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PUMP AND SYSTEM TROUBLESHOOTING HANDBOOK

Troubleshooting Centrifugal Pumps

ffective troubleshooting should be an integral part of any plants equipment reliability and maintenance program. Before you examine the system, however, take time to review maintenance records. The performance history of your pumps will point you in the right direction. Also, pump operators can provide clues to what is happening. Troubleshooting should focus on these areas of investigation: pling hubs, can also be transmitted to other parts of the pump and/or system. Users should note any incorrect positioning of the driver and pump such that the distance between shaft ends (DBSE) exceeds the axial exing limits of the coupling. tion) can create trouble.

1. THE FOUNDATION Poor foundations, grouting and baseplate design often cause problems. 2. DRIVER Vibrations of the driver (motor, steam turbine, gearing) can be transmitted to other components. 3. MECHANICAL POWER TRANSMISSION Excitations from the coupling area, especially because of driver misalignment or eccentrically bored cou-

4. THE DRIVEN PUMP Pump design has a major influence on the hydraulic interaction between the rotor and the casing and consequently the problems encountered. Misconceptions about pump thermal-growth can create problems. 5. SUCTION PIPING AND VALVES Improper design and layout of suction piping and valves can create ow disturbances such as cavitation, intake vortexing or suction recirculation. 6. DISCHARGE PIPING AND VALVES Unfavorable dynamic behavior of piping resulting from loads traceable to dynamic, static or thermal causes (including resonance excita-

7. INSTRUMENTATION FOR CONTROL OF PUMP FLOW Pressure pulsations can result from control system-pump interaction during start-ups, periods of low ow and valve changes. 8. MAINTAINING ALIGNMENT Once the alignment is established, dowels into the baseplate must hold the pump in alignment. Troubleshooting centrifugal pumps begins with observing operating conditions at the site. While a myriad of problems can exist with any pumping system, here are some of the more typical scenarios, possible causes and corrective actions.
Ed Nelson has more than 40 years of experience with industrial pumping systems as a former end-user at a major petrochemical company, and today as a turbomachinery consultant. He is a member of the Pumps and Systems Editorial Advisory Board.

Cavitating-type Problems
A cavitating sound is heard in a pump that does not normally cavitate, and it is not clear whether it is pumping into the system.

POSSIBLE CAUSES
The suction piping layout is poor. There may be too many ells in too many planes or not enough straight run before the suction ange of the pump. Suction piping conguration causes uid to rotate adversely when approaching impeller. Flow rate is high enough above design that NPSHr has increased above NPSHa. Pump is operating at a low-ow, producing suction recirculation in the impeller eye, resulting in a cavitation-like sound The suction screen is clogged. Piping gaskets with undersized IDs have been installeda common problem in installations of small pumps. Pipelines are constricted because of buildup of corrosion materials.

CORRECTIVE ACTION
Redesign piping layout, using fewer ells and laterals for tees, and have ve or more diameters of straight pipe before suction ange. Install enough straight run of suction piping, or install vanes in piping to break up prerotation. Reduce ow rate to the level for which the pump was designed. Install bypass piping back tosuction vessel to increase ow through pump. Note: Bypass ow may have to be as high as 50% of design ow. If screen is present, remove and clean it. Install properly sized gaskets.

Replace deteriorated pipe.

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Capacity-type Problems
Pump does not have enough capacity. No signicant noise is coming from it.

POSSIBLE CAUSES
Pump suction is below atmospheric pressure, causing air leaks into system. Wear ring clearances are excessive (closed impeller design). Impeller-to-case or head clearances are excessive (open impeller design). The discharge block valve is partially closed. Any of the following conditions may have increased friction in the piping to the discharge vessel: 1. Gate has fallen off the discharge valve stem. 2. Check valve spring is broken. 3. Check valve apper pin is worn, and the apper will not swing open. 4. There is collapse of lined pipe. 5. The control valve stroke is improperly set, resulting in too much pressure drop. Suction and/or discharge vessel levels are not correct. Motor is running backward or impeller of double suction pump is mounted backward. Discharge pressure developed in both cases is about one-half design value. Entrained gas from the process is lowering NPSH available. Mechanical seal in suction system under vacuum is leaking air into system, causing pump curve to drop. There is polymer or scale buildup in discharge nozzle areas. Vortex formed at high ow rates or low liquid level. Does the vessel have a vortex breaker? Does incoming ow cause surface to swirl or agitate? A variable speed motor is operating too slowly. Bypassing is occurring between volute channels in a double volute pump casing due to a casting defect or extreme erosion. Axial positions of impeller(s) are not centered with diffuser vanes. Offset of several impellers will cause vibration and lower head output. When the suction system is under-vacuumed, the spare pump has difculty getting into system. Some pump designs incorporate an internal bypass orice port to change head-ow curve. However, high liquid velocities often erode the orice, causing the pump to go farther out on the pump curve. The system head curve increase corrects the ow back up the curve. The volute and cutwater area of casing is severely eroded. A replacement impeller does not have a correct casting pattern, so NPSH required is different.

CORRECTIVE ACTION
Eliminate air leaks with appropriate actions. Overhaul pump. Replace wear rings if clearance is about twice design value for energy and performance reasons. Reposition impeller for correct clearance. Open valve completely. Do the following: 1. Repair or replace gate valve. 2. Repair valve by replacing spring. 3. Overhaul check valve. Restore proper clearance to pin and apper bore. 4. Replace damaged pipe. 5. Adjust control valve stroke as needed. Calibrate level controllers as needed. Check for proper rotation and mounting of impeller. Reverse motor leads if necessary. Reduce entrained gas in liquid by process changes as needed. Change percentage balance of seal faces or increase spring tension. Shut down pump and remove scale or deposits. Reduce ow to design rates. Raise liquid level in suction vessel. Install vortex breaker in suction vessel. Adjust motor speed as needed. Overhaul pump. Repair damaged areas.

Overhaul pump; reposition individual impellers as needed. Reposition rotor by changing thrust collar locator spacer. Install a positive-pressure steam (from running pump) to ll the suction line from the block valve through the check valve. Overhaul pump. Restore orice to correct size.

Overhaul pump. Replace casing or repair by welding. Stress- relieve after welding as needed. Overhaul pump. Replace impeller with correct pattern.

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Motor Overload Problems

POSSIBLE CAUSES Pump is circulating excessive liquid through a breakdown There is polymer buildup between wear surfaces (rings or vanes). There is excessive wear ring (closed impeller) or cover-case clearance (open impeller).
Open impeller has slight rub on casing. This usually occurs in operations from 250400F due to piping strain and differential growth in the pump.

CORRECTIVE ACTION
Overhaul pump, replacing parts back to suction needed. bushing or a diffuser gasket area. Remove buildup to restore clearances. Replace wear rings or adjust axial clearance of open impeller. In severe situations cover or case must be replaced. Increase clearance of impeller to casing.

The minimum ow loop has been inadvertently left open Close minimum ow loop or control valve bypass valve. at normal rates, or bypass around control valve is open. Discharge piping is leaking beneath liquid level in sump-type design. One phase has low amperage due to electrical switch gear problems. Specic gravity is higher than design specication. Inspect piping for leakage. Replace as needed. Check out switch gear and repair as necessary. Change process to adjust specic gravity to design value, or throttle pump to reduce horsepower requirements. (Note: This will not correct the problem with some vertical turbine pumps which have a at horsepower required curve.) Replace motor with a larger size, or reduce ow rate. Remove impeller from pump. Turn to correct diameter.

Pump motor not sized for end-of-curve operation. A replacement impeller was not trimmed to the correct diameter.

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