various testing performed on a centrifugal pump can also provide
useful information concerning the state of the pump. Impact testing of casing/ bearing housing may detect the
proximity of natural frequencies to synchronous frequency and diagnose structural resonances. Tests using
speed variations may detect structural resonance excitation and/or rotor critical speeds. Tests using flow
variations at fixed speed may detect hydraulic unbalance. Tests using a change of temperature may detect
misalignment due to thermal growth; and a change in casing natural frequency due to jamming / loosening of
keyways. And finally, tests using trim balancing may also determine a coupling unbalance.
2.4.5 Fatigue
Fatigue is mainly categorized into one or more of the following: cyclical loading, material fatigue, or
environmentally assisted fatigue. Pumps are basically machines that have a fluid, with or without solids,
inducing a cyclic load on their components. Although centrifugal pumps are mainly steady-state rotational
equipment, pulsations or fluctuating applied stresses are encountered. The source of these cyclic stresses can be
from fluid interaction between impeller exit vanes and diffuser vanes, or, in the case of a volute pump, the
impeller vanes and the casing at the cutwater. Mechanically induced forces result from the bending moments
that act on the pump shaft or a component imbalance in the rotor assembly.
When cyclic forces are applied to parts found in the pump, a crack may appear over a period of time, in a
component’s surface. Fractures can occur on a component, even though the loading produces stresses that are far
less than the tensile strength of the material. After the crack has been introduced into the component, the crack
may grow with each cyclic loading until the component finally fractures.
Corrosion assisted fatigue occurs when corrosion damage changes the surface texture and significantly increases
the local stresses acting on a pump component due to notch sensitivity. When this happens, fatigue cracking of
the component is likely. In some cases, crack propagation can be influenced by oxidation, which can mask the
features of the fatigue mechanism. Corrosion oxides, which form along the face of the crack, can produce a
wedging effect, which mechanically is able to increase the local tensile forces acting on the crack tip, and thus,
increase the rate of crack propagation. Fretting or wear can also produce sites where fatigue cracking can
 Page-27

initiate. In addition, sharp radii and defects on the material surface, such as in the case of porosity and poor
machining, can act as stress concentrations in susceptible materials.
Fatigue can be seen in its three stage progression from (1) crack initiation, which is sometimes associated with
pre-existing defects, (2) crack propagation, and (3) final failure. The applied stress level, geometry, flaw size,
and mechanical properties determine the existence and extent of these stages of fatigue. These three stages of
fatigue cracking can be observed on the fracture surface, provided that there is no secondary damage that masks
the characteristic appearance. The bands that result from the fatigue are often referred to as “clamshell
markings”, “crack arrest lines”, or “beach marks” and reflect different periods of the crack growth. “Ratchet
lines”, which are the joining of two different crack fronts on different planes, are observed in cracks originating
from multiple origins. These types of fatigue fractures are normally associated with rotating components. Once
the cause of the fatigue cracking has been identified, corrective actions can be taken to remedy the problem.
These corrective actions may include: using fatigue resistant materials, modifying the design of the pump,
treating the affected surface, or using more highly corrosion resistant materials.

2.5 OTHER MODES OF FAILURE

There are some modes of failure that fall neither under the categories of hydraulic or mechanical problems.
These modes of failure are sometimes structural, such as in the case of erosion and corrosion, or are a result of a
multitude of different sources, such as in the case of excessive power consumption. This section will cover the
causes and solutions, if any, of these types of problems.
1.5.1 Erosion
Erosion on pumps takes on one of five different forms: cavitation erosion (see 2.1), adhesive wear, fretting,
abrasive wear, or erosion by solid particle impingement.
Adhesive wear is a result of material to material contact. This is the primary cause of material loss when
handling fluids that contain no solids in the stream. Surfaces of parts inside the pump are able to have material-
to-material contact, producing surface disruptions, material grooving, transferal of material, and possibly,
galling. Two important characteristics that should be considered for materials that come into contact are their
adhesive wear traits and their galling threshold. Adhesive wear is the only theory of sliding wear that is able to
offer a general wear equation that quantifies the prediction of wear.
Fretting is a special case of adhesive wear. It occurs when two parts of the pump experience repeated, small
amplitude relative motion between close-fitting surfaces such as between an impeller and a shaft. In a pump,
there is the potential for fretting in the small amplitude motion of loose fitting impellers, beneath loose bearings,
and between impeller wear rings and the impeller hub. Although not placed into the design by the engineer
intentionally, it can still happen and lead to catastrophic results. And since the amplitudes are small, it makes
fretting almost impossible to detect. Fretting can be recognized on parts in the pump when a red powdery oxide
forms along the fretted surface. In a pump, however, this red-colored debris is often washed away, although a
distinct damaged surface appearance will develop on the fretted surfaces. This type of damage is often described
as having colored spots or blotches in its appearance, along with an eroded surface with what appears to be
random damage. And even though the red- colored debris may be washed away with the fluid, some staining of
the adjacent components may be observed after the pump is disassembled. Fretting can be avoided with tighter
 Page-28

clearances between two components, or shrink fitting the components to prevent small, unnecessary movement.
If fretting is unavoidable, then various methods, such as coating or lubricating the contact surfaces, are advised.
Coatings may include flame-sprayed high-nickel alloys, silver plating, or possibly adding thin, dense chrome
plating to one or both of the faces in contact.
Abrasive wear is characterized by solids interacting with internal components, as either two-body or three-body
wear. Three body abrasive wear is the primary mechanism of damage in centrifugal pumps. This occurs when
hard solid particles, which are found in the pumped fluid, enter between the ring fit areas or the impeller keyway
faces. To minimize this effect, a few variables must be taken into consideration. The wear ring clearance,
which is the clearance between the casing ring and the impeller ring, influences the amount of damage on the
pump. If the particles in the fluid are too large or too small to be trapped within the clearance, then the damage
will not occur. However, if there are particles that barely fit the wear ring clearance, and become lodged
between the two rings, then damage can occur. Since fluids usually contain particles of different sizes, various
conditions will exist.
Finally, the last category of erosion is due to solid particle impingement. Many fluid-handling applications
require pumps to move fluids that are not clear liquids. Solid particles found in these fluids may be removed
with the use of a costly filtration system, with impact on fluid velocity, and pressure heads. In addition to the
particles in these fluids from their source, either naturally such as from river or sea water or man-made,
fabricated piping systems may also introduce solids in the fluid from weld slag and pipe burn. There are several
factors that should be taken into consideration when pumping fluids with particles found in the flow: the
hardness of the particle, the concentration ofthe particles, size distribution, geometry, velocity of the fluid flow,
and the angle of the fluid impingement. Particle velocity is an important component in the degree of damage
that occurs in a pump handling slurries. The pump gives the entrained particle kinetic energy that, when striking
a hard surface, erodes the material. In addition, the pump’s ability to absorb the kinetic energy of the particle,
based on the material’s hardness and/or resilience, also plays a role in the amount of material loss upon impact.
The characteristic feature of erosion damage due to solid particles striking the pump is usually recognizable;
however, sometimes it is mistaken as corrosion-erosion or vice versa. In cases like this, improper diagnosis will
lead to an improper solution to the problem.
2.5.2 Corrosion
Corrosion is the chemical alteration of a material. Corrosion comes in 7 different forms (general, de-alloying,
galvanic, stress corrosion cracking, hydrogen embrittlement, microbiologically induced corrosion, intergranular
corrosion), some of which are more common than others. General corrosion occurs without any localization of
attack. This type of corrosion occurs on metals or alloys that do not develop an effective passive film on the
surface. Corrosion usually occurs as a result of oxidation, and metal oxide is produced. Most often, pumps
made with carbon steels, cast iron and copper base alloys experience this type of corrosion. Carbon 9 steel,
which is sometimes used in pump applications, does not develop a protective oxide film and will corrode at a
rate that is dependent upon factors such as temperature, oxygen content, pH, fluid chemistry, and the velocity of
the fluid. For most pump applications, since the corrosion rate is too high for this material to provide a useful
life, a form of protective coating is placed over the steel to prevent corrosion.
De-alloying, the second type of corrosion, is a result of the removal of one phase from a multi-phase alloy or one
element from a material. One of the most common cases of de-alloying found in pumps is the graphitic
corrosion of gray cast iron. Due to its low cost, easiness to machine, and its versatility, it is used in a wide
variety of applications in the waterworks industry and in the pump industry. Although this type of corrosion is
found in both fresh water and salt water, the high conductivity of salt water increases the corrosion rate.
 Page-29

However, the corrosion rate can be slowed down if the water has a high mineral content, since the minerals tend
to plug up the apertures left behind from the de-graphitization, sealing off the base metal from exposure to the
passing fluid, and thus reducing the corrosion rate.
Galvanic Corrosion is the third type of corrosion, and occurs when one alloy is electrically coupled to another
and is exposed in a conductive liquid. Several factors affect the rate of galvanic corrosion, such as the
conductivity of the fluid, where seawater has less conductivity than fresh water; the ratio of the area of the
coupled metals; the negative potentials of the metals; and the use of coatings to hinder the galvanic corrosion
process.
The fourth type of corrosion is called Stress Corrosion Cracking (SCC). This form of corrosion is dangerous
since it is not usually detected until it has advanced to a stage that can cause catastrophic failure. Although
uncommon in most pumps, this type of failure can occur in several classes of material and thus the pump
designer should be aware of its potential. The factors aiding SCC include tensile stress (residual or applied), a
susceptible material, an environment capable of causing stress corrosion, and time.
Hydrogen embrittlement is the next type of corrosion that results from the combination of hydrogen and a
residual or applied tensile stress. This type of damage results in cracking, blistering, hydrating, or a loss of
ductility. Damage done by hydrogen embrittlementis occasionally found in pumps as a result of plating
processes, such as chrome plating, that is used to rebuild pump shafts.
Microbiologically induced corrosion is a result of microbiological activity, which is mostly found in stagnant
water. This type of corrosion occurs most frequently when stagnant water remains in the pump when shut down
for an extended period of time. Sulphate producing bacteria, which are found in many waters, form tubercles
(slimy, reddish hemispherical shaped mounds or colonies) on carbon steel or cast iron. Upon scraping off, they
leave behind a saucer-shaped pit, inside of which will be a wet, black deposit. The pitting is a result of sulphuric
acid excreted by the bacteria; however, this will not result in premature failure. In cases such as this, biocides
have been found on occasion to help alleviate the problem. Finally, the decay of biological organisms can also
generate hydrogen sulphide, which affects the protective oxide film on copper base alloys. This biological
activity can impair the corrosion resistance of bronzes.
The final type of corrosion is called inter-granular corrosion. This infrequent type of corrosion is usually caused
by local chemical differences, such as the chrome-depleted regions of an austenitic stainless steel plate. Bronze
alloys susceptible to this type of corrosion include aluminum brasses, silicon bronzes, mounts metal, and
admiralty metal. This type of corrosion often leads to corrosion-assisted fatigue cracks when cyclic loading is
applied to the metal.
2.5.3 Excessive Power Consumption
Excessive pump power is an indication that there may be one of a number of different problems going on with
the pump. One of the main problems that results in excessive power consumption, and possibly ultimately a
motor trip, is the existence of small or high concentrations of particles in the fluid. Even though the fluid looks
clean, it may have very small concentration of particles that can lead to long-term performance problems as
running clearances gradually increase from the wearing down of parts. This can be found in any centrifugal
pump application, regardless of how clear or clean the fluid looks like. This wearing away produces a loss of
hydraulic performance, which will cause the control valve to gradually open wider without being noticed. The
wider it becomes, the more power is required from the motor, which may result in a motor trip.
 Page-30

Other main causes of faults in a pump that could cause excessive power consumption are: the speed of the
impeller is too high; the shaft packing is too tight; the liquid that is being pumped has a viscosity that is more
than what the pump was designed for; there is a misalignment in the pump; the impeller is touching the case; the
pumped liquid is denser than specified; the impeller is rotating in the wrong direction; the impeller is installed in
the wrong direction; the pump has trapped air inside; there is a serious leak in the delivery line to the pump; the
pump is delivering more than its rated quantity; the neck rings on the impeller are worn excessively; the impeller
is damaged; there is a mechanical tightness at the pump’s internal components; or the pipework is exerting a
strain on the pump.

2.6 Vacuum Pumps Common Problems and Troubleshooting

Vacuum pumps and systems are one of the widely used equipment in process plants. It is very important
to correctly size and select the vacuum pump as it is to lay down the right specifications. Understanding
the fundamentals of vacuum as well as the system and its integration would enable the operators to deal
with the day to day problems, which are inevitable.
This article highlights various trouble shooting guidelines for some of the most commonly used vacuum
machines like liquid ring vacuum pumps, rotary piston vacuum pumps, dry vacuum pump, rotary vane
vacuum pump and vacuum blower.

Several factors govern and influence the performance of a vacuum system. It is important to periodically
inspect the vacuum system and all its accessories including the upstream and down- stream piping and
equipment for leakages as it plays a major role in the performance of a vacuum system.
Some of the common problems faced in vacuum systems could be on account of the following major
factors:
 Process conditions and variations
 Variation in utility specs
 Equipment malfunction
The suction load, temperature, leakage rate and other process parameters including the composition of
suction gas are crucial for proper functioning of a vacuum system. These parameters can be estimated as
per the standards of the Heat Exchange Institute and other standards. These standards can also be applied
for testing the performance of the vacuum system. Once the external step is to evaluate and solve the
problems associated with the vacuum unit.
Some of the most commonly observed problems in different kinds of vacuum pumps along with suitable
trouble-shooting guidelines are discussed in this article.
2.6.1 Problems in Liquid Ring Vacuum Pump
High Horsepower Causes of high horsepower can be various. Comparing actual data with performance curve is
the best starting point. Probable causes are:
 V-belt misalignment and improper tensioning of the belts.
 Pump is severely overloaded with water.
 Restriction at the pump inlet or pump discharge
 Motor problem
 Pump running at a speed above the required speed.
2.6.1.1 Leakage
If the seal water is leaking from the pump, a careful observation of the exact location of the leak and the
quantity of the leakage should be carried out. Most likely areas of leakage are:
 Gland packing area - It can be resolved by tightening the packing and if leak still persists,
replace the packing.
 Leakage at body gasket – Torque the body bolts evenly, if leak does not stop, then replace
the body gasket.
 Page-31

 Leakage at the body plugs – Tighten the plugs. If leak still persists, check for corrosion on
plug threads and body threads. Replace plug if corrosion is severe.
 Leakage through castings – Causes can be erosion, corrosion or insertion of a hard object
into the pump.

2.6.1.2 Noisy Pump Operation

Noisy pump operation could be due to:
 Foreign object trapped into the pump – This is a very serious case and is usually accompanied by erratic
noise and vibration.
 Pump severely overloaded with water – Causes groaning and hydraulic noise.
 Cavitations – Sounds like marbles in the pump.
 Bearing noise – Possibility of bearing failure.
 Lots of carryover to the pump – This is accompanied by high horsepower.
2.6.1.3 Vacuum Problems
Could be due to:
 Vacuum surges – Surging is often caused by carryover from separators, or from low points in the line
that accumulate water that burp over periodically into the pump. Look for piping problem in the inlet
line.
 Restriction in the pump inlet piping – This could be due to closed or partially closed valves, object in the
line, plugged inlet screen, etc. This restriction will cause pressure drop that gives low vacuum in the
system and a higher vacuum in the pump.
 Check for correct seal water flow – Excessive or inadequate seal water flow will adversely affect vacuum
level.
 Variation in seal water temperature – If temperature of the seal water is too high, the pump may operate
at a reduced capacity. The higher the vacuum level, the more important it is to have cool water in
sufficient quantities.
 Variation in pump rpm – If rpm is low, pump will run at a lower capacity. Check motor and V-belt.
 System leaks – Sources of leaks can include open drain valves, blown gaskets, loose flanges, poorly
packed valves, inadequate barometric drop legs on separator, broken pipes etc. Higher leakage will result
in lower vacuum.
 Warn pump – This is indicated if vacuum loss has been gradual over a period of time. Check to see if any
before the vacuum problem surfaced.
2.6.1.4 Vibration Problems
Vibration problems could sometimes be due to system problems but at times could also be related directly to the
pump. They can be broadly classified into two categories, namely intermittent and continuous.
Intermittent vibration
 Check for liquid slugs or carry-over from separator.
 Check for low pockets in inlet piping where liquid can accumulate and burp over into the vacuum pump
at irregular intervals.
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 Check for irregular sources of vibration originating. Piping or separators can be the source of vibration if
they are not properly secured in place or supported.
Continuous chronic Vibration
 Look for constant carryover and / or excessive seal water to the pump.
 Look at discharge piping or level indicator to be sure that the pump is not operated when in flooded
condition.
 Check coupling or V-belt alignment and tensioning.
 Make sure pump is not started against blank suction subjecting it to immediate high vacuum. This does
not allow the ring to form properly.
 If the unit is gear driven, make sure vibrations are not from gear itself.
 Check pump mounting and alignment. Loose feet, improper shimming, resonating bases and improper
grouting can set up unwanted vibrations.
 Check bearings and lubrication and replace failed bearings.
 Check the inlet piping for vibrations.
 Check pump for excessive wear.

2.6.2 Problems in Rotary Piston Vacuum Pump

2.6.2.1 Excessively High System/Pump Ultimate Pressure
This could be due to:
 Faulty process equipment faulty or improper functioning of the vacuum pump – Check pump
performance.
 Process equipment contaminated by high vapor pressure material – Clean equipment with acetone or
alcohol, or either Pump down with vacuum pump overnight.
 Process equipment leaks – Check process equipment for leaks.
 Improper flow of vacuum pump oil – Clean oil ducts.
 Contamination of vacuum pump oil – Change pump oil,
 Discharge valves malfunctioning – Check valves per “Discharge Valves”.
 Vacuum pump leaks – Check pump for leaks
 Vacuum pump shaft seal malfunctioning – check shaft seal
 Internal parts worn or damaged – Disassemble pump and inspect internal part.
 Oil flow blocked – Clean oil lines.
2.6.2.2 Excessive Pump Noise
Excessive Pump Noiseat Low Pressure Could be due to:
 Hydraulic noise of pump discharge – Open gas ballast valve.
2.6.2.3 Pump Stalls
Pump stalls could lead to production loss. Probable causes could be:
 Electrical power loss – Check power at pump.
 Page-33

 Pump malfunctioning. Pump oil contaminated or pump is insufficiently lubricated.

 Pump discharge line blocked – Clear pump discharge line, check oil mist eliminator element for
blockage. Pumps does not Start
 Electrical failure – Check for power supply at pump Check motor.
 Pump flooded with oil – Clear oil from pump by turning over manually or disassembling the pump.
 Excessively low temperature – Heat pump to recommended minimum starting temperature. Oil
Discharged from Oil Mist Eliminator
 o Excess oil on discharge side of oil mist eliminator – Unscrew oil mist eliminator and pour oil through
the discharge fitting back into the pump, or reduce pump inlet pressure below certain set pressure to
allow collected oil to drain back through the integral check valve in to the oil mist eliminator.
2.6.2.4 Dry Screw Vacuum Pump Insufficient Pumping Capacity
Probable causes:
 Suction filter or strainer is clogged – Clean or change it
 Too much Clearance – Check clearance Overload on Electric Motor Probable causes:
 Foreign matter could be caught in the pump – Adjust or replace the screw and casing
 Pressure loss in piping increases – Check the pressure difference between inlet and outlet
 Interference between screws – Adjust side clearance, clearance between screw and casing larger
 Discharge port or line is clogged & back pressure is increased – Drain and clean discharge port and line

2.6.2.5 Overheat
Overheating of the pump could be due to:
 Excessive lubricant in front end cover – check oil level
 High temperature at vacuum pump inlet – Reduce inlet temperature
 High compression ratio – Check suction and discharge pressure
 Interference between screw and casing – Search for the cause of interference
 Problem with cooling water flow – Clean cooling water line
Discharge port or line is clogged and back pressure is increased
 Page-34

Objectives:
 Main Objective of our project is to create a compilation not only for the industries but also for the
students so that they could find a huge, updated and easy to find data to identify the problems in pumps
and their trouble shooting.
 To effectively develop a pump trouble shooting methodology and suitable processes to troubleshoot
the problems.
 The basic idea behind the project is to gain an ample amount of knowledge that can be used and
implemented in the industry.
 To develop effectively tools required to trouble shoot a problem.
 To identify by using the tools, the problems associated with foreseen working of pump.
 To implement the Troubles shooting methodology with design aspect and prove the effectiveness and
efficiency of the developed methodology.
 To effectively deal with the problem and provide an optimal solution to the problem with its cost
estimations.
 Page-35

Chapter 3
Material and methods used

The ongoing topic of the project is “troubleshooting of pumps”. In this project we mainly dealt with the usual
and everyday problems that happen inside an industry as a part of the production process. To effectively deal
with every tiny problem occurring we need to have an accurate and a detailed knowledge of the problems or the
causes which re made them happen. In the previous chapter we deal with the theoretical aspect of the pump. This
project mainly deals with the theoretical aspect of the study. Not much was performed practically except the
calculations part. Due to presence of the theoretical zest inside the project we adopted the methods and
procedures by our own. In order to effectively identify problems inside the industry we first need to have a
detailed outlay of the parameters, causes which make the thins happens. In this section we will establish the base
and the procedures and the techniques we used to effectively complete our troubleshooting on a case study up
taken in next section.
We basically used two methods in the discussion related to the troubleshooting:
 Theoretical aspect of the project
 Designing tools

3.1 Materials

3.1.1 Flow sheets: A process flow diagram (PFD) is a diagram commonly used in chemical and process
engineering to indicate the general flow of plant processes and equipment. The PFD displays the
relationship between major equipment of a plant facility and does not show minor details such as piping
details and designations. Another commonly used term for a PFD is a flow sheet.

3.1.2 Pump specifications: A system cannot be analyzed until we have the parameters which are controlling
the process. We need to account every parameters change in which can affect the working system. To
effectively analyze a system we need to identify every process stream, the units associated the numbers
of equipment accessories used.
Specifications of the process units:

1. Operatingpressure of V-2023: 0.98 M Pa

2. Suction pressure of pump: 0.95 M Pa
3. Initial discharge pressure of pump: 2 M pa
4. Operating pressure of T-2021: 1.71 M pa

3.1.3 Troubleshooting charts: Troubleshooting charts are the most important part of this project. The
troubleshooting charts were prepare for this project after analyzing and concluded the data related to the
 Page-36

problems and the solutions available for the pumps. Troubleshooting charts provide a way to excess
every possible cause related to the problems occurring inside pump without giving hectic and analyzing a
complex data. For some cases of pump problems we developed the troubleshooting charts which are
shown below.

 For the capacity lower than the design

 For the capacity lower than the design

 Page-37

 For flow higher than design

 For flow higher than design

 Page-38

 For mechanical problems

The troubleshooting charts used in this project are:

3.1.3.1 Trouble shooting chart-1

Pump does not deliver water 1—2—3—4—6—11—14—16—17—22—23

Insufficient capacity delivered 2—3—4—5—6—7—8—9—10—13—16—

19—21—22—28—29—30
Insufficient pressure delivered 5—13—15—16—19—21—28—29—30
Pump losses prime after starting 2—3—5—6—7—8—10—11—12
Pump requires excessive power 14—15—16—17—18—19—22—23—25—
26—28—32—33—36
Stuffing box leaks excessively 12—23—25—31—32—33—34—35—37—
38—39
Packing has short life 11—12—23—25—27—31—32—33—34—
35—36—37—38—39
 Page-39

Pump vibrates or is noisy 2—3—4—9—10—20—22—23—24—25—

26—27—29—34—35—40— 41—42—43—
44—45—46
Bearings have short life 23—25—26—27—34—35—40—41—42—
43—44—45—46
Pump overheats and seizes 1—4—20—21—23—26—27—34—35—40

Table 2.1

(Trouble shooting chart-2)

3.1.3.2 LIST OF POSSIBLE CAUSES

Suction troubles

1. Pump not primed

2. Pump or suction pipe not completely filled with liquid
3. Suction pipe lift too high
4. Insufficient margin between suction pressure and vapor pressure
5. Excessive amount of air or gas in liquid
6. Air pocket in suction line
7. Air leaks in suction line
8. Air leaks into pump through stuffing box
9. Foot valve too small or partially clogged
10. Inlet of suction pipe insufficiently submerged
11. Water seal pipe plugged
12. Seal cage improperly located in stuffing box, preventing sealing fluid entering space to
formseal
System troubles

13. Speed too low

14. Speed too high
15. Wrong direction of rotation
16. Total head of system higher than design head of pump
17. Total head of system lower than design head of pump
18. Specific gravity of liquid different from design
19. Viscosity of liquid different from design criteria
20. Operation at very low capacity
21. Parallel operation of pumps unsuitable for such operation

Mechanical troubles

22. Foreign matter in impeller

23. Misalignment
24. Foundations not rigid
25. Shaft bent
26. Rotating part rubbing on stationary part
27. Bearings worn
28. Wearing rings worn
29. Impeller damaged
30. Casing gasket defective permitting internal leakage
31. Shaft or shaft sleeves worn or scored at the packing
 Page-40

32. Packing improperly installed

33. Incorrect type of packing for operating conditions
34. Shaft running off center because of worn bearings or misalignment
35. Rotor out of balance resulting in vibration
36. Gland too tight resulting in no flow of liquid to lubricate packing
37. Failure to provide cooling liquid to water cooled stuffing box
38. Excessive clearance at bottom of stuffing box between the shaft and casing, causing packingto be
forced into pump interior
39. Dirt or grit in sealing liquid, leading to scoring of shaft or shaft sleeves
40. Excessive thrust caused by a mechanical failure inside the pump or by the failure of the
hydraulic balancing device, if any
41. Excessive grease or oil in bearing housing or lack of cooling, causing excessive
Bearing temperature
42. Lack of lubrication
43. Improper installation of antifriction bearings (damage during assembly, incorrect assemblyof
stacked bearings, use of unmatched bearings as a pair, etc.)
44. Dirt getting into bearings
45. Rusting of bearings due to water getting into housing
46. Excessive cooling of water cooled bearing resulting in condensation in the bearing housing from
moisture in the atmosphere.

3.1.3.3 Troubleshooting chart-2

Problems
regularly.
hot or fail
Bearing run

failure
High seal
packing
Short life of

at high rate
Pump vibrates
much power
drawing too
Pumps is

accelerated.
internal parts
Wear of
liquid
not deliver
Pump does
Capacity
sufficient.
not deliver
Pump does
Pressure.
sufficient.
not deliver
Pump does

intently
flow inter-
Pump deliver
Causes/
Symptoms

Pump not    
primed or
prime lost
Suction    
and/or
discharge
valves closed
or clogged

Suction   
piping
incorrect
Insufficient      
NPSH
available
Excessive air    
entrapped in
liquid
Speed (rpm)   
too low
Incorrect  
rotation
Broken    
impeller or
vanes
Incorrect 
 Page-41

impeller
diameter
System head 
too high
System gives  
erroneous
reading
Air leak in 
suction line
Excessive   
shaft
misalignment
Inadequate 
lubrication
Lubricant 
contamination
Inadequate 
lubricant
cooling
Axial thrust 
or radial
loads higher
than bearing
rating
Improper  
coupling
lubrication
Suction  
pressure too
high
Bearing   
incorrectly
installed
Impeller out   
of balance
Overheating 
of seal faces
Excessive   
shaft
deflection
Lack of seal 
flush at seal
faces
Pump is run 
dry
Pump run off     
design point
Shaft/shaft  
sleeve worn
Packing  
gland not
 Page-42

properly
adjusted
Packing not 
properly
installed
Impeller  
clogged
Coupling out   
of balance
Baseplate not   
installed
properly
Operating 
speed close to
system’s
natural
frequency
Bearing   
failing
Piping not   
properly
anchored
Pump and/or   
driver not
secured to
baseplate
Specific    
gravity
higher than
specified
Viscosity   
higher than
specified
Internal  
clearances too
tight
Chemicals in 
liquid other
than specified
Pump      
assembled
incorrectly
Higher solids 
concentration
than specified

Table – 2.2
 Page-43

(Trouble shooting chart-2)

3.1.4 Designing tool: This tool was developed in excel sheet using various formulae relating the flow
conditions inside the pipe with the pressure drops. This tools was used in the troubleshooting process in
next chapter to evaluate an alternative solution to the problem took in the case study.
 Page-44

3.2 Method of study

To establish a proper troubleshoot one has to take into account the procedures and principles developed till now
with great precision. Till now we have developed the tools and materials required for the troubleshooting of the
section taken into account. There are some steps which one has to follow while troubleshooting an equipment
(pump).
1. Firstly a flow diagram or the process diagram of the given plant is studied noting every possible
information regarding the process parameters, equipment, etc.
2. The obtained data is analyzed keeping in mind the problem associated with the process. A section of the
process is taken for troubleshooting.
3. The macroscopic problem associated with the equipment is written down. Now the associated causes and
reasons are evaluated using the troubleshooting chart developed during the project study.
4. The causes obtained are further analyzed to obtain a microscopic view of the reasons and factor causing
the problem.
5. There can be many reasons but we need to take assumptions and avoid minor problems which in some
way re related to major ones.
6. Now we find the possible solutions to troubleshoot the different problems. The solutions are checked on
the basis of their feasibility and the economics. The best alternates and solutions are obtained. We can
also take into account the designing aspect of the troubleshooting in this case to find more optimum
solutions
7. The solutions to deal with the problems re analyzed on the basis of cost estimation. And an estimated
cost associated with every solution is taken into count and the best one is chosen on the basis of
efficiency and the economic factors.
8. The solution obtained is the result of our troubleshooting.
 Page-45

Chapter 4
Results and Discussions

To use and Implement the ideas and methods to troubleshoot the problems in chemical industries as
discussed in chapter 1 will be used in this chapter along with a practical example of a working industry.
It will provide us a descriptive idea about how to identify the problem, how to find the reasons behind
the problem, how to initiate the troubleshooting, how to collect all the relevant solutions and to give cost
estimation of each of the possible solution.
4.1 Problem Description
Let’s take a working example of a hydrocarbon industrial unit in which problem is to be identified, is to
be troubles hooted and the relevant solutions is to be provided according to the cost, engineering basis.
We are having a process in which reflux stream is moving from one unit-V-2023 to T-2021(names of
the units are taken for our convenience). A pump P is installed in between the line system of two units to
draw the reflux stream coming at low pressure and sent to T-2021 unit at high operating pressure.

V-2023

T-2021

Pdischarge: 2 MPa

Specifications of the process units:

 Operating pressure of V-2023: 0.98 MPa
 Suction pressure of pump: 0.95 MPa
 Initial discharge pressure of pump: 2 Mpa
 Operating pressure of T-2021: 1.71 Mpa

Heat and material balance (HMB) details:

 Temperature of stream: 373 K
 Pressure of stream: 2 MPa
 Phase of stream: Liquid
 Page-46

 Molecular weight: 76 gms

 Density: 631 Kg/m3
 Coefficient of cubical or volumetric thermal expansion: 0.00124
 Viscosity :0.056 Centistokes
 Porosity of material of line: 0.000259

The system was designed for 110% design factor and was working accurately. Since the problems are
with equipment are a part of every industrial process, here in this process we faced sudden Pump
Failure. Pump was not producing required discharge head. It was designed to produce Discharge
pressure of 2 Mpa but it was producing Pressure of 1.9 Mpa. Due to which with constant flow of stream
through the pump there was constant pressure drop in the line connecting pump P to unit T-2021. This
resulted in failure to push reflux stream from pump P to the unit T-2021 by lacking of 0.1 Mpa pressure
in the stream reaching the unit after pressure drop of 0.29 Mpa. The operating pressure of unit T-2021
will not allow the reflux stream to enter and we will face decline in supply of reflux to the unit T-2021.
Here by resulting in loss of production and high working load on pump.

V-2023

T-2021

New Pdischarge:1.9 MPa

So as an engineer one has to face such problems from day to day working and it must be essential for a
engineer to know the reason for a problems so that one can find the solution to every minute level so that
the solutions can be wide covering topics.in this project we will carry out a detailed troubleshooting
analysis to identify problems associated with the given above problem with our methodology of
troubleshooting made through this project, the possible solutions associated with the the reasons behind
the problems and finally as estimations of cost equipped with the implementation of the solutions.

4.2 Reasons of problem

Theremight be many possible reasons for pump to provide a low discharge pressure than expected. All
the possible reasons have already been discussed in troubleshooting chart in chapter 1. Few of the
possible reasons for provided problem are:
 Cavitation
 Multiphase flow
 Page-47

 Speed too low

 Total head required in greater than pump head
 Viscosity of liquid different from designing criteria
 Bearing worn
 Impeller damaged

4.3 Possible Solutions

Following could be some of the possible solutions of the given problem. These are the super set of all
the solutions of this problem, we might be using one or two or three at a time depending on many
factors.
4.3.1 Theoretical Aspect:
Different problems we face in Pumps can be identified and troubleshooted by following the different
step methods. Some of the techniques are show below in the below charts.

Figure – 1.7
Troubleshooting – 1
 Page-48

Figure – 1.8
Troubleshooting – 2

Figure – 1.9
Troubleshooting – 3
 Page-49

Figure – 2.0
Troubleshooting – 4

Figure – 2.1
Troubleshooting – 5
 Page-50

Figure – 2.2
Troubleshooting - 6
4.3.2 Design engineering aspect
4.3.2.1 Design and Engineering
The engineering design process is a methodical series of steps that engineers use in creating functional
products and processes. The process is highly iterative - parts of the process often need to be repeated
many times before production phase can be entered - though the part(s) that get iterated and the number
of such cycles in any given project can be highly variable.
It is a decision making process (often iterative) in which the basic sciences, mathematics, and
engineering sciences are applied to convert resources optimally to meet a stated objective. Among the
fundamental elements of the design process are the establishment of objectives and criteria, synthesis,
analysis, construction, testing and evaluation
One framing of the engineering design process focuses on the following general aspects: research,
conceptualization, feasibility assessment, establishing design requirements, preliminary design, detailed
design, production planning and tool design, and production. The steps tend to get articulated,
subdivided, and/or illustrated in a variety of different ways, but they generally reflect certain core
principles regarding the underlying concepts and their respective sequence and interrelationship.
(a) Research:

A significant amount of time is spent on locating information and research. Consideration should be
given to the existing applicable literature, problems and successes associated with existing solutions,
costs, and marketplace needs.
 Page-51

The source of information should be relevant, including existing solutions. Reverse engineering can be
an effective technique if other solutions are available on the market. Other sources of information
include the Internet, local libraries, available government documents, personal organizations, trade
journals, vendor catalogs and individual experts available.
(b) Feasibility:
At first, a feasibility study is carried out after which schedules, resource plans and, estimates for the next
phase are developed. The feasibility study is an evaluation and analysis of the potential of a proposed
project to support the process of decision making. It outlines and analyses alternatives or methods of
achieving the desired outcome. The feasibility study helps to narrow the scope of the project to identify
the best scenario. A feasibility report is generated following which Post Feasibility Review is performed.
The purpose of a feasibility assessment is to determine whether the engineer's project can proceed into
the design phase. This is based on two criteria: the project needs to be based on an achievable idea, and
it needs to be within cost constraints. It is important to have engineers with experience and good
judgment to be involved in this portion of the feasibility study.
(c) Conceptualization
Following Feasibility, a concept study (conceptualization, conceptual engineering) is performed. A
concept study is the phase of project planning that includes producing ideas and taking into account the
pros and cons of implementing those ideas. This stage of a project is done to minimize the likelihood of
error, manage costs, assess risks, and evaluate the potential success of the intended project.
(d) Design Requirement
Establishing design requirements is one of the most important elements in the design process,[4] and this
task is normally performed at the same time as the feasibility analysis. The design requirements control
the design of the project throughout the engineering design process. Some design requirements include
hardware and software parameters, maintainability, availability, and testability.
(e) Detailed Designing
Following FEED is the Detailed Design (Detailed Engineering) phase which may consist
of procurement as well. This phase builds on the already developed FEED, aiming to further elaborate
each aspect of the project by complete description through solid modeling, drawings as well
as specifications.
Some of the said specifications include:

 Operating parameters
 Operating and non-operating environmental stimuli
 Test requirements
 External dimensions
 Page-52

 Maintenance and testability provisions

 Materials requirements
 Reliability requirements
 External surface treatment
 Design life
 Packaging requirements
 External marking
Computer-aided design (CAD) programs have made the detailed design phase more efficient. This is
because a CAD program can provide optimization, where it can reduce volume without hindering the
part's quality. It can also calculate stress and displacement using the finite element method to determine
stresses throughout the part. It is the engineer's responsibility to determine whether these stresses and
displacements are allowable, so the part is safe.

4.3.2.2 Manual of Line Sizing (Pump Lines)

Procedure followed to form an in-house excel sheet for line sizing is based on the wide range of study,
observing regular trends, some assumptions and design engineering practices. It includes following
steps:
(a) Stream number: stream number is the number provided to the stream flowing just to
differentiate in from other streams.
(b) Flow rate: the mass flow rate of the stream flowing in the line is taken in kg/m3
(c) Temperature of the stream flowing: the average temperature of the stream flowing in the line.
It is taken in 0C.
(d) Pressure: pressure exerted the flowing stream. It is taken in Mpa units.
(e) Phase of the stream: whether the flowing stream is in Liquid, Gas, or multiphase.
(f) Molecular weight: Molecular weight of the flowing stream is provided.
(g) Roughness: roughness of the material of the pipe is obtained from the data available in literature
and it is taken in the units of meter.
(h) Density: Density of the stream at given temperature and pressure is obtained.]
(i) Variable density: density varies with the change in temperature. If there is any change in
temperature of the stream it is to be provided in the manual and new density is to be used for our
calculations.

ϼn=ϼo/ (1+β(t1-to))
 Page-53

ϼn: New density at changed temperature

ϼo: old density
β: Volumetric temperature expansion coefficient
t0: initial temperature
t1: changed temperature
(j) Viscosity: Viscosity of the flowing stream is provided in the units cst. Also the viscosity of the
flowing will change if we will change if the temperature of the stream will change.
Using Power Law:
μ/μo=(T/To)^0.7

μ: changed viscosity due to temperature

μo: initial viscosity
T: new temperature
To: initial Temperature
(k) Velocity of stream: Velocity of the stream flowing is calculated by the following formula
V = M*10^6/ (3600* ϼn (3.14 D^2)/4)
M: Mass flow Rate (kg/m3)
D: Diameter of the line
(l) Reynolds’s Number: Reynolds’s number is the ratio of inertial force upon viscous force acting
on the fluid. It tells us about the flow pattern of the fluid.
Re<2200 Laminar Flow
2200<RE<4000 Transient Flow
Re>4000 Turbulent flow

Re= ϼn*V*D/ μ
Re: Reynolds’s Number
V: Velocity of the stream
D: Diameter of line
Μ: Viscosity of the stream flowing
(m)Porosity: Refer to the annual provided in the excel tool.
 Page-54

(n) Friction Factor: Friction factor in the line is calculated either by the Moody’s chart or by the
Colebrook equation. We are using Colebrook & White equation in this manual to solve the
system.

We can use either of the Numerical Method to solve the Colebrook & White equation. Haaland
in 1983 simplified the Colebrook & White’s equation to the following equation.

(o) Length of the line: Length of the line includes actual length of the line, length of the line
equivalent to the pressure drop in all type of fittings, length of line equivalent to the height of
foundations of unit and pump etc.
(p) Pressure Drop: Pressure drop in the line of total length can be calculated by the Darcy -
Weisbach Equation.

hf: Head Loss in the line due to friction

fD: Darcy’s friction factor
L: Length of the line
D: Diameter of line used
U: Velocity of the Stream
G: Acceleration due to gravity

4.4 Cost estimation of different possible solutions (Theoretical) of problem

For every industry the main motive of its working is to attain profits so that its profits obtained can be
used for the company expansion and for its future development. When it comes to the working the cost
factor is considered as the most relevant factor. The cost estimation is important in order to provide an
estimate of cost. As an engineer one has to consider the economics regarding every tiny activity done at
the plant may it be the installation on of any new facility, or the unit produced or for repairing and
maintenance. When we encounter any problem within an plant the first approach is to find the possible
reasons to the problem, the next step is to make possible solutions with the alternatives available. the
best economized solution is implemented and the one which has a long life in this part of the project
 Page-55

developed till now ,we will emphasize on the cost estimation part of the problem we have considered
before.
For any effective cost estimation of a situation one has to go through every tiny details available , be it
the possible causes, solutions, the working atmosphere etc. the majors steps to calculate the economics
of any solution implementation the following steps are followed.

Troubleshooting the
situation to find the
possible solutions to
problem

Find the effective solutions

to the problems

Compare the solutions by

simple cost estimation by
various vendors, sellers,
manufacturing shops etc.

Figure 2.3
Steps- Troubleshooting
The calculation for the given troubleshooting problem will require information’s regarding the cost of
various thing used in the industry. In this project we will assume a rough idea of rates due to the wide
variance in the use of rates with the hydrocarbon industry. We are considering the production of benzene
from an naphtha refining unit, the tanks T-2023 is the input for the entrance in naphtha unit. And tankV-
2021 supplies the required raw material for the naphtha unit.
Cost specifications of the Naphtha cracking unit:
The production capacity of the plant: 600000 tons per annum. The selling price of the benzene
produced: $ 800 per metric ton= Rs 51.2 per kg. The annual production cost price of unit (operating +
fixed)=$ 793 per metric ton= Rs 50.7 per kg. The daily production of the plant: 600000/365= an
approximately 1645 metric ton per day
Note: we are assuming that the plant is working on its full capacity and its working 365 days an year
Theoretical cost analysis of project
in the previous section of the project, we took a sample problem and defined the causes associated with
it from the troubleshooting chart. From the different solutions obtained we proposed a number of
 Page-56

solutions of throttling th problems .now we will consider each individual solution and will apply an
effective cost analysis to find the best solution available to us to make the pant work again.
The problem associated with system: the pump P was not developing sufficient head to develop a
sufficient head to transfer the raw material to naphtha unit by the pump P.
The possible problems developed using the troubleshooting procedure:
 Insufficient Priming
 Cavitation
 2- Phase flow
 Speed too low
 Total head required is less than pump head generated
 Viscosity of liquid different from design criteria
 Bearing worm
 Impeller damaged
 Suction line flaws
 Pump not assembled correctly
 Gas trapped in liquid
 Damages to valves used

The possible solutions available to solve the problem:

 One of the solutions to deal with such a problem is to totally replace a pump or buy a new one.
But such type of alternatives are kept at last priority because such solutions deals with a heavy
expenditure and affect the production loss, as replacing or buying a new pump usually takes 4-5
days which leads to higher productions loss, high labor rates, and high replacement cost.
 The other solution to dealing with a pump is to make it repaired by the machinery shop of the
industry or by the professionals dealing with the problems. Such solution are preferred as they
lead to less expenses and they make less production losses.in this case the possible solutions
derived in mind keeping the problems associated are:

 Priming the pump which is basically not a very expensive work. The daily production schedule
can be instructed to initiate a better priming

 Another solution available with the problems of suction valve damage is to get the valve opened
from the installed line and get it repaired in the machinery workshop. The basic objective of such
a solution is to overcome the fouling happened inside the valves.The basic process for chemical
cleaning follows a five step procedure:

Alkaline clean: Removes organic material buildup such as oil and fats leaving the inorganic
surfaces exposed and ready for treatment.

Rinse: Following each step there is a rinse using high flow water flushes which removes loose
debris and remaining chemical residue.
 Page-57

Acid cleaning: The inorganic material is now treated with an appropriate acid blend designed to
soften or dissolve the fouling material.

Rinse: The process of rinsing occurs once more to remove any debris, sludge or residual acid
from the heat exchanger following the acid cleaning process.

Passivation: This is required to add a protective coating to the base metal that is now exposed
and vulnerable to oxidation should it continue to be exposed to the atmosphere.

Assuming a total cost of solutions needed for the chemical treatment of fouling be Rs. 450/ liter.

 Another solution to the problem of suction piping line is to replace the line with a new one of the
required size and specifications so as to develop a proper hear and working conditions.

The price per unit of the 90 degree elbows: Rs.215

The price per unit of the ball valves: Rs.1750

The price per unit of the stainless steel flanges: Rs.850

Cost of the pipeline of dia (197 mm) used: Rs.157 per meter

The total cost of applying this solution is: (157*300) + (4*850) + (2*215) + (1950*2)

= Rs42440

 Another solution to the problems is to increase the cooling capacity and the cooling operations
on the input streams so as to avoid the problems of the air trapped in the input stream.
 Another solution as suggested for the problems of the shaft speed being too slow is to replace a
pump or get its shaft repaired by the manufacturer. Such problem does not take into account for
the replacement as the manufacturer knows that the fault is on the design part rather than the
operational part.
 In cases of wear and tear of the pump impeller the only solution is to get it repaired by the
workshops’ available. Since the price of repairing varies from place to place, and it depends on
multiple factors, therefore we are considering an approximate cost regarding this case the cost of
repairing the impeller is to be 14000.
 Another problem we encountered during the troubleshooting was that the pump was assembled
incorrectly. In such case the expenses are related basically to the installation and the overhead
charges. The engineering cost of Rs.20000.

The cost estimation of solution (Theoretically):

 In case of fouling removal and valve repair: 450*5= Rs.2250+ Rs. 10000 (overhead
charges)=Rs. 12250
Assuming that the production is affected for one day due to which the net daily loss
is=7*64*1645=Rs. 736960
Total Expenses+ cost of manufacturing loss: Rs 749210
 Page-58

 In case of discharge incorrect piping Replacement:

Piping Cost from vendor: Rs 42440
Engineering Cost: Rs 20,000
Labor Charges + Miscellaneous= 10,000
Gross Total = Rs72,440
Production loss for two days: Rs 1473920
Total Expenses+ cost of manufacturing loss: Rs 1546360

 In case of Pump Replacement due to insufficient NPSHa:

Assuming the cost of a single pump: Rs 55000 to 65000
Duration for Pump Replacement: 2 Days
Labor Cost: Rs 10,000
Engineering Cost: Rs 20,000
Total Expenses+ cost of manufacturing loss: Rs 1563920

4.5 Cost estimation of different possible solutions (Design) of problem

We are done with the theoretical aspect of troubleshooting the problems in lining of a pump system now
let’s do a smart work, think smartly to solve the problem. Following 2 figures are provided, first figure-
2.4 containing the designing of the line when the pump is operation according to the designed criteria
and no problem is encountered in pump, line or any of the Unit connected with it and second figure- 2.5
containing the designing of line when the pump is producing less head than expected.

Figure- 2.4
 Page-59

Here we can clearly see that the length of pipe required having a pressure drop of 0.29 Mpa is 300m
(estimated), in which we are getting the flow velocity of 4.46 m/sec and the flow condition is Turbulent.

Figure- 2.5
(a) Replacement of Discharge Pipe Line
Here in figure – 2.5 you can clearly see that as the required pressure drop now has declined to 0.192
Mpa. We have changed the Temperature of the flowing stream in order to have its effect on the flowing
fluid density and viscosity. Obviously changing the temperature of the stream is only possible if the
relaxation in the change in temperature of the fluid is available. We are not changing the nominal
diameter of the line. Then according to the flow rate we are just having some iteration by changing the
line length required to achieve the pressure drop of 0.192 MPa. At last we end with the line length of
200m (expected) with the flow velocity of 4.32 which is close to the velocity in the initial case so there
are no chances of vibrations in the line.
Doing cost estimation in it. We got the following observations:
Length of the line required: 200m
Cost of pipe line from vendor: 200*157= Rs. 23140
We can actually save this amount by using the old pipe available. We are having pipe of e specifications,
cut it to 200m length.
 Page-60

Engineering Cost: Rs 20000

Labor Cost + Miscelleneous= Rs 10000
Gross total investment: 10,000+20,000= Rs 30,000
As we are using the same pipe line and same fittings the duration of repair and replacement will be less
than a day.
So production loss for maximum one day: Rs 736960
Total cost + cost of production loss: 736960+30000= Rs 766960

Taking the case 2 discussed in theoretical aspect of troubleshooting. If we will go with that methos we
are having the total investment on replacing the piping and manufacturing loss of Rs1546360.
But if we will go with the solution discussed in the designing aspect we are getting the cost of
Rs766960. Which shows the direct saving of Rs 809400 (52.3%?)
(b) Replacement of Suction Pipe line (as it was incorrectly installed or designed)
Case1: Length of the pipe line changed
Original length of pipe line: 150 m
Original diameter: 170 mm
Operating pressure of source: 1.25 Mpa
Suction pressure of pump : 0.95 Mpa
Designed pressure drop: 0.3 Mpa
But we are will recover this pressure drop by reducing the pressure drop in the line to 0.2 Mpa
Now as per cost analysis,
Cost of replacing the pipeline of 170 mm of length 150 m= Rs. 22530
Engineering Cost: Rs 20,000
Labor Charges + Miscellaneous= 10,000
Gross Total = Rs52,530
Production loss for one days: Rs 736960
Total Expenses+ cost of manufacturing loss: Rs 789490
Case 2: Diameter of the pipe changed:
Original length of pipe line: 150 m
Original diameter: 170 mm
 Page-61

Operating pressure of source: 1.25 Mpa

Suction pressure of pump : 0.95 Mpa
Designed pressure drop: 0.3 Mpa
But we are will recover this pressure drop by reducing the pressure drop in the line to 0.2 Mpa
Now as per cost analysis,
Cost of replacing the pipeline of 185 mm of length 150 m= Rs. 22821
Engineering Cost: Rs 20,000
Labor Charges + Miscellaneous= 10,000
Gross Total = Rs52,821
Production loss for two days: Rs 1473920
Total Expenses+ cost of manufacturing loss: Rs 1526741
Case 3: Diameter and Length of the pipe changed:
Original length of pipe line: 150 m
Original diameter: 170 mm
Operating pressure of source: 1.25 Mpa
Suction pressure of pump : 0.95 Mpa
Designed pressure drop: 0.3 Mpa
But we are will recover this pressure drop by reducing the pressure drop in the line to 0.2 Mpa
Now as per cost analysis,
Cost of replacing the pipeline of 180 mm of length 132 m= Rs. 19809
Engineering Cost: Rs 20,000
Labor Charges + Miscellaneous= 10,000
Gross Total = Rs52,821
Production loss for two days: Rs 1473920
Total Expenses+ cost of manufacturing loss: Rs 1523729
Sr. No Case Total Cost Percent Saving
1 Length Changed+ 789490 48.28%
2 Diameter Changed 1526741 -
3 Length and Diameter changed 1523729 0.19 %

+ this method can only be used if we are having flexibility in changing the length of the line between two fixed unit considering the cost of construction.
 Page-62

Conclusion

In the present work done till now, we defined a systematic way of finding and detective every smallest
possible causes related to a malfunctioning of the pump. Through this project we basically went through
a learning process of the possible cases and solutions while troubleshooting a pump with in a following
industry. Our base work was related to find the solutions and problems of every possible problem
occurring with a pump while operating in a process line. From the study it is evident that every solution
cannot be encountered by the theoretical work, we always have to work on assumptions which lead to
inefficient results. The following conclusions are made during this study:

 Gathered data related to the pump functioning and through the refinement of the different
theoretical aspect, developed a systematic ways of troubleshooting the pump.
 Troubleshooting chart 1
 Troubleshooting chart 2
 Designing tool

 Developed effectively the solutions related to different possible problems occurring while
functioning and checked the feasibility of the solutions obtained.

 During the troubleshooting the best alternatives in the category were concluded. As per the
case taken up during the project ,the following reasons were obtained from the troubleshooting
chart:
 Cavitation
 Insufficient priming
 2- Phase flow
 Speed too low
 Bearing worm
 Impeller damaged
 Suction line flaws
 Pump not assembled correctly
 Gas trapped in liquid
 Damages to valves used

 A cost estimation of the project was done and from the cost data used for replacing the pipe line
we obtained the direct saving of Rs 809400 (52.3%).

 Successfully covered all the aspects of the case study and evaluated the reasons and solutions to
the given problem.
 Page-63

References
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AdeboriSaheedBalogun, (2013). Corrosion Problems During Oil and Gas Production and its
Mitigation, International Journal of Industrial Chemistry (IJIC), (2-6)
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