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Gear Pumps Failure Analysis
Gear Pumps Failure Analysis
Failure Analysis
Mounting Roller
Flange Bearings
Drive
Spline
Drive Gear
Idler Gear
Inlet Port
Out Board
Bearing
Pumping Sections
3
Gear Pump Cutaway
OUT
IN
Pressure Balanced Thrust Plates
4
Thrust Plate View
OUTPUT
Force Force
OIL FLOW
5
Contamination
6
Particle Sizes
SUBSTANCE SIZE IN MICRONS SIZE IN INCHES
Grain of salt 100 .0039
Human Hair 70 .0027
Lower limit of visibility 40 .00158
White blood cell 25 .001
Talcum powder 10 .00039
Red blood cell 8 .0003
Bacteria 2 .000078
7
ISO Codes
8
Contamination
Causes
9
Contamination
Effects Reduced
pump
Reduced Life efficiency
Bearing /
bushing
failure
Failed
pump
Accelerated
wear
Internal
leaks
• bearings, thrust plates, and
housing
Heat
10
Foreign Object Damage
11
Foreign Object Damage
12
Foreign Object Damage
13
Large Particle Contamination
Motion
Gear
Large particle contaminant
Thrust plate
14
Scored Thrust Plate
15
Scored Gear Housing
16
Scored Root Area of Gear
17
Scored Thrust Plate
18
Scored Thrust Plate
19
Fine Particle Contamination
Thrust plate
20
Thrust Plate View
OUTPUT
Force Force
OIL FLOW
21
Fine Particle Contamination
22
Fine Particle Contamination
23
Fine Particle Contamination
24
Scored Thrust Plate
25
Scored Thrust Plate
26
Scored Thrust Plate
27
Leakage in Hydraulic Components
3
Q =flow
(leakage)
0
0 •Length of Seal 1 +
•Clearance 2
•Pressure 3
28
Driveshaft for Motor
29
Cavitation and Aeration
Thrust plate
30
Cavitation and Aeration
Thrust plate
31
Cavitation and Aeration
Thrust plate
32
Cavitation Damage
Cause
Inlet Condition - Restriction
33
Cavitation Damage
Effect
Accelerated
Reduced Erratic
wear thrust Internal
Noise Heat pump actuator Failed pump
plates / leaks
efficiency performance
housing
34
Aeration Damage
Cause – Air enters oil
Foam
Vortexing of oil
Loose inlet Worn pump Worn cylinder suspended in oil
Low oil level above strainer -
fittings shaft seal rod seal due to sloshing
whirlpool
in the reservoir
35
Aeration Damage
Noise Effect
Heat
Accelerate
Failed
pump
d wear
thrust
plates /
housing
Internal
leaks
Erratic
actuator
performance
Reduced
pump
efficiency
36
Cavitated Thrust Plate
37
Cavitated Thrust Plate
38
Cavitated Gear Housing
39
Cavitated Thrust Plate
OUTLET
INLET
40
Cavitated Thrust Plate
41
Cavitated Motor Thrust Plate
42
Cavitated Motor Thrust Plate
43
Pressure Damage
Repeated
Heavy
Loading
44
Pressure Damage
Cause
Improper size
elbow or fitting
downstream
Improper relief Relief valve Slow acting Absence of a
of the valve
valve setting malfunctioned relief valve relief valve
affecting the
relief valve
performance
45
Pressure Damage
Effects
Reduced Life
Thrust
Excessive Bearing / plates Broken drive
Accelerated Cracked Reduced Internal
housing cut- bushing coined, / connecting
wear housings efficiency leakage
out failure warped or shaft
cracked
46
Bearing Failure
47
Bearing Failure
48
Bearing Failure
49
Pressure Damaged Gear Housing
50
Pressure Damaged Gear Housing
51
Heavily Coined Thrust Plate
COINING
55
Pressure Damaged Drive Shaft
56
Pressure Damaged Drive Shaft
57
Pressure Damaged Connecting Shaft
58
Pressure Damaged Drive Shaft
59
Rotational Bending Fatigue Failure
60
Heat
61
Heat Damage
Causes
Cavitation / Undersized
Poor reservoir
Low oil level aeration / Contamination Inlet restriction Relief valve Incorrect fluid fittings, hoses,
design
water components
62
Heat Damage
Breakdown
of oil
Seizure
Loss of
lubricity
Accelerated
wear
Reduced
efficiency
Leakage
Varnish /
sludge
Internal
seal
destruction
63
Heat Damage
Lead Motion
Motion
Gear
Gear
Thrust plate
64
Heat Damage
Lead Motion
Motion
Gear
Gear
Thrust plate
65
Heat Damage
Motion
Gear
Thrust plate
66
Heat Damage
Motion
Gear
Thrust plate
67
Heat Damaged Thrust Plate
68
Heat Damaged Thrust Plate
69
Heat Damaged Thrust Plate
70
Heat Damaged Thrust Plate
71
Heat Damaged Gear
72
Heat Damaged Thrust Plate
73
Rifled Gear and Thrust Plate
74
Rifled Gear and Thrust Plate
75
Rifled Gear and Thrust Plate
76
Fretting Damage
Coupling
Small amplitude
vibration
Drive spline
Contaminant
suspended
in grease
77
Fretted Driveshaft
78
Fretted Driveshaft
79
Rebuild Errors
80
Potential Assembly Errors
Causes
81
Potential Assembly Errors
Effects
Reduced
Internal and efficiency
External
Damaged leak
Components
Extruded
section
seal
Heat
82
Broken Drive Shaft
83
Pinched and Fretted Seals
85
The System
Includes
Actuator
• motor Hydraulic
• cylinder Oil
Directional
Hoses/tubing
Valve
Hydraulic
Fittings
Pump
Filters
86
Substitutions
87
Hydraulic Oil
Follow OEM
recommendations as
closely as possible
Unnecessary
additives may
be detrimental
88
When Replacing Hoses, Lines &
Fittings
Use products with the same:
Size Length
Material
Pressure
Rating
89
Hydraulic components
Testing
Pressure
Design
rating
Safety
Material
factor
90
Substitutions Can Deal You a Losing
Hand
91
Pump / Motor Replacement
92
Recommended Start-Up For New or
Rebuilt Pumps and Motors
Insure system cleanliness
Reset the main relief valve while the unit is operating at maximum
operating speed
93
Recommended Start-Up for New or
Rebuilt Pumps / Motors
94