Tech Seminar

Pump Troubleshooting & Maintenance

Tech Seminar
Pump Troubleshooting & Maintenance
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Session will
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Pump Troubleshooting & Maintenance 2 Minutes

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Welcome
A Few Housekeeping Items
Course Workbook
Additional materials:
• Supplemental Material Packet
• At Your Service Bulletins
Pump Troubleshooting and
Maintenance Seminar
P H O TO O P P O R T U N I T Y – G R O U P P H OTO
 Table of Contents
Introduction 4
Pump Basics 8
Pump Safety 28
Tool of the Trade 40
Pump Forensics (Troubleshooting) 44
Troubleshooting Checklist & Guide 52
Noisy Operation 67
Reference 86

Pump Pump Tools of Pump Checklist Noisy Reference

Basics Safety the Trade Forensics & Guide Operation Section
Text Ref: Pg. 3
 Introduction
More pumps are manufactured than any other piece of
machinery with possibly the exception of electric motors
Several applications and uses including:
• Transportation - Automobiles, ships, airplanes, or trains
• Appliances - Washing Machines, dishwashers, or air conditioners
• Commercial Buildings – Boiler feed service, hot water service, water
service, & sanitation service
• Service Stations, Treatment plants, Oil Fields, Farming…

Text Ref: Pg. 4

 Introduction (cont.)
If not moved by gravity, pumps are needed to move any liquid
Dating back to the time of the early Egyptians & Pharaohs – Pumps
were used to raise water from the Nile River for irrigation purposes

Archimedes
Screw Shaduf

Text Ref: Pg. 4

 Introduction (cont.)
What is a pump?
• A device that adds energy to a liquid in order to move it from
one point to another
There are several types and styles of pump designs
• Our focus will be on a variety of G-R’s more popular products
• Self-priming, priming-assisted, submersibles, & positive
displacement

Text Ref: Pg. 5

 Introduction (cont.)
Basic hydraulic terms:
• Gallons per Minute (GPM)
• Static
• Dynamic
• Friction Head
• Atmospheric Pressure
• Performance Curve (Chart)

Pump Pump Tools of Pump Checklist Noisy Reference

Basics Safety the Trade Forensics & Guide Operation Section
Text Ref: Pg. 5
Pump Basics

Text Ref: Pg. 6

Pump Basics (cont.)

Text Ref: Pg. 7

 Pump Basics (cont.)
Centrifugal Force ??
• Outward force placed on rapidly spinning (rotating) objects
• Fc=mv²/r
Examples of Centrifugal Force
• Sports car on a circular race course
• Spinning a bucket of water tied to a rope
• Tire on a wet roadway

Text Ref: Pg. 8

 Pump Basics (cont.)

Centrifugal pumps operate on a

similar principle
• Impeller with vanes guide and
increase the velocity of the
liquid
• Casing (volute) controls the
path of the liquid as it leaves the
impeller

Text Ref: Pg. 8

 Pump Basics (cont.)
Types of Pumps Discussed
• Standard (Straight) Centrifugal
• Self-Priming Centrifugal (Wet Primer)
• Priming-Assisted (Dry Prime)
• Submersible
• Positive Displacement
• Diaphragm
• Internal Rotary Gear

Text Ref: Pgs. 8-12

Pump Basics (cont.)

Standard Centrifugal Pumps

• Most common of centrifugal pumps
• Typically driven by electric motors or engines
• Used for a variety of water like liquids:
• Water
• Sewage
• Petroleum
• Petrochemical

Text Ref: Pg. 8

 Pump Basics (cont.)
Self-Priming Centrifugal Pumps
• Capable of “self-priming” with dry (empty) suction line
• Pump needs to have liquid in casing to prime
• Some models capable of a 25 ft. (7.6 m) lift
• Some designs capable of “re-priming” (half casing)
• Many applications
• Water like liquids
• Excellent trash (solids) handling
• Industrial, Municipal, Construction

Hyperlink
• Agriculture and Petrochemical
to Priming
Video
Text Ref: Pg. 9
 Pump Basics (cont.)
Priming-Assisted Pumps
• Designed to handle large volumes of air
• Dry-prime capable (empty pump casing)
• Requires an external priming device (venturi,
diaphragm, or vacuum pump)
• Large seal oil chamber for extended dry run capability
• Suitable for long suction lines, snoring or slurping
applications
• Many applications:
• Water like liquids
• Excellent trash (solids) handling
Hyperlink
to Priming • Industrial, Municipal, Construction
Video
• Mining & Agriculture Text Ref: Pg. 10
Pump Basics (cont.)
Submersible Pumps
• Operates on same principle as all centrifugal pumps
• Designed with integral watertight motor assembly
• Entire assembly typically submerged in liquid
• Depending on environment may require explosion-
proof design (UL, FM, CSA, or MSHA)
• Many applications:
• Water like liquids
• Excellent trash (solids) handling
• Industrial, Municipal, Construction
• And Agriculture

Text Ref: Pgs. 10-11

Pump Basics (cont.)
Diaphragm Pumps
• Positive displacement style of pump
• Operates in combination of a reciprocating
diaphragm and two valves on either side of
diaphragm pot chamber
• Work well on viscous or liquids containing large
solid content
• Flow is typically not linear (subject to surging)
• Many applications:
• Excellent trash (solids) handling
• Industrial, Municipal
• Construction & Agriculture Text Ref: Pgs. 11-12
 Pump Basics (cont.)
Internal Rotary Gear Pumps
• Positive displacement style of pump
• Operates in combination of a rotor with internal cut
teeth and a nested idler with external cut teeth
• Work well on thick viscous liquids to 2,000,000 SSU
• Flow remains constant with change in pressure
• Relatively high pressure capability - 300 psi
• Many applications
Hyperlink to
• Industrial, Municipal, & Petrochemical
Operation
Video
Text Ref: Pg. 12
 Pump Basics (cont.)
• Typical Pump installations?

Text Ref: Pg. 13

 Pump Basics (cont.)
How does liquid get in the pump?
• Atmospheric Pressure –
• Pushes liquid into the pump
• Keeps liquid in a liquid state

14.7 psi
Atmospheric 33.96 Ft of Water
Pressure 29.9 In. Hg.
@ sea level 10.3 Meters or
1 Bar

Text Ref: Pg. 13

 Pump Basics (cont.)

How much will a pump produce?

• Centrifugal Pump Elements
• Pump Design – Size of pump, impeller
design & quantity
• Speed (RPM) of impeller
• Impeller size (diameter)
• System pressure (Total dynamic head –
TDH)

Text Ref: Pg. 14

 Pump Basics (cont.)

How much will a pump produce?

• Positive Displacement (Gear) Elements
• Rotor & idler design
• Speed (RPM) of rotor
• Size of rotor and tooth profile depth along with
idler height

Text Ref: Pg. 14

 Pump Basics (cont.)

Reading Pump Performance Curves and Charts

• Manufacturer’s chart plotting the performance characteristics
• Use to select and troubleshoot pump performance
• Use in conjunction with speed, pressure and electrical data
• Often contain additional useful information
• Every pump model has its own exclusive curve

Text Ref: Pg. 15

Pump Basics (cont.)

Text Ref: Pgs. 16-17

Pump Basics (cont.)

Text Ref: Pgs. 18-19

Pump Basics (cont.)

Text Ref: Pgs. 19-20

Pump Basics (cont.)

Text Ref: Pg. 21

Pump Basics (cont.)

Text Ref: Pgs. 22-23

Pump Basics (cont.)

Text Ref: Pgs. 23-24

Pump Basics (cont.)

Text Ref: Pgs. 24-25

 Pump Basics (cont.)

Pump Pump Tools of Pump Checklist Noisy Reference

Basics Safety the Trade Forensics & Guide Operation Section
Text Ref: Pgs. 26-27
Pump Safety

Text Ref: Pg. 28

 Pump Safety (cont.)

This material is meant to be a “Quick-Reference” guide only!

Use it with an Installation, Operation and Maintenance Manual
• Typically developed to alert personnel of situations that could damage
equipment and/or could be dangerous to personnel
Follow all established safety guidelines and protocols
It is the responsibility of the owner, operator and maintenance
personnel to assure that only safe procedures are followed!

Text Ref: Pg. 29

 Pump Safety (cont.)
Hyperlink to

Potential Pump Hazards Pump Safety

Video

• High Voltage • Confined Space Entry

• Automatic Equipment
• High Pressure
• Physical Heights
• Rotating Equipment
• Open Sumps
• Drowning and Diseases
• Hazardous Gases
• Cool, Damp Environment
• Insects, spiders, bees, snakes, rats, alligators…

Pump Pump Tools of Pump Checklist Noisy Reference

Basics Safety the Trade Forensics & Guide Operation Section
Text Ref: Pg. 29
 Pump Safety (cont.)

Potential Pump Hazards

• High Voltage • Confined Space Entry
• Automatic Equipment • Open Sumps
• High Pressure • Drowning and Diseases
• Physical Heights • Hazardous Gases
• Rotating Equipment • Cool, Damp Environment
• Insects, spiders, bees, snakes, rats, alligators…

Text Ref: Pg. 29

 Pump Safety (cont.)
General Pump Safety
• Do NOT operate pumps without all guards and shields in place
• Pump ONLY liquids for which pump was designed
• Do NOT pump flammable or corrosive liquids unless pump and
driver is design for such
• NEVER operate pumps in explosive or volatile atmospheres unless
designed for environment
• CAUTIOUSLY approach any pump that has been in operation
• Do NOT operate a pump against a closed suction or discharge
• Unless designed, NEVER operate centrifugal pumps with no liquid in
the pump casing
Text Ref: Pg. 30
 Pump Safety (cont.)
General Pump Safety (cont.)
• DISCONNECT driver and/or lock-out and tag control panel
before maintenance
• Overheated pumps can cause severe burns and injury
• Approach a hot pump cautiously
• ALWAYS allow pump to cool to room temperature
• Isolate suction and discharge lines
• Lock-out and tag all isolation valves
• SLOWLY and CAUTIOUSLY vent pump at drain
• Do NOT work underground or in limited egressed areas without
following confined space guidelines
Text Ref: Pg. 31
Pump Safety (cont.)
Electric Motor Driven Pumps
• ONLY have qualified personnel install, wire
and operate electric driven pumps
• Make sure all electrical connections are in
accordance with all local and National
Electrical Code requirements
• ALWAYS properly ground electric-driven units
• Check an assure proper rotation on three-
phase electrical power installations
• DISCONNECT driver and lock-out and tag
control panel before maintenance
Text Ref: Pg. 32
Pump Safety (cont.)

Engine-Driven Pumps
• Assure ONLY qualified personnel operate
engine-driven pumps
• Do NOT operate combustible engines
without proper ventilation
• DISCONNECT spark plugs and/or battery
from starter before working on pump
• NEVER refuel a hot or running engine
• Follow the engine manufacturer’s OM
manual instructions
Text Ref: Pg. 33
Pump Safety (cont.)
Electric-Driven Submersible Pumps
• ONLY have qualified personnel install, wire and
operate submersible pumps
• Make sure all electrical connections are in
accordance with local and National Electrical
Code requirements
• Always operate with properly sized and
protected control panel
• NEVER attempt to lift pump by its power cord
or discharge hose (portable pumps)
• Check an assure proper rotation on three-phase
electrical power installations
• DISCONNECT or lock-out and tag control panel
before any maintenance Text Ref: Pg. 34
Pump Safety (cont.)

General Electrical Safety

• Severity of electrical shock depends on:
• Amount of current
• Person’s resistance
• How well-grounded the service tech is
• Path the current takes through a body
• Length of time a body is exposed to current

Text Ref: Pg. 35

Pump Safety (cont.)

General Electrical Safety (Cont.)

• Possible effects of low-voltage contact
(110V):
• 1 mA – No sensation
• 2-8 mA – Slight sensation, not harmful except
possibly to pacemaker wearers
• 15-20 mA – In the “can’t let go” range; likely to
cause painful shock, muscle control loss &
ventricular fibrillation should current flow
across the heart

Text Ref: Pg. 35

Pump Safety (cont.)

General Electrical Safety (Cont.)

• Possible effects of high current exposure:
• Severe burns
• Loss of limb
• Muscular contractions to the point where
the heart is stopped (Requires CPR and/or
defibrillation shock to revive victim)

Text Ref: Pg. 35

Pump Safety (cont.)

General Electrical Safety (Cont.)

• Before maintenance of any electrical device:
• Read all warning tags
• Shut-off main power
• Follow proper lockout and tag protocol
• Adhere to all caution and warning labels
• Good rule in Electrical Safety:
• If you do NOT have a good basic knowledge
of electricity LEAVE IT ALONE!

Text Ref: Pg. 36

Pump Safety (cont.)

General Confined Space Guidelines

• Before entering make sure protocol is
followed
• Confined spaces include - tanks,
vessels, silos, vaults, pipelines, sewers,
tunnels, or pits

Text Ref: Pg. 37

Pump Safety (cont.)
General Confined Space Guidelines (cont.)
• In addition, any open top space 4 ft. or deeper
with at least one of the following:
• Limited means of egress
• Not designed for continuous occupancy
• Less than 19.5% O2
• Flammable, combustible, or explosive
atmosphere
• Toxic atmosphere
• Substances that could potentially trap,
suffocate, or harm – (Water, gas, sand, gravel,
ore, grain, coal, biologicals, radiation or
corrosives)
• Poor ventilation Text Ref: Pg. 37
 Pump Safety (cont.)

Commonly Found Hazardous Gases

• Methane – CH4
• Ammonia – NH3
• Hydrogen Sulfide – H2S
• Carbon Dioxide – CO2
• Carbon Monoxide – CO
• Chlorine Gas – Cl2

Pump Pump Tools of Pump Checklist Noisy Reference

Basics Safety the Trade Forensics & Guide Operation Section
Text Ref: Pg. 38
Tools of The Trade

Text Ref: Pg. 39

 Tools of the Trade (cont.)
Essential Tools for the Job
• Equipment data
• Record-keeping program
• Education on product(s)
• Physical tools
• Gauges
• Amp Probe
• Tachometer
• Voltmeter
• Temperature probe
• Unique or special tools
Text Ref: Pg. 40
 Tools of the Trade (cont.)

What Gauges Can Tell You?

• Where system is allowing the pump
to perform
• If pressure is too high or low
• If there is an obstruction in suction
• Evidence of vortexing or entrained air
• When pump is not running:
• Static pressure
• Suction leak
• Discharge check valve problem

Text Ref: Pg. 40

Tools of the Trade (cont.)

• Connect gauges close to

pump inlets and outlets
• Account for gauge correction
• Adding the values of the two
gauges will provide system
performance

Text Ref: Pg. 42

 Tools of the Trade (cont.)

• Use quality gauges

• Consider using hose
connections to raise
or lower gauge height

Text Ref: Pg. 42

Tools of the Trade (cont.)

• To assure accurate gauge

readings consider a bleed valve
• Vacuum gauges should be
absent of any liquid
• Pressure gauges should be
absent of air

Text Ref: Pg. 43

Tools of the Trade (cont.)

• Gauge corrections may

require addition or
subtraction of value
• Zero gauges (vent) to
assure accuracy
• If permanently mounted,
use isolation valves

Pump Pump Tools of Pump Checklist Noisy Reference

Basics Safety the Trade Forensics & Guide Operation Section
Text Ref: Pg. 43
Pump Forensics
(Troubleshooting)

Text Ref: Pg. 44

 Pump Forensics (cont.)

My Pump Isn’t pumping… Why?

• First reaction – It’s the pump fault!
• Reality is – 85-90% of the time it’s
a system problem
• Pump is simply responding to
changes in the system

Text Ref: Pg. 45

 Pump Forensics (cont.)
Troubleshooting Topics Discussed
• Low Performance
• Reduction in flow, pressure or no flow
• Priming challenges
• Loss of prime, slow to prime, failure to prime
• Air Bound
• Noisy Operation
• Mechanical Causes
• Shaft Failures
• Corrosion and Abrasion Damage
Text Ref: Pg. 45
Pump Forensics (cont.)
Low Performance – Cause #1
• Excessive Clearances
• Over equipment lifespan performance lowers
as internal components wear
• Critical components include; wear rings, wear
plates, impellers, & pump casing cutwater area
• Real cause is excessive clearances
• Solution - Replace worn components
• Some models have adjustable clearances
• Field analysis and shut-off test will assist in
performance validation
Text Ref: Pg. 46
 Pump Forensics (cont.)
Low Performance – Cause #2
• Reverse rotation
• Typical result is lower flows and pressures
• In addition, increased amperage due to increased horsepower
• Cause in new installations, typically due to improper wiring
• Modification of wiring will correct the problem
• Cause in existing installation ,occur from a variety of reasons:
• Modification of electrical panel, motor, or incoming power grid
transformer change out
• Note – Running PD pumps in reverse will reverse the flow
• Suction becomes discharge and discharge becomes suction
Text Ref: Pg. 46
Pump Forensics (cont.)
Low Performance – Cause #3
• Change in Speed (RPM)
• Typical cause - Incorrect speed selection
• Slower speed – Lower flow and less pressure
• Incorrect replacement motor – 3450, 1750, or
850 RPM
• Noted – Increase of RPM typically results in
higher flow rate and pressure

Text Ref: Pg. 46

 Pump Forensics (cont.)

Low Performance
• Additional Common Causes
• Incorrect replacement impeller
• Debris lodged in impeller
• Partially blocked or clogged piping

Text Ref: Pg. 47

 Pump Forensics (cont.)

Priming Challenges – Cause #1

• Excessive Clearances
• Worn components reduce ability
to create a vacuum
• Replace or adjust clearances
• Note – Priming-Assisted pump
priming issues can stem from
worn auxiliary priming system
components

Text Ref: Pg. 47

 Pump Forensics (cont.)

Priming Challenges – Cause #2

• Air Relief System Issues Air Bleed Line

• Air relief line missing

• Incorrect air release valve
• Poor ARV plumbing design

Text Ref: Pg. 47

Pump Forensics (cont.)
Priming Challenges – Cause #3
• Leak on vacuum side
• Often difficult to locate
• Thoroughly review all suction
piping, hose, joints, & pipe plugs
• Could be mechanical seal
• Use gauge and monitor vacuum
reading when pump is not
running

Text Ref: Pg. 48

 Pump Forensics (cont.)

Priming Challenges – Cause #4

• Obstruction in Plumbing or Pump
• Slow to prime or failure to prime
as a result of an obstruction
• Typical cause- Debris in impeller or
a partially block suction line or
suction strainer
• Solution remove, clean and restart

Text Ref: Pg. 48

 Pump Forensics (cont.)

Air Bound (Failure to go Dynamic) – Cause #1

• Too much air in impeller/casing area
• Problem can occur with standard centrifugal,
submersible and certain self-priming pumps
• At start up on new installations typically this is
a result of air left in suction lines
• Manually fill pump and bleed off air

Text Ref: Pg. 48

 Pump Forensics (cont.)
Air Bound (Failure to go Dynamic) – Cause #2
• Failure to overcome static discharge pressure (head)
• Missing air bleed (vent) line
• Often Self-Priming pumps require an air release line
Air Bleed Line
when there is more static head on a system check
valve to push the air out discharge
• Automatic air release valves (ARV) are recommended
to operate more efficiently and/or to reduce potential
nuisance clogging

Text Ref: Pg. 48

 Pump Forensics (cont.)

Air Bound – Cause #3

• Failure on existing installation
• Result of air entering pump inlet
• Typical causes include:
• Insufficient submergence – (vortexing, slurping, snoring)
• Force entrapped air – inverts cascading over pump inlets
• Solutions include raising liquid level and/or redirecting inflows
• Noted – Applications where slurping and snoring cannot be
designed out, a priming-assisted (dry prime) pump may be a
better solution
Text Ref: Pg. 48
 Pump Forensics (cont.)

Noisy Operation (Mechanical Noise)

• Noise can be hydraulic or mechanical
• Will cover Hydraulic Noise in a separate section
• How can you tell the difference?
• Submersible - Remove pump from liquid and run briefly dry
• Centrifugal, self-primer or PD pump - drain pump and run briefly dry
• If noise goes away it’s hydraulic challenges
• If noise remains…

Text Ref: Pg. 49

 Pump Forensics (cont.)
Noisy Operation (Mechanical Noise) – Cause #1
• Debris in the pump causing hydraulic imbalance

Text Ref: Pg. 49

 Pump Forensics (cont.)

Noisy Operation (Mechanical Noise) – Cause #2

• Badly worn or damaged bearings

Text Ref: Pg. 49

 Pump Forensics (cont.)

Noisy Operation (Mechanical Noise) – Cause #3

• Impeller rubbing due to improper clearances
• Debris lodged between
• Wear ring(s)
• Wear plate(s)
• Seal plate
• Suction head
• Diffuser

Text Ref: Pg. 49

 Pump Forensics (cont.)

Noisy Operation (Mechanical Noise) – Cause #4

• Impeller out of balance
• Damaged (Vane broken)
• Severe wear

Text Ref: Pg. 49

 Pump Forensics (cont.)
Noisy Operation (Mechanical Noise) – Cause #5
• Drive Alignment
• Misalignment or worn
• Coupling
• Belt(s) & Sheaves

Text Ref: Pg. 49

 Pump Forensics (cont.)
Noisy Operation (Mechanical Noise) – Cause #6
• Driver Issues
• Motor bearing problems
• If possible uncouple motor from pump and run briefly
• Follow motor manufacture’s procedures

Text Ref: Pg. 49

 Pump Forensics (cont.)

Shaft Failures
• Shaft breakage occurs
typically in one of two
modes
• Radial (fatigue) breaks
• Torsional (twisting) breaks

Text Ref: Pg. 50

Pump Forensics (cont.)

Shaft Failures (cont.)

• Radial (fatigue) breaks
• Impeller end failure due to hydraulic
imbalance (air) or TDH too high
• Drive end failure due to improper
drive arrangement including extreme
side load such as belts over tightened

Text Ref: Pg. 50

Pump Forensics (cont.)
Shaft Failures (cont.)
• Torsional (twisting) breaks
• Failure cause is typically due to
something being injected into the
pump causing it to lock-up
• Extreme start torque due to reverse
rotation with sudden call to start
• Typically a result of discharge check
valve failure or absent of valve
causing flow to pass back through
pump when not running

Text Ref: Pg. 50

 Pump Forensics (cont.)
Chemical and Abrasion Damage
• Abrasive Damage
• Pumps are often exposed to fluids that have small suspended
solids such as sand or grit traveling a high velocities
• Typical failure mode will be a smoothing, rounding or grooving
of areas of the pump in direct contact to the flow
• Solution is an alternate material more suitable
• Austempered Ductile Iron
• High-Chrome
• Polymer based (urethanes)
• Specialized coating (ceramics or epoxy)
• Wear will also transmit to casings, shafts, wear rings, etc.
Text Ref: Pgs. 50-51
Pump Forensics (cont.)
Chemical and Abrasion Damage (cont.)
• Corrosion or Chemical Attack
• Stems from material compatibility
• Under dynamic operation, chemical attack
can soften surface of material - gives
appearance of divots/ melon balling
• In extreme cases, chemical attack erodes
or dissolves the material (all surfaces get
thinner and any holes grow in size)
• Solution - Select a more suitable material
more compatible with liquid

Pump Pump Tools of Pump Checklist Noisy Reference

Basics Safety the Trade Forensics & Guide Operation Section
Text Ref: Pg. 51
 Troubleshooting
Checklists & Guides

Text Ref: Pg. 52

 Checklists & Guides (cont.)

Suggested checklists and troubleshooting guides

• Assist in keeping pump at peak performance
• Decreases operation cost and/or boosting profits
• Reduce fuel consumption
• Reduce unnecessary replacement parts use
• Minimize down time

Text Ref: Pg. 53

 Checklists & Guides (cont.)
Refer to text for further
details
• Use of Checklist
• Preventative Maintenance
Schedules
• Maintaining these records
will assist when problems
arise

Text Ref: Pgs. 53-58

 Checklists & Guides (cont.)

Troubleshooting guides
are useful tools when
you are unfamiliar with
equipment

Pump Pump Tools of Pump Checklist Noisy Reference

Basics Safety the Trade Forensics & Guide Operation Section
Text Ref: Pgs. 60-66
Noisy Operation
(Hydraulic Noise)

Text Ref: Pg. 67

Noisy Operation (cont.)
My pump is noisy… Why?
• Mechanical noise challenges were
discussed earlier
• Nonetheless, hydraulic noise is
another challenge that causes a
variety of pump issues
• Addressing these will not only
improve the site operating
conditions, but will improve the life
of the equipment

Text Ref: Pg. 68

 Noisy Operation (cont.)

Items to discuss in this section

include:
• Vortexing
• Air entrainment
• Cavitation
• Improper inlet spacing
• Surging or water hammer
• Excessive velocity
Text Ref: Pg. 68
Noisy Operation (cont.)

#1 Cause - Vortexing
• One of the more common problems of
hydraulic noise challenges
• Makes a growling noise within pump
• Can produce a visible whirlpool at surface
• Created due to insufficient surface tension
• Caused due to insufficient submergence

Text Ref: Pg. 68

Noisy Operation (cont.)
Vortexing (cont.)
• In extreme cases, a vortex tail will extend
to pump inlet, allowing a direct path for air
to enter pump inlet
• Will cause noise, vibration and potentially
can cause several failure modes:
• Bearings, shaft fatigue, seals, weldments…
• Solution is to increase level in sump and/or
add an increaser to pump inlet
• Larger cross-sectional area - reduces the
inlet velocity, eliminating vortex formation
Text Ref: Pg. 69
 Noisy Operation (cont.)

Vortexing (cont.)
• Minimum submergence
recommendations to resist
formation of vortexes

Text Ref: Pg. 69

Noisy Operation (cont.)

#2 Cause - Air Entrainment

• Standard centrifugal, self-priming or
submersibles are not designed to operate
continuously on mixtures of liquid and gases (air)
• Continued operations in these conditions lead to:
• Shortened life
• Unsatisfactory performance
• Serious mechanical trouble

Text Ref: Pg. 70

Noisy Operation (cont.)

Air Entrainment (cont.)

• 2% free air can result in a 10%
reduction in capacity
• Additional challenges may include:
• Destructive vibration
• Loss in prime
• Accelerated corrosion
• Solution is to install a baffle or extend
the invert below the surface of liquid

Text Ref: Pg. 70

Noisy Operation (cont.)

#3 Cause - Cavitation
• All types of pumps can
suffer from effects of
cavitation
• Standard Centrifugal
• Self-Primer
• Priming-Assisted
• Submersible
• Rotary Gear

Text Ref: Pg. 71

Noisy Operation (cont.)

#3 Cause – Cavitation (cont.)

• What causes cavitation?
• The rapid formation and collapse of
vapor pockets in a flowing liquid in
regions of very low pressure
• When these collapse, pitting or other
damage is caused on metal surfaces in
contact

Text Ref: Pg. 71

Noisy Operation (cont.)
#3 Cause – Cavitation (cont.)
• When does cavitation occur?
• When negative pressure exceeds the
vapor pressure of a liquid
• These vapor bubbles collapse when
sufficient localized pressure is found
• The concentrated force of implosion
can exceed 100,000 psi
• Metal in close proximity will flake or
chip away by this exerted force

Text Ref: Pg. 71

 Noisy Operation (cont.)

#3 Cause – Cavitation (cont.)

• What causes cavitation?
• Suction (Eye) Cavitation
• Occur in eye of an impeller
• Caused by too high of a vacuum
• Discharge (Tip) Cavitation
• Occurs at external tips of an
impeller as it crossed the cutwater
• Caused by too high of discharge
pressure

Text Ref: Pg. 72

 Noisy Operation (cont.)

#3 Cause – Cavitation (cont.)

• Damage caused by discharge cavitation
• Breaks shafts
• Shortens bearing life
• Destroys impellers and volute casings
• Ruins mechanical seals

Text Ref: Pg. 73

 Noisy Operation (cont.)

#3 Cause – Cavitation (cont.)

• Damage caused by suction cavitation
• Shortens bearing life
• Destroys impellers
• Destroys wear plates
• Ruins mechanical seals

Text Ref: Pg. 74

Noisy Operation (cont.)

Text Ref: Pg. 76

 Noisy Operation (cont.)

#4 Cause – Pump and Suction Spacing

• In multiple pump installations spacing
and invert locations should be reviewed
to prevent starvation

Text Ref: Pg. 77

 Noisy Operation (cont.)

#5 Cause – Net Positive Suction Head (NPSH)

• Measure of liquid pressure at the pump end of a suction system
• NPSHa – Difference between atmospheric pressure and (atmospheric
pressure at site, TDSL, vapor pressure, and a safety factor)
• NPSHr – Atmospheric pressure required to move liquid through
suction side of a pump
• When finished for any pump to operate satisfactory the value
must be a positive number.

Text Ref: Pg. 77

 Noisy Operation (cont.)

#5 Cause – NPSH (cont.)

• NPSH Calculation (five deductions)
• Starting with standard atmospheric
pressure
• Altitude elevation at job site
• Vapor pressure of liquid pumped
• Total Dynamic Suction Lift (TDSL)
• Safety Factor (2 ft. water/3 ft. fuel)
• NPSHr @ flow rate

Text Ref: Pg. 80

 Noisy Operation (cont.)

#5 Cause – NPSH (cont.)

• NPSH value must be a positive number
• If negative, NPSH needs to be
increased
• To increase NPSH - Reduce the TDSL
• Lower pump elevation
• Raise liquid level
• Increase suction line diameter

Text Ref: Pg. 82

 Noisy Operation (cont.)

Review example in text

Pump Pump Tools of Pump Checklist Noisy Reference

Basics Safety the Trade Forensics & Guide Operation Section
Text Ref: Pgs. 83-85
Reference

Text Ref: Pg. 86

 Reference (cont.)

Variety of useful materials

• Terminology
• Charts and Tables
• Formulas
• Affinity Laws

Text Ref: Pgs. 87-108

 Reference (cont.)

Variety of useful materials

• Motor Maintenance
• Electrical Insulation
Resistance
• V-Belt Maintenance
• Coupling Alignment

Text Ref: Pgs. 87-108

 Questions
and
Comments
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