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Pump problems and repair
Pump problems and repair
Three type of problem
Many times when the pumps are opened
with low or no delivery conditions but on
opening no fault is observed.
In such conditions, there are three type of
problem which mostly encountered are:
1. Design error
2. Poor process operation
3. Poor maintenance practices
Principles of Installation of Pumps and
Drivers’
The correct installation of pumps and drivers is
an often overlooked requirement. Incorrect
installation indirectly costs millions of dollars a
year in increased maintenance and lost
production due to premature equipment
failure
A good pre‐installation program should
accomplish the following:
¾ Inspect all equipment upon arrival for
any shipping damage.
¾ Ensure ggood liftingg practices
p
¾ All nozzles and openings should be kept
covered or plugged until piping is
attached
¾ Fill all oil‐lubricated bearings with the
proper lube oil as soon as possible.
¾ Coat all exposed machined surfaces
¾ Foundation And Anchor Bolts
¾ Baseplate and Soleplate Preparation
¾ Epoxy Grout
¾ Cement‐Based Grout
¾ Machinery Alignment
¾ Pre Operational Checks
¾ Pump Preparation for Start‐up
¾ Shutting Down the Pump
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Operational check
Severe operating conditions in most refineries
Many mechanical seal failures have been
and chemical plants subject process pumps to
the result of wear or deterioration of pump
high temperatures, abrasion, corrosion and
bearings or internal pump components.
premature bearing and mechanical seal
failures
The investigation should involve a thorough
Damage to the pump can occur not only inside
study of pump hydraulics to determine if
the mechanical surfaces, but on the outside as
the pump is performing per design
well.
Accurate suction and discharge pressure
Surrounding atmospheric conditions can also
readings need to be taken.
shorten the life of any pump, especially in
corrosive environments.

The pump should also be checked for excessive vibration,

vibration shaft deflection,
deflection
noisy bearings, and excessive temperature
If the pump bearings have been subjected to severe vibration, the pump will
have to be removed to the shop for repairs, and if the mechanical seal is
leaking it will also need replacing

Pump Preventive Maintenance

• Daily ‐Check pump for noisy bearing & cavitations noise.
• Daily ‐Check gearing oil for water, discoloration & contamination.
• Daily ‐Feel all bearings for temperature.
• Daily ‐Inspect bearings & oil rings through filling orb. Wipe bearing
covers clean.
• Daily ‐Check for oil leaks at gaskets, plugs ,& fitting
• Daily ‐Self flushed pumps‐hand check flush line temperature to
determine flow through line.
• Daily ‐Determine if mechanical seal condition is normal.
• D il ‐Check
Daily Ch k any water t cooling
li for
f effective
ff ti operation.
ti Hand
H d test
t t
temperature differential across coolers, jackets & exchangers.
Disassemble & clean out as required.
• Daly ‐Check for operation of heat tracing
• Daily ‐Check for leaks at pressure casing & gaskets.

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Monthly
• Monthly ‐‐Ascertain that oil level is correct distance from shaft
center line. Adjust oiler as required.
• Monthly
M hl ‐Add Add oilil if required.
i d
• Monthly ‐Clean oiler bulbs & level windows as required.
• Do seasonal oil change out if required by Lube Guide.
• External flushed‐pumps‐determine if flow indicator & needle valve
adjustment is OK.
• Fall ‐‐Inspect for damaged or missing insulation
• Monthly ‐Clean out debris from bearing brackets. Drain hole must
be open
• Determine if .steam leakage at packing & valves is normal.
• Determine if steam traps are operating properly‐no continues blow
no water in casing or drain lines.

Half yearly
• 1/2 Year ‐Machines
not running
running‐standby
standby
service:
• 1/2 Year ‐Apply light
coat of Rust Ban to
exposed machined
surfaces to prevent
rust & corrosion
Annually
‐Thoroughly inspect disc coupling
for signs of wear & cracks In
laminations. tighten bolts.
p g
‐Dial indicator check coupling
alignment in coupled condition. Use
special coupling indicator clamps
where possible. Ensure that thermal
growth allowance is correct.
‐With indicator clamped to coupling,
depress & lift on each coupling and
note dial indicator change.
Determine if deflection is normal for
this machine.
‐Dial indicator check axial float of
pump & driver shafts in similar
manner 6

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Pump Repair
Typical failure causes are: Steps before the removal
• Leaking shaft seal of the pump
• Reduced pumping 1.Check with operator
p as to
rate perceived failure cause.
2. Run the pump where possible and
• Pump binding or
attempt to diagnose failure by:
stuck
Looking
• Failed bearings Listening
• Excessive vibration Feeling
• Leaking casing Smelling
Measuring bearing temperatures
Measuring power
Analyzing vibration
Measuring flow and pressure
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Field Checks during Removal

1. Check coupling for wear or lack of
If failed bearings are suspected in pump
grease. or motor
2. Visually check oil and oil level.
3. Remove pump, check body
8. Check radial clearance and end float
gaskets, seats.
in motor.
4. Visually check impeller and casing 9. Run motor and check for abnormal
wear rings. Also check impeller vs. noise, vibration.
casing wear ring clearance, check 10. If motor is bad, remove and repair.
impeller, volutes and balance
holes for plugging.
5. Check flush lines and qquench lines
for internal corrosion or plugging.
6. Visually check condition of
gauges, etc.
7. Remove pump to shop for repair.

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Diagnosing Pump and Seal Problems

In the Shop
1. Visually check impeller and
nut for wear, erosion, 8. Remove stuffing box body from
corrosion and pump frame
frame.
2. Remove seal flange nuts and 9. Check stuffing box gasket face,
check seal tension. bore, and pilots. other
3. Record impeller position in deterioration.
relation to pump frame. 10. Remove and inspect all shaft keys.
4. Remove impeller nut and 11. Remove sleeve, seal, sleeve
impeller.
gasket and sleeve flange. If
5. p wear rings
Inspect g inboard, if
any. necessary determine the cause of
necessary,
6. Check and record throttle seal failure and inspect condition
bushing clearance. of parts.
7. Check body gasket faces 12. Check pump bearings for
roughness. Record shaft end float,
check shaft for wear, erosion,
corrosion and straightness. 9

13. Excessive shaft axial end play:

Excessive shaft movement can result in pitting, fretting, or wear at points of contact
in shaft packing and mechanical seal areas. It can cause over or under‐loading on
springs resulting in high wear rates and leakage. It can also cause excessive strain and
wear on pump bearings

It can also cause excessive strain and wear

on pump bearings. Defective bearings in
turn can cause excessive shaft end To
check for this condition a dial indicator
should be installed so that its stem bears
against the shoulder on the shaft (see
Figure for checking for end play)

A soft hammer should be used to lightly

tap the shaft on one end and then the
other. Total indicated end play should be
between .001 in. and .004 in. for proper
assembly
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14. Bent shaft

• When a pump shaft is bent or out
of alignment, bearing life, seal life,
and performance are impaired.
Bent shafts also cause vibration
and coupling failures. To check for
this condition,
condition install a dial
indicator to the pump housing and
adjust so that the stem bears on
shaft outside diameter. Rotate
shaft and check for run‐out. If run‐
out is greater than .002 in. the
shaft should be straightened
(Figure 1‐7).
Figure. Checking for bent shaft
• The shaft should be checked in
several different locations

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15. Check all pilot fits for concentricity. Also

check for excessive shaft radial movement:
• Excessive radial shaft movement
allows shaft and seal to whip,
d fl t and
deflect, d vibrate.
ib t Thi
This ttype off
movement is caused by improper
bearing fit in pump bearing
housings or possibly an
undersized shaft. If the bearing
• bore is oversized, determine if it
was caused by corrosion, wear or
improper machining. To check for
this condition, a dial indicator
should be placed on the shaft OD
as close to the bearings as
possible. The shaft should be
lifted, or light pressure applied to
shaft. If the total movement
exceeds .003
003 in
in. maximum
maximum,
bearings and bearing fits should
be checked and necessary repairs
made

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16. Stuffing box squareness

• If the face of the pump stuffing box is
not perpendicular to the shaft axis, the
mechanical
h i l seall gland
l d will
ill tilt when
h
installed. This may cause the seal to
wobble and could lead to seal failure.

To check for this condition, clamp a dial

indicator to the shaft with the stem against the
face of the stuffing box, after the cover has
been bolted in place. Total indicator
measurement should not exceed .002 002 in.
in Figure Checking for stuffing box
squareness
If face measurement should exceed this tolerance, the cover should be placed in a
lathe and machined square. Stuffing box faces should always be checked for
pitting, nicks, burrs, and possible erosion before installing the seal (see above
Figure ).

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17. Check for bore concentricity:

• The concentricity of a
stuffing box bore and shaft
can be difficult to measure
because of rust or
corrosion due to leaking
gaskets.
• Stuffing box bore
concentricity
• It can be checked using a
dial indicator. The stuffing
box bore should be
concentric to the shaft,
with 0.1 mm
Checking for bore concentricity.

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18. If bearings are found to be rough

or the end float is excessive
• Remove pump shaft and
bearingg from housing.g
• Remove bearings from shaft.
• Check shaft fits, coupling,
bearings.
• Check shaft straightness and
polish lightly.
• Clean
Cl and d check
h kb bearing
i fits
fit
in housing.
• Repair or replace all faulty
and worn parts prior to
reassembly.
Smaller bearings can be cleaned in a wash tank
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Detailed Inspection Procedures

1. Have a good understanding
what clearances and fits
should be met.
2. Record all data and
measurements on suitable
inspection forms.
Record all unusual deterioration
found while dismantling the
pump.
pump
3. Use new gaskets and O‐rings
when reassembling the pump.
4. Keep the work place clean

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Inspection of Parts
Shafts
1 Check for straightness:
1.
Runout is not to exceed
.002 in. Bearing
2. Inspect threads, keyways,
and shoulders on shaft.
Repair if dam seats must
be in good condition.
aged
aged.
3. Measure and record all
shaft fits. Undersized or
damaged fits should be
repaired
Inspection of Parts ( cont.)
Bearing Housing and Bearings
1. Observe good anti‐friction bearing mounting
procedures
2. Ball bearings: Replace if worn, loose, or
rough and noisy when rotated.
– If dirty, clean with solvent, dry and
coat with a good lubricant.
– New bearings should not be
unwrapped until ready for use.
– Whenever in doubt about the
condition of a bearing, scrap it. But if
the bearingg is still relativelyy new,, and
feels and looks good, don’t discard it.
3. Sleeve bearings: Check surfaces of bearing
and shaft for imperfection, babbitt build‐
up, and hot spots. Small imperfections do
not harm the bearing. A typical diametral
clearance is .0015 in. per in. of shaft.
Clearances should never exceed .003 in.
per in. of shaft diameter on typical pumps.
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Case End Wall and Cover
1. Measure and record all fits
1
between pump casing and mating
parts.
2. Remove all plugs and fittings to
inspect threads. Reinstall all plugs
and fittings
3 Inspect and indicate mounting
3.
pads to ensure they are flat and
parallel with pump centerline.
Machine, if out of alignment
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Impellers
Replace if excessively worn or corroded.
The impeller should have been statically
and dynamically balanced at the factory
factory,
and static and dynamic balance must be
maintained for proper operation of your
equipment.
2. Inspect and measure impeller bore and if
worn or deteriorated, machine true.
Recondition the shaft to fit revised impeller
bore size.
3. Measure outside diameter of impeller
p
wear rings and record size.
Refer to Table for diametric clearances
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Impeller Nuts: When installing impeller nuts, DO NOT use an impact wrench. Use of
impact wrenches has proven to damage the impeller washers, impellers, and impeller
shafts. Proper tightening procedure is to bring it snug tight, and then tighten it to the
next available cotter pin hole in shaft and notch in the castle nut. Then install stainless
steel cotter pin.

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Lock Washer/Lock Nut: Secure shaft so that it

doesn’t rotate when tightening lock nut.
Line up tab on lock washer with keyway slot in
shaft and slide washer onto shaft. Screw
lock nut onto shaft until snug, then turn until a
tab and slot line up. Using a punch, tap
tab from
o lock
oc washer
as e into
to sslot
ot o
on lock
oc nut.
ut

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Damaged cut wat Casing with repair rings in place Casing bottom half and element.

Cutwater repair partially finished Damaged cut water Complete Assembly

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GENERAL BEARING HANDLING AND INSPECTION
Induction heater
Pressing on bearings
Smaller bearings may be pressed onto the
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Heating bearings
In applications that require a tight fit of the
inner ring on the shaft, it can be easier to
install the bearing if it is first heated to expand
slightly.
g y For applications
pp that require
q a tight
g fit
of the outer ring in a housing, it may also be
possible to heat the housing to expand it,
allowing the bearing to install more easily.
Temperature guidelines for heating or cooling
rolling element bearings for installation
These maximum and minimum temperatures,
as well as maximum time‐at‐temperature
p
limits, have been established to prevent
metallurgical transformation of steel
components, and potential, detrimental
physical changes in seals or non‐metallic
components.
Cooling (Freezing) another way for installing or
removing the bearing
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BASIC ASSEMBLING TECHNIQUES
• Work with clean tools in clean surroundings
during assembly.
• Clean parts thoroughly and keep free from
nicks and abrasions.
• Keep loose parts marked otherwise
identified to avoid error in assembly.
g Keep
• Bearings: p bearings
g in original
g containers
until ready to install.
• Bearings/Press fits: Clean and oil bearing
seats and other parts having press fits to
prevent galling.
• Bearings: When pressing a bearing onto a
shaft, the bearing must be started
perpendicular (square) to the shaft.
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Loctite/thread locker: When applying

Loctite/thread lockers, only use one small drop
per hole, unless explicitly told differently by
engineering, a WI, or assembly/repair
instruction or assembly supervisor.
• Loctite/thread locker: When applying
Loctite/thread lockers to lock fasteners going
into captive holes (a hole that is only open on
one end), apply the thread locker to the
threads of the hole.
O‐rings/Quad rings: When installing o‐rings and quad rings LIGHTLY lube with oil or
silicon grease (Dow Corning 111). Be careful not to apply too thick of a film of lubricant
when using the silicone grease because over application of the grease can cause the oring/
quad ring to bridge and leak

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Inspection
After cleaning the bearing, housing and shaft,
and ensuring that
the seats and backing are in good condition,
evaluate the bearing
to determine if it can be reinstalled or should
be replaced.
Bearings should be replaced if they show:
¾ Fatigue spalling
¾ Heat discoloration
¾ Rust
¾ Damaged cage
¾ Noticeable wear Bearings must be inspected before
returning to service
Seals
If the unit uses seals or closures,, theyy should
also be inspected
for wear or damage. Worn seals can allow dirt
or water to enter
the bearing.

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Bearing fit Inner ring assemblies should be pressed on the

shaft using the proper drivers

Bearings should be checked

with a feeler gage to ensure
proper fit

Outer rings can be pressed into the housing

with a simple driver TAPERED ROLLER
BEARINGS INDUSTRIAL

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