Troubleshooters Back Pocket

Part IV. . .

Troubleshooting Centrifugal Pumps

By Edward Butts PE, DEE, Contributing Editor same basic components: 1) an impeller; 2) a volute, case or diffuser; and 3) a rotating shaft. The impeller (Fig. 1A) is the principal working part in a centrifugal pump and the only rotating part that actually performs any work. While it is normally classified as closed, semi-open and fully open impellers are also used on occasion, generally for wastewater applications. By virtue of its speed and diameter, the impeller imparts kinetic energy or entrifugal pumps, by definition, include a velocity to a fluid by centrifugal force. Impeller large family of rotating (rotary) dynamic rotation creates a negative pressure (commonly, but pumps in which enerincorrectly, referred to as sucgy is imparted to the pumped tion) in the eye of the With just two fluid by a rotating disc, called impeller, which is relieved by an impeller, to move a specified moving parts, some form of pressure (atmovolume of fluid, usually classispheric or pressure head) that a conventional fied as gallons per minute pushes additional fluid into (GPM), against a specified the eye to relieve this pressure centrifugal pump is amount of resistance, comdifferential. Fluid velocity is monly referred to as feet of actually the simplest rapidly converted to pressure head. Although the centrifugal head by the volute or diffuser category includes the vertical (Fig.1B) enclosing the impelmember of the turbine and submersible style ler. The shaft (Fig. 1C) is simof pumps that have been previply the means of transmitting centrifugal family. ously discussed in this series, the required power (comfor the purposes of this article As with most pumps, monly referred to as horsewe limit our discussion to end power) and rotative speed to suction and split case centrifu- any problems generally the impeller. All of these gal pump designs. End suction components generally work fall into one or more in relative harmony, each and split case centrifugal pumps are markedly different with a specific job. If any of of three primary in construction and appearthe three parts fails to work ance, but both types, like most properly, however, the pump categories. centrifugals, incorporate the will not perform as designed.
Following previous discussions on vertical tubine pumps (July 2003), submersible pumps (October 2003) and electrical systems (February 2004), this months installment of our Troubleshooters Back Pocket series focuses on the most common problems and corrective measures associated with end suction and split case centrifugal pumps.
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Shower Curtain Shield to prevent water from reaching front motor bearing

Fully machined bronze impeller with double curvature vanesprecisely located, fitted and locked on shaft

Fig. 1A

Double-volute design standard on larger sizes

Clean contoured design for smooth liquid entry

Copper wound, open, drip-proof motor

Fig. 1C
Large, deep stuffing box

External hydraulic balance line

Figure 1. Conventional centrifugal pump (courtesy of Cornell Manufacturing Company)

Replaceable, recessed bronze wear rings Rigid, heavy walled construction resists distortion (ASTM A48 Class 30 cast iron)

Fig. 1B

Types of Problems
With just two moving parts, a conventional centrifugal pump is actually the simplest member of the centrifugal family. As with most pumps, any problems generally fall into one or more of three primary categories: 1) Mechanical 2) Driver related 3) Hydraulicsuction lift or head Mechanical Mechanically-related problems in a typical centrifugal pump are generally limited to either the impeller or shaft.
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Since the impeller is the only part of the pump that actually performs any workwhich it does at fairly high speedslogic would dictate that this component would be the item exposed to the most problems. Common mechanical problems associated with impellers include: excessively worn running surfaces (eyes or wear rings), corrosion and cavitation damage (usually caused by hydraulic issues). Problems involving the shaft include: material fatigue, excessive wear along the sealing surface and problems of fatigue and breakage caused by overhanging loads (a large impeller). Even though the volute or
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diffuser does not actually rotate, mechanical problems with these components can also occur, usually due to material fatigue. Driver related Just as is the case with other classes of centrifugal pumps, such as vertical turbines and submersibles, driver, electric or other types of problems often comprise the most frequent and common problems in an installation. In fact, many problems that technicians often believe are coming from the pump are really coming from the driver. Since most styles of centrifugals can be powered by an electric motor, engine,
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hydraulic drive or other method, the list of potential problems with the driver is endless. Generally, trouble resulting from problems with electric motors is related to the incoming power supply, motor windings or bearings. Problems related to the power supply or windings often result in the inability of the motor to run at all, while bearing problems usually give some type of warning (i.e. noise or vibration) before total failure occurs. Bearing problems in a driver can often be the result of problems within the pump itself. A centrifugal pump with a large impeller can create severe side (axial) loads on a bearing, especially one that is undersized for the application. Pumps that are driven by means of belts can also create severe driver and/or pump problems, especially when the belts are either too tight or too loose. Hydraulic Hydraulic problems with centrifugal pumps are very common, especially when the pump is exposed to a suction lift (where the pumped fluid is below the impeller eye). In cases of a suction lift, the pump is required to create a sufficient vacuum (negative pressure) so that atmospheric pressure can push the fluid into the pump to relieve the vacuum. This situation can be a very tenuous one, dependent on various parameters, such as: fluid temperature, elevation above or below sea level, the specific pump suction characteristics (NPSHR), and the actual amount of lift. Because everything must work just right, it does not take much disruption

An experienced and knowledgeable troubleshooter will consider all possible causes and solutions to a particular problem beyond the clearly obvious ones.
for a pump under a suction lift to partially or completely fail to pump properly. The technician who must work with a pump under a suction lift must truly understand the physics and principles involved, otherwise they could waste a lot of time trying to find out why a certain pump will not operate. Pumps under a suction head (where the pumped fluid is above the impeller eye) are generally much less problematic and easier to troubleshoot than those under a suction lift. Needless to say, a technician planning to work on centrifugal pumps should first of all, become very

familiar with the fundamentals of these designs, especially the hydraulic characteristics and principles.

Specific Problems and Solutions

Troubleshooting an ordinary centrifugal pump, as previously indicated, is mostly a process of logical elimination consisting of: identification of the general problem, subdividing the most likely problem into either a mechanical, driver-related, hydraulic or electrical-system issue (or in rare cases, a combination), and then pinning down the final diagnosis to the ultimate cause, followed by the solution. When this procedure is followed, in the order indicated, the time and effort to identify and correct the problem can be significantly reduced. Typical problems, causes, and solutions associated with centrifugal pumps (not necessarily in the order of frequency or likelihood) are outlined in Table 1. The situations listed in Table 1 list include most, but not necessarily all, of the common conditions associated with various centrifugal pump and/or motor problems. Centrifugal pumps, although relatively simple in design and construction, are often prone to unique and unusual problems that may not be listed here, especially those operating under a suction lift. An experienced and knowledgeable troubleshooter who regularly works with centrifugal pumps will consider all possible causes and solutions to a particular problem beyond the clearly obvious ones. P&S

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Table 1. Centrifugal Pumps Typical Problems, Causes and Solutions

PROBLEM
Mechanical

POSSIBLE CAUSE

SOLUTION

1. Pump runs, but will not deliver water

Broken pump shaft or pump/motor coupling Excessively worn impeller(s) Impeller loose from pump shaft Plugged inlet or impeller Wrong pump Hole/break in suction pipe Repair/replace shaft or coupling Replace/repair impellers/wear rings Reset impellers to shaft Clean inlet or impeller/install screen Install correct pump Replace defective pipe

Driver Related
Inadequate speed (wrong motor or engine speed) Improper electric motor speed-(variable speed drives) Wrong rotation of motor Motor running on single phase power (3-phase motors) Correct driver speed Correct motor speed Reverse rotation Restore 3-phase power

Hydraulic
Pump not fully primed Excessive lift (pump under suction condition) Inadequate inlet head (NPSH) Suction (inlet) not submerged Air or gas in pumped fluid Fully prime pump Change pump or lower lift Increase inlet head or submergence Lower inlet setting Increase submergence (suction) or eliminate air

2. Pump delivers less water than desired

Mechanical
Excessively worn impeller or wear ring Partially plugged inlet/impeller Leak/break in suction pipe Impeller not properly set into wear ring Incorrect pump Incorrect impeller trim Defective check valve (suction or discharge) Inaccurate flowmeter Rebuild/replace impeller/wear rings Clean or install inlet screen Replace defective pipe Correct impeller settings Install pump Install impeller with correct trim Replace defective check valve Verify/repair flowmeter

Driver Related
Motor running on single phase power (3 phase motors) Inadequate electric motor speed(variable speed drives) Wrong driver speed (electric or engine) Wrong rotation of driver Low voltage to motor Restore 3 phase power Correct motor speed Correct driver speed Reverse rotation Correct low voltage condition/increase wire size

Hydraulic
Entrained air or gases in pumped fluid Excessive lift (suction conditions) Inadequate inlet head or throttled suction supply (NPSH) Inadequate submergence (well or sump condition) Excessive discharge head (pressure) Eliminate air introduction Change pump or lower lift Increase inlet head Increase submergence Lower discharge head

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PROBLEM

POSSIBLE CAUSE

SOLUTION

3. Pump delivers less pressure than desired

Mechanical
Excessively worn impellers and/or wear rings Partially plugged inlet or impeller Leak or break in suction or inlet pipe Impeller(s) not properly set in wear rings Defective diffuser or volute Incorrect impeller trim Defective check valve Improper design conditions Defective pressure gauge Rebuild impellers/wear rings Clean inlet/impellers Repair leak Correct impeller setting Replace diffuser/volute Install impeller with correct trim Replace defective check valve Review head conditions & modify pump, if needed Replace pressure gauge

Driver Related
Inadequate speed (electric or engine) Wrong electric motor speed Wrong rotation Low voltage to motor Raise driver speed Correct motor speed Reverse rotation Correct low voltage condition/increase cable size

Hydraulic
Entrained air or gases in pumped fluid Inadequate inlet (suction) head Excessive lift for specific pump(NPSH problems) Pre-rotation of fluid into pump Inadequate submergence Eliminate air/gas Increase inlet head Change pump or lower lift Install straightening vanes in inlet Increase submergence

4. Pump vibrates or is noisy

Mechanical
Bent shaft Misaligned/loose impeller connection to shaft Worn bearing surfaces in pump/motor Discharge/inlet pipe strain Partially plugged impeller Pump operating within critical speed region (reasonance) Impeller(s) not balanced Misaligned coupling between pump and driver Straighten/replace shaft between .003-.005 Correct impeller/shaft connection Replace bearings/shaft sleeves Relieve strain on pipe(s) Clean obstruction Raise or lower flow Balance impeller(s) Correct coupling

Driver Related
Imbalance within motor (bearings, rotor, etc.) Electrical imbalance in motor due to power imbalance Worn bearings in motor Motor operating on single-phase power (3-phase motors) Defective motor starter or VFD Bent motor shaft Replace/repair motor Contact power company Replace bearings Restore 3-phase power Repair/replace starter/VFD Replace motor

Hydraulic
Cascading water in well or vortex in sump Inadequate inlet head Pre-rotation of water into pump inlet Pump operating outside normal flow boundaries Lower pump or shroud intake Increase inlet head Install straightening vanes in pump inlet Correct operating condition

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PUMPS & SYSTEMS

PROBLEM

POSSIBLE CAUSE
Pump is cavitating (NPSH problems) Resonance in piping

SOLUTION
Lower lift, increase inlet head, etc. Install flex couplings or pressure tank

5. Pump draws more power than intended

Mechanical
Excessively tight bearings Inadequate lateral clearance between impellers/wear rings Bent shaft Pumping sand or other abrasives Replace/ream bearings Modify clearances Straighten/replace shaft Raise inlet setting Decrease flow Correct sand condition Incorrect impeller or impeller trimming Wrong pump (new pump) Incorrect design conditions Packing/seal too tight on shaft Install correct impeller/trim Install correct pump Verify conditions and modify as necessary Loosen/replace packing; replace seal

Driver Related
Defective bearing in motor Motor operating on single-phase power (3 phase-motors) Low or unbalanced voltage Wrong motor rotation Excessive or wrong speed Loose rotor bars in motor Inadequate size of wire to motor Defective motor starter or VFD Replace bearings or motor Restore 3-phase power Correct low voltage condition Reverse motor rotation Correct motor speed Repair/replace motor Increase wire size as needed Repair/replace starter/VFD

Hydraulic
Pre-rotation into pump inle Lower operating head than designed Cascading water (causing air entrainment) Install straightening vanes in pump inlet Increase head or modify bowl Increase submergence or correct cascading condition Excessive flow rate Excessive inlet head (resulting in lower pump head) Gas or air entrainment in the pumped fluid Excessive lift (suction conditions) Restrict flow rate Lower inlet head Correct condition Verify allowable lift and NPSHR of pump

6. Pump/motor wll not start

Electrical System
No power below main, Blown fuse or tripped circuit breaker No power above main, Tripped line fuse Tripped overload Incomplete 3 phase power (single phasing) Loose or burned wire or connection Control system failure Defective motor starter Defective motor Defective phase monitor or blown fuse to monitor Open lead, splice, or wire to motor Replace fuse Reset circuit breaker Contact power company Reset overload Contact power company Repair bad connection Ascertain cause and correct problem Repair/replace starter Repair/replace motor Replace/repair monitor Repair/replace wire to motor

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The next installment of this series, the fifth, will be devoted to troubleshooting your systems. Edward Butts, PE, DEE, is President and Chief Engineer of Stettler Supply Company in Salem, OR, a 55-year old company specializing in design/build construction of water and wastewater systems. He has over 30 years of experience in the application, design, installation, and service of all types of pumps and pump systems. He is a Registered Professional Engineer in Civil, Environmental, and Control Systems Engineering in addition to possessing certifications as a pump installer, irrigation designer, plant engineer, and in environmental and forensic engineering. A graduate of the Cornell School of Pump and Hydraulics, he has served on the Hydraulic Institute Canvass Committee that developed the current standards for centrifugal and vertical turbine pumps. An author of over 50 technical papers and articles, he also serves as a Contributing Editor for Pumps & Systems magazine. Contact him directly at epbpe@juno.com By the way, Ed Butts will be a featured speaker, presenting on the topic of troubleshooting, at Pumps & Systems Expo 2004, in Baton Rouge, LA, during the week of November 8. For more information, call (205) 212-9402, or look for complete conference details in future issues of Pumps & Systems or on www.pump-zone.com.)

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