This document discusses troubleshooting common pump problems such as low flow rate, excessive pressure, loss of prime, noise, vibration, and overheating. It describes potential causes for these problems, both within the pumping system and due to defects in the pump itself. Methods are provided for determining whether the problem lies with the pump or elsewhere in the system, and steps are outlined for diagnosing and addressing specific issues.
This document discusses troubleshooting common pump problems such as low flow rate, excessive pressure, loss of prime, noise, vibration, and overheating. It describes potential causes for these problems, both within the pumping system and due to defects in the pump itself. Methods are provided for determining whether the problem lies with the pump or elsewhere in the system, and steps are outlined for diagnosing and addressing specific issues.
This document discusses troubleshooting common pump problems such as low flow rate, excessive pressure, loss of prime, noise, vibration, and overheating. It describes potential causes for these problems, both within the pumping system and due to defects in the pump itself. Methods are provided for determining whether the problem lies with the pump or elsewhere in the system, and steps are outlined for diagnosing and addressing specific issues.
This document discusses troubleshooting common pump problems such as low flow rate, excessive pressure, loss of prime, noise, vibration, and overheating. It describes potential causes for these problems, both within the pumping system and due to defects in the pump itself. Methods are provided for determining whether the problem lies with the pump or elsewhere in the system, and steps are outlined for diagnosing and addressing specific issues.
Prepared by: NAK 147 11.0 TROUBLESHOOTING PUMP PROBLEMS: Like any other machine, a pump may develop operating problems. These problems, such as low flow rate, excessive discharge pressure, loss of prime, noise, vibration and overheating may be caused either by a problem with the pumping system or by a defect in the pump itself.
It may sometimes happen that a pump is sent to the workshops for repair in the belief that it is not working properly, when the true reason for the problem lies within the pumping system. This wastes a great deal of time and so it is important to be able to determine whether a pumping problem is because of a pump defect or some other cause.
The following sections outline the most common types of pump problems, their probable causes and the methods used to correct them when they occur.
Low or Irregular Discharge Flow Rate: A low or irregular discharge flow rate is a common pumping problem. Typical causes of a pump failing to deliver the proper capacity include the following:
The pump was not properly vented or purged during start-up.
The pump has lost prime.
The pump does not have enough NPSH available to prevent liquid from vaporizing inside the pump.
An increase in downstream pressure has increased the total head developed by the pump, which in turn reduces capacity.
The pump sealing or packing is leaking.
The pump has a mechanical defect, such as worn out wear rings, damaged impeller or is running at a reduced speed.
The quickest way to find the reason for a low or irregular discharge flow is to check the discharge pressure gauge. If the discharge pressure is greater than normal, then the cause of the low flow is most likely to be found on the downstream (discharge) side of the pump. If, however, the discharge pressure is less than normal or if it fluctuates between a low and normal reading, then the cause of the low flow is likely to be found on the upstream (suction) side of the pump.
If the discharge pressure is higher than normal, then the following troubleshooting procedures should be followed:
Pumps Principle , Operation and Maintenance
Prepared by: NAK 148 First of all, verify the high pressure reading by checking the reading at the first pressure gauge that is downstream from the pump. If the pressure reading is normal, then the pump discharge pressure gauge is faulty and should be replaced.
Then check differential pressures across any filters or strainers in the discharge line. If differential pressure is high, then the filter or strainer is blocked and is restricting flow. It should be bypassed until it can be cleaned or replaced.
If the discharge flow from the centrifugal pump is being regulated by a flow control loop (which is installed in the discharge line), the set point on the controller should be checked as well as the position of the valve stem on the control valve. Since flow is below normal, the valve should be fully opened. If it is not, flow can be returned to normal by opening the bypass line around the control valve. Action should be taken to find the cause of the problem with the control valve and have it repaired or replaced.
If the operation of the control loop is normal, check if the receiving vessel (the vessel into which the pump is discharging liquid) has an abnormally high level or pressure condition. If so, action should be taken to restore levels and / or pressures to normal, as this will increase the capacity of the pump by reducing the total head which the pump must develop to deliver the liquid.
If the discharge pressure is lower than normal or if the discharge pressure gauge fluctuates between a low and a normal pressure reading, then the following troubleshooting procedure will probably find the cause of the problem:
Check that the pump is being driven at the correct speed. The flow rate through a centrifugal pump is proportional to the speed of impeller rotation.
Check that the section block valve and any other valves in the suction line are fully opened. A partly closed valve in the suction line will decrease the suction head that is available to the pump by increasing the resistance to flow.
Check the level in the vessel from which the pump is taking liquid. If it is lower than normal, then there may not be enough NPSH available to provide a steady supply of liquid to the pump.
Check the suction temperature of the liquid. If it is higher than normal, then the vapor pressure of the liquid will have also increased. This will result in a decrease in the NPSH which is available to the Pumps Principle , Operation and Maintenance
Prepared by: NAK 149 pump and possibly cause it to fall below the Npsh required for the pump to operate properly.
Finally, check the pump for loss of prime (see the next section).
If none of the actions carried out so far restore the flow rate to its normal value, then the problem is likely to be a mechanical defect in the pump. Some of the most common mechanical defects which cause low or irregular flow rate include the following:
Damage impeller or impellers. This can be verified by touching the pump casing. If it feels hotter than normal or if there is excessive vibration, then the pump should be taken out of service and dismantled for inspection.
Leakage at seals, gaskets, packing or drain plugs.
Excessive wear of impeller and casing wear rings. This allows a greater amount of liquid in the pump casing to re-circulate back to suction and so reduces the pump capacity.
Loss of Prime: Loss of prime is another common problem encountered in pumping operations. It may be caused by several factors which include incomplete purging (venting) when the pump was placed in service, a partially blocked suction line or entrained vapor in the liquid being pumped. Entrainment of vapor in the liquid can be cased by vortexing in the suction vessel (similar to the vortexing that occurs when a bathtub is being drained).
Other possible causes of loss of prime are the leakage of air through joints in the suction line or through the pump packing and also by flashing, which occurs as a result of pumping liquids which have low vapor pressures. A centrifugal pump will stop pumping liquid when its casing becomes filled with air or vapor, so when a pump loses its prime it will cease to operate effectively.
A pump may sometimes be re-primed whilst still in operation by cracking the pump vent valve and allowing vapor to escape. However, this practice can be hazardous, especially if the vent line relieves to the atmosphere and hot liquids are being pumped. If these conditions exist, it is best to shut down the pump before venting any vapor from the casing.
Occasionally vapor pockets will form in high sections of the pump suction line. If the suction line is equipped with vent lines, these should be opened until liquid emerges from them. Simply venting a pump, however, may only give a temporary solution to the problem. If there is not enough NPSH available to the pump then liquid will continue to vaporize as it reaches the suction eye of the impeller and will cause the pump to lose prime once again. Pumps Principle , Operation and Maintenance
Prepared by: NAK 150
To make sure that a pump does not suffer loss of prime it is important to ensure that the level, temperature and pressure conditions in the suction vessel are such that the NPSH available is always significantly greater than the NPSH required by the pump at the desired capacity.
Noise and Vibration: Unusual noise or vibration in a pump is often a sure sign that the pump has developed some sort of problem, such as:
Insufficient NPSH.
Loss of prime.
Excessive pressure and / or level in the receiving vessel.
Partial blockage of the discharge line (as may be caused by a clogged filter or a faulty flow control valve).
Cavitation caused by flashing in the suction line.
The best way to avoid unusual noise and vibrations is simply to make sure that the pump is operating within its design limits. A centrifugal pump for example will tend to vibrate as it operates near either end of its performance curve, away from its design point.
To troubleshoot noise and vibration problems, it is best to seek out any other abnormal conditions such as low or fluctuating discharge pressure, irregular flow rates and the like. In many cases, noise and vibration can be traced to a problem on the suction side of the pump.
Noise and vibration may also be caused by several mechanical defects. These include:
Misalignment between driver shaft and pump shaft.
Worn or damaged bearings.
A worn or loose coupling.
Unbalanced impellers or bent shaft.
Loose or broken internal components.
Loose bolts or pipe supports.
Bearing failure is a major cause of noise and vibration in a centrifugal pump and it can be detected by checking the temperature of the bearing Pumps Principle , Operation and Maintenance
Prepared by: NAK 151 housing. If it is too hot, the pump should be shut down as soon as possible, because overheated bearings will destroy the properties of the lubricant.
This will cause the bearing to overheat still more and will eventually lead to a complete breakdown of the bearings. This, in turn, will trigger a series of chain reactions, which could destroy the rest of the pump.
Seal Failure: One of the most frequent mechanical problems encountered with centrifugal pumps is seal failure. Seals may fail for many different reasons. Some times the heat generated by the rubbing seal faces causes the liquid in the stuffing box to vaporize and form a vapor pocket. When this happens, lubrication is lost and the seal faces run dry and soon wear out.
Seal failure can also occur if the liquid being pumped is hotter than normal. The heat from the liquid is transferred along the pump shaft to the seal, causing it to fail.
Insufficient cooling is a frequent cause of seal failure and may be due either an inadequate flow of seal oil or jacket water. Another cause of seal failure is the presence of hard, gritty solid particles in the pumped liquid, which will score the seal faces and allow them to leak.
When a mechanical seal fails and serious leaks develop, then the only course of action is to shut down the pump and take it out of service for repair. Before fitting a replacement seal, an attempt should be made to find the reason for the seal failure and have it corrected before the pump is placed back in service.
No advice on troubleshooting pump problems can cover every possible cause of a pump to malfunction. The problems discussed in this section are the most likely to be encountered, but they are by no means the only problems that may develop in a centrifugal pump.
A summary of typical pump problems, their causes and possible solutions are listed in (Table 11.1) overleaf.
Pumps Principle , Operation and Maintenance
Prepared by: NAK 152 SYMPTOM & CAUSE SOLUTION
No Liquid Deli vered
Lack of prime.
Suction lift too high.
Discharge head too high.
Impeller plugged.
Fill pump and suction pipe completely with liquid.
If no obstruction at inlet, check for pipe friction losses. If static lift is too high, liquid to be pumped must be raised or pump lowered.
Check pipe friction losses and those valves are fully open.
Dismantle pump and clean impeller.
Insufficient Liquid Deli vered
Air leaks in suction piping.
Air leaks in stuffing box.
Impeller partially plugged.
Defective impeller.
Defective packing or mechanical seal.
Test flanges for leakage. Suction line can be tested by plugging inlet then, putting line under pressure.
Increase seal liquid pressure to above atmospheric.
Dismantle pump and clean impeller.
Inspect impeller and shaft. Replace if damage or if vanes are severely eroded.
Replace packing or mechanical seal.
Insufficient Head Deli vered
Speed of rotation too low.
Air leaks in suction piping.
Mechanical defects.
Obstruction in liquid passages.
Air or gases in liquid. (Look for bubbles).
Check if motor is receiving full voltage.
Test flanges for leakage. Suction line can be tested by plugging inlet then, putting line under pressure.
Inspect impeller and shaft. Replace if damage or if vanes are severely eroded. Replace packing or mechanical seal.
