DJJ50203
TROUBLESHOOTING AND MAINTENANCE
FOR MECHANICAL COMPONENTS
TOPIC 5 :PUMPS
Prepared by:
Mr. Roslan bin Hashim
Mechanical Engineering Department
Ungku Omar Polytechnic
TOPIC 5: PUMPS
Definition
A Pump is a mechanical device that uses to
transfer different fluids from one location
to another. It is a hydraulic device that lifts
fluids from low to high levels, moves fluids
from low to high-pressure areas. The pump
transfers fluid by converting the fluid’s
mechanical energy into pressure energy
(hydraulic energy).
APPLICATIONS OF PUMPS
Pumps are used throughout society for a variety of
purposes. Early applications includes the use of the
windmill or watermill to pump water.
Today, the pump is used for irrigation, water
supply, gasoline supply, air conditioning systems,
refrigeration (usually called a compressor),
chemical movement, sewage movement, flood
control, marine services, etc.
THE TERMINOLOGY OF PUMPS
Head of a pump
The pump head or discharge head of a water pump is a measure of the power of a
pump. The greater the pump head, the greater the pressure that the pump can
generate. This statistic is measured in meters (or feet) and is calculated by placing a
tube on a pump’s discharge and measuring the maximum height to which it can
pump water.
THE TERMINOLOGY OF PUMPS
Pump Capacity
Pump capacity is a term used to define the flow rate through a pump at its designed
conditions. It describes the volume of liquid that is allowed to travel through the
pump in a given time.
In other words, pump capacity is the rate at which the pump can push fluid through its
system. Based on this definition, pump capacity is expressed as fluid volume per unit
time. Some of the most common units of pump capacity are:
Gallons per minute (gpm)
Liters/minute (L/min)
Cubic meters per hour (m3/h)
THE TERMINOLOGY OF PUMPS
Pump Power
The pump power output (PQ) is the useful power transmitted to the fluid handled by
the pump. The unit is watt (W). If the fluid handled is compressible, the density (ρ) is
conventionally agreed to refer to the condition in the pump suction nozzle or the
arithmetic mean (ρs + ρd)/2.
Pump efficiency
A pump’s efficiency is determined by how effectively the pump can convert one form of
energy to another, based on the difference between the horsepower going into and out
of a pump. Ideally, the horsepower entering the pump would equal the horsepower
exiting the pump; making the pumping system 100% efficient.
It is important that you calculate the pump efficiency to determine if you have a powerful
enough pump for the application. This is generally done prior to the purchase of a pump,
but should be considered when repurposing an already owned pump.
The horsepower is delivered to the pump from a power unit, commonly an electric motor
or engine.
The flow rate and total head need to be calculated to properly determine the pump’s
efficiency.
THE TERMINOLOGY OF PUMPS
NPSH (Net Positive Suction Head)
NPSH (Net Positive Suction Head) is a measure of the pressure experienced by a fluid on
the suction side of a centrifugal pump. It is used to avoid running a pump under
conditions which favour cavitation. NPSH-R (NPSH Required) and NPSH-A (NPSH Available)
are two key NPSH values:
NPSH-R is a pump property quoted by pump manufacturers as the suction pressure at
which cavitation has already reduced pump performance by 3%.
NPSH-A is a system property calculated from the suction-side system configuration. It is
essentially the suction-side pressure less the vapour pressure of the pumped fluid at that
point.
To avoid cavitation, it is necessary to ensure that NPSH-A exceeds NPSH-R by a sufficient
safety margin, for example: NPSH-A ³ NPSH-R + 0.5m. This margin depends on the type of
pump and application and may be quoted as a ratio or a head difference.
THE TERMINOLOGY OF PUMPS
Suction Specific Speed
Suction Specific Speed can be used to determine stable and reliable operations for
pumps with max efficiency without cavitation
Suction Specific Speed - Nss - can be useful when evaluating the operating conditions on
the suction side of pumps. Suction Specific Speed is used to determine what pump
geometry - radial, mixed flow or axial - to select for a stable and reliable operation with
max efficiency without cavitation. Nss can also be used to estimate safe operating ranges.
Characteristic Curve Of A Pump
The characteristic curve of a pump is the interaction of two variables that describe its
performance:
HEAD: the energy by unit of mass that the pump can supply to the fluid
FLOW RATE: the quantity of fluid that goes through a section in a certain period of time
See below for an example.
TYPE OF PUMPS
1.0 POSITIVE DISPLACEMENT PUMP
In these types of pumps, the moving parts (gears,
lobes, plungers, pistons, and rotors) drain fluid from
the pump housing and increase the hydraulic pressure
at the same time. Therefore, a positive displacement
pump does not build up pressure. It just generates fluid
flow. It also doesn’t need manual priming because it
has the self-priming capability.
POSITIVE DISPLACEMENT PUMP TYPES
1.1 RECIPROCATING PUMP
In these types of pumps, the plunger or piston moves downward
and upward. During the suction stroke, the cylinder is filled with
fresh liquid. After filling the cylinder, the inlet valve closes and
discharge stroke starts. During the discharge stroke, the outlet
opens and pressurized liquid discharges from the outlet valve. The
inlet and outlet sides have a check valve for preventing the
backward flow of the liquid.
These types of pumps produce very high pressure.
They use in petrochemical, oil & gas, refinery,
agriculture, and fertilizer industries.
Reciprocating Pump
Advantages and Disadvantages:
Advantages Disadvantages
These pumps are not best for high flow
It creates large pressure than a
applications because it produces a low
centrifugal pump.
flow rate.
It is best for high-pressure requirement It has a high initial cost because it uses a
applications. large number of components.
Because it uses a piston and cylinder for
It can’t deliver a continuous supply of
pressurizing the fluid, therefore, it has an
water or other fluids.
easy operation.
Due to a large number of components, it
It has a self-priming capability.
has a high weight.
The friction between the piston and
It has high efficiency. cylinder is high; therefore, a reciprocating
pump has high wear & tear.
It can also use for air compression. It has a high maintenance cost.
Reciprocating Type
Plunger Type Pumps
The plunger pump has a crosshead operated by a cam handle
device. Its capacity adjusts by varying the pump speed or the stroke.
The stroke changes through the setting of the eccentric pin.
These pumps are utilized for scum, sludge, water jet machining,
sewage, and clarifier concentrator underflow applications. They can
be used for metering and transmission services. They mostly use for
applications such as descaling, oil hydraulics, cleaning, water
irrigation, and transporting paints, chocolates, pastries, etc.
Reciprocating Type
Plunger Type Pumps
Advantages and Disadvantages:
Advantages Disadvantages
It consumes low energy. It delivers a pulsating flow of fluid.
It can handle only those fluids that
Linear performance curve.
have a low flow rate.
These pumps have high maintenance
It has maximum possible efficiency.
costs.
It has a wide range of pressure. These have a large size.
It has the capability to move in
They require high space for
slurries, high viscosity liquids, and
installation.
abrasives with good control.
Reciprocating Type
Diaphragm Pumps
These types of pumps are versatile and can handle a large number
of liquids, including dry food powders, wastewater, additives,
pharmaceuticals, and chemicals.
The advantage of the diaphragm pump is that it does not require
any packings or seals. That is, it uses in applications that do not
require leakage. It designs for pumping sludge, slurries, and liquids
These pumps are used for mining,
industrial and general plants.
Reciprocating Type
Diaphragm Pumps
Advantages and Disadvantages:
Advantages Disadvantages
It can’t supply high pressure during the
It has Self-priming capability.
pumping process.
It is less reliable in the supply of fluid
These pumps have an Easy installation.
during the pumping process.
These are portable. The costs of the spare parts are very high
A diaphragm pump has a long service life. It has a high initial cost.
These can handle fluids with low, In some cases, it takes a large time for
medium, and high viscosities. product delivery.
It doesn’t have seal problems.
Reciprocating Type
Piston Pumps
The piston pump is a simple and powerful device. It has a piston, a chamber,
casing, and a series of control units. The piston of this pump gets power from an
electric motor via a shaft. The piston connects with a shaft, and the rotating part is
also linked with the shaft. As the rotating part turns, it turns the shaft and piston
down to pull it back.
The piston pumps operate by moving the piston upward and downward inside the
chamber. As the piston moves downward, it sucks the fluid while it moves upward
then it pressurizes the fluid. During the piston’s downward movement, the pump
sucks water or other fluid from the outside via an inlet valve. During the upward
movement, the piston increases the pressure of the fluid by reducing its volume.
These types of pumps are utilized for applications such as
withdrawing water from the well or depth of the earth,
reliable pressure, water irrigation, oil & gas, and
distribution systems for transporting paint, pastry,
chocolate, etc.
1.2 ROTARY PUMP
The rotary pump’s rotor rotates or replaces the fluid by orbiting and rotatory movement.
The rotary pump mechanism consists of housing, vane, cams, runner, inlet, and outlet
ports. These components of the rotary pump help to transfer fluids.
ROTARY VANE PUMP
ROTARY PUMP
These are self-priming pumps and offer an almost constant delivery
rate regardless of the pressure. They are manufactured with a
minimum clearance between the stationary and rotating components
for minimizing the leakage from the pressure side to the suction side.
These pumps work at low speeds to sustain these clearances.
As the rotary pump operates at high speed, it causes excessive wear
and erosion, resulting in larger clearance and reduces pump
performance.
These pumps are most frequently utilized to transfer highly viscous
fluids like oils, including handling lubricating oils and fuels, into the
engine room.
ROTARY TYPE
The rotary pump has the following further types:
Rotary Lobe
The rotor of this type of pump does not touch the housing during its working.
The liquid sucks in from the suction valve to the cavity between the chamber
wall and the lobes. Due to the meshing of the rotors, the liquid can’t escape
between them. Therefore, liquid exits from the nozzle along the rotation
direction of the outer lobe. These have various characteristics such as
reliability, hygienic quality, rust resistance, and excellent efficiency.
They are frequently utilized in the applications such as biopharmaceutical
manufacturing, beverage & food processing, and hygienic processing
industries.
ROTARY TYPE
Rotary Lobe
Advantages and Disadvantages:
Advantages Disadvantages
These pumps can handle pastes,
slurries, solids, and many other It requires two seals.
liquids.
It doesn’t have metal-to-metal
It requires timing gears.
contact.
It provides pulsating free flow. Reduces lift with thin liquids.
This pump can run dry for a long
It has a high cost.
time.
ROTARY TYPE
Screw Pumps
It is a singular kind of positive displacement rotary pump in which
the liquid flow through the pump element is axial. It is a non-clog,
large capacity, atmospheric pressure device that can pump various
wastes and solids from the original raw sewage. However, these
have practical limitations about pumping the head. It uses two
screws (driver and driven screws) for pressurizing the fluid. These
screws are meshed with each other.
ROTARY TYPE
Screw Pumps
Advantages and Disadvantages:
Advantages Disadvantages
Ir can operate in dry condition. It has a high cost.
This type of pump can use for It needs a gas blast to transfer
all fluids. light gases.
These pumps have a compact
It has a low pumping speed
design.
Self-priming capability
1.3 LINEAR TYPE PUMP
A linear type pump is a kind of pump where a loose hanging rope/chain is
lowered into a well and drawn up through a long pipe with the bottom
immersed in water.
On the rope/chain, round disks or knots matching the diameter of the pipe
are attached which pull the water to the surface.
Rope/chain pumps are often used in developing areas, the most common
design of which uses PVC pipe and a rope with flexible or rigid valves.
Rope/chain pumps are cheap to build and easy to maintain.
Rope/chain pumps can be powered by low speed gasoline
/diesel engines, electricity, human energy, wind
and solar energy.
2.0 DYNAMIC PUMP
A dynamic pump transfers the fluid by increasing its
pressure as it passes through the impeller and
diffuser.
In this type, the impeller increases the speed of the
fluid and the diffuser converts this speed into
pressure energy. It uses centrifugal force for the
pumping of fluid.
DYNAMIC TYPE
Centrifugal Pump
These are the most widely used pumps around the world. The
Centrifugal pump has a straightforward working principle. These
pump types are efficient, robust, and relatively inexpensive to
manufacture.
HOW DOES CENTRIFUGAL PUMPS WORK
DYNAMIC TYPE
Centrifugal Pump
It improves performance by transferring mechanical
power from the motor to the liquid via the rotating
impeller.
It is a pump that has an impeller and a diffuser for
pressuring the water or other fluids.
The impeller moves the fluid axially and radially with the
help of a centrifugal force.
This impeller is connected with an electric motor via a
shaft. As the shaft starts its rotation, the impeller also
rotates. This impeller has fixed blades that also rotate
with the impeller movement.
DYNAMIC TYPE
Centrifugal Pump
The centrifugal pumps are the best options to transfer fluids from
one place to another for many applications such as pharmaceutical,
chemical, mining, oil, power plants, industrial, municipal (water and
wastewater treatment plants), agriculture, etc.
They are generally designed for relatively low viscosity fluids such as
water and light oil. The liquids having high viscosity, like 10 or 20 wt.
oil at 68-70 degrees Fahrenheit requires additional horsepower to
run the centrifugal pump. Therefore, the positive displacement
pumps are the best options for liquids having a viscosity of more
than 30 wt.
The most common uses of the centrifugal pumps are sewage
drainage, mud, sludge, crude oil pumping, hot water circulation,
pressurization, water supply, and boiler water treatment.
Centrifugal Pump Types
TROUBLESHOOT A PUMP
How can we identify, Pump is pumping or not?
There are many factors through that we can identify that either our Pump
is pumping or not. Some of them are given below in detail.
If you are suspected that there is a problem with the Pump, then lightly
touch it. If it is working normally, it vibrates slightly, and you will feel it
warm. If the Pump is not making a vibration and it’s not warm, then turn it
off and open it with the help of a screwdriver to examine the problem.
If water comes back from the Pump after switching it off, it may be
because the one-way valve is not closed. This is another method to
identify your hydro pump’s problems.
If the water level does not change while the Pump continues to run, the
Pump itself may be defective, the check valve may be stuck in the closed
position, or the drain line may be blocked.
Wear & Tear
Wear & Tear: No matter how robust the pumping system is, it will
eventually suffer from wear tear.
How longstanding are your parts? If you have been using the Pump
for a long time, it may be essential to be exchanged. Check the
system for any obvious signs of wear and tear, such as dirt or debris
that has damaged the inside of the fitting, valve, hose, or Pump.
What Are the Symptoms of Water Pump Failure?
An early identification of the problems is one of the best ways to troubleshoot and
avoid pump failure. Following are some symptoms that indicate pump failure:
1. Leaks: Inspect the pump and pipes to identify the leakage that needs to be fixed.
Because leakage can cause poor performance and loss of pump performance,
frequent leaks come from mechanical seals or stuffing box packings. A mechanical
seal is a wearing component, and it must be replaced regularly.
2. Abnormal noise: The very first sign of a pump problem is abnormal noise. It is
normal when the pump is running in normal condition. However, unusually loud or
screeching noises can specify problems such as bearing wear.
3. Excessive vibration: A properly installed and well-functioning pump doesn’t vibrate
excessively. So, if it is vibrating excessively, you must immediately investigate the
reason for the vibration. In maximum cases, the pump vibrates due to misalignment,
damage, impeller imbalance, or misalignment of the electric motor.
What Are the Symptoms of Water Pump Failure?
4. Corrosion: Discoloration, cracks, or rust of the pump housing or
piping are symptoms of corrosion and should be removed instantly.
Corrosion is a process that leads to pump failure by damaging the
housing and other parts and also contaminates the pumping fluids.
5. Overheating: Very high temperature of the bearings, motor, or
pump always indicates a problem and should not be ignored. When
you detect this problem, then you immediately investigate the
problem and resolve it.
6. Clogging: If the pump cannot handle the solid particles, it passes
through the clogging problem. The presence of solid matter can clog
the impeller or valve.
Types of Pump Maintenance
The pump maintenance has the following types:
1. Routine Maintenance
2. Annual Maintenance
3. Daily Maintenance
1) Routine Maintenance of Pump
Routine maintenance of the pump includes the inspection of the following
parts:
i) Bearing And Lubricant Condition
Daily monitor and record bearing temperature, lubricant levels, and
vibrations. The lubricant must be clear and without foaming. If there are air
bubbles, it means that your bearing lubrication has a high temperature, and
you must add more lubricant to lower the bearing temperature. If the bearing
vibration increases, it may cause due to the failure of your bearing, and you
must replace it immediately.
ii) Shaft Seal Condition
It would be best if you regularly inspected the mechanical seal of your pump.
If there is any sign of leakage, it represents that your shaft seal has been
leaked.
During the shutdown, check the packing of the pump to ensure proper
lubrication. If the stuffing box packing appears dry and compressed, replace it
and add lubricant according to the instruction manual.
1) Routine Maintenance of Pump
iii) Overall Pump Vibration
An impending pump failure can detect via monitoring the entire
pump vibration. Changes in pump alignment, bearing failure,
cavitation, and blockages in the suction and discharge lines can
cause excessive vibration.
iv) Pump Discharge Pressure
The total delivery pressure of the pump can be determined from
the pressure difference on the inlet and outlet pressure gauges.
Make sure the readings are within the pump’s design performance
range. You can search it on the manufacturer’s website or in the
operating instructions.
2) Annual maintenance of Pumps
Record the performance of the pump at least once a year. The benchmarking data should
contain at least motor amp draw, flow rate, head pressure, and vibration for bearings.
Before the maintenance of your pump, you must disconnect the power source.
Following are major parts of the pump that you should inspect compulsory during the
annual maintenance:
Bearing Frame and Foot: Check the bearing frame for scale, rust, roughness, or cracks. The
machined surface should have pitting or erosion.
Bearing Frame: Check all tapped connections for contamination. Clean all the threads as
essential. Eliminate all foreign or loose materials. Check the passages of the lubrication
passages to ensure that they are free from any type of blockage.
2) Annual maintenance of Pumps
Shaft and Sleeve: Check the pitting or grooves. Inspect the shaft runout and
sleeves, change the sleeve and shaft if worn or if the shaft has runout more than
0.002-inch.
Casing: Check the pitting, corrosion, or wear symptoms of the casing. If wear depth
becomes more than 0125-inch, the casing must be replaced immediately. Inspect
the surface of the gasket for distinctive signs.
Impeller: Check the impeller of your pump for damage, corrosion, erosion, or wear.
If the impeller blades have bent shape or show wear more than 0.125-inch, change
your impeller as soon as possible.
Frame Adapter: Check the frame adapter for signs of damage, corrosion, warping,
or cracks. If your frame adaptor has these conditions, then replace it immediately.
Bearing Casing: Check the cracks, corrosion, and wear signs on the casing of your
pump bearings. If the bearing casing has any of these signs, replace it.
3) Daily Maintenance Checklist
• Daily inspect your pump for cavitation and noisy bearing problems.
• Inspect the gaskets and casing for pressure leakage.
• Check the glands and packing for any steam leaks. There should be no
leakage of steam.
• Inspect the working of the heat tracing.
• Inspect the oil of the bearings for discoloration and water.
• Check the temperature of all bearings.
• Inspect the water-cooling system for efficient working. Check the
temperature of the heat exchanger, jacket, and cooler by touching them.
• Check oil ring and bearing via a filling port. Wash covers of the bearings
clean.
• Check the condition of the mechanical seal, and it should be in normal
condition.
• Inspect oil leakage at the gasket.
TROUBLESHOOTING IN CENTRIFUGAL PUMP
APPENDICES
PUMP FORMULA
PUMP FORMULA
PUMP FORMULA
It is a positive displacement
pump
It consists of two meshing
gears with one driving the
other
Fluid flows between the
casing and the gear teeth
Commonly employed for
lube & fuel oil transfer
Must have relief valve
installed in the system
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Screw pumps are positive
displacement pumps
Screws are meshed togeth er
with one driving other
Fluid is displaced through
the recesses between the
screws and the casing
May have single, double or
triple screws
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Vane pumps are positive
displacement pumps
Rotors having slots for
vanes
Centre of rotor is eccentric
with casing
This causes vanes to mov e
in and out as the rotor
rotates
Causes change in volume in
the respective chamber,
similar to reciprocating pu mp
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Often Known as dynamic
pumps or centrifugal pumps
Centrifugal pumps are more
suitable for delivery of large
quantities at low discharge
pressure
Are Non-self priming pumps
Looses suction and unable to
pump once air gets into the
pump system
Must be primed before starting
Used on ship as G.S. pump,
Ballast Pump, S.W. & F.W.
cooling pumps
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Main Components
Impeller
Impeller wear ring
Volute Casing
Shaft
Ball bearing
Gland
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Working Principle
Impeller rotates at high speed
Fluid enters through the ‘eye’ of the
impeller
Fluid is thrown by centrifugal force
from the centre (suction side) radially
outwards to the periphery of impeller
(discharge side)
High velocity fluid enters the
stationary volute casing
Volute casing converts the kinetic
energy of fluid into pressure energy
at the discharge of the pump
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Impeller Wear Ring
Located on the casing at the
impeller suction
Must have clearance to allow
rotation of impeller
If clearance is too small, wear
ring may come in contact with
impeller due to misalignment,
expansion
If clearance is too big, fluid
flows back to suction side
Cause drop in discharge
pressure & pump efficiency
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