Lesson 32 Maintenance and Troubleshooting of Centrifugal Pumps

32.1 Introduction
Proper maintenance of a centrifugal pump is very important in order to ensure its trouble-
free operation and long service life. The major causes of deteriorating pump performance
can be summarized as follows (Roscoe Moss Company, 1990):
1. Improper pump installation. For example, leakage from the column pipe and power
losses due to crooked shafts and improper tightening.
2. Changes in system conditions that force the pump to operate inefficiently.
3. Insufficient line-shaft lubrication that causes power loss and premature wear of line-
shaft bearings.
4. Motor overloading and/or overheating that decreases efficiency and breakdown
insulation.
5. Improper pump adjustment causing increased wear and power losses.
6. Cavitation either from entrapped air or from insufficient NPSH.
7. Abrasion from sand and/or silt produced from the well.
8. Wear from rubbing mechanical parts. This can be normal wear expected over time
or abnormal wear caused by deformed or bent parts.
9. Corrosion and incrustation of pump components.
10. Mechanical plugging of the impellers or the pump suction. 
Therefore, a good maintenance program should be implemented. A well-planned
maintenance program maintains high pump efficiency, helps reduce power costs,
improves dependability of the equipment, reduces operating costs and provides extended
service life of the pump (Jensen, 1980). The maintenance operations of a centrifugal
pump can be classified into two groups (Michael and Khepar, 1999): (a)
preventive/routine maintenance, and (b) overhaul or repair operations. They are discussed
in subsequent sections. 
32.2 Preventive Maintenance of Centrifugal Pumps
32.2.1 Daily Maintenance
The operating conditions of pumps vary widely and so do the maintenance requirements.
The performance of the pump should be observed daily. Any abnormality in operation
should be taken care of promptly. This refers mainly to any change in the sound of
running, undesired leakage in the stuffing box, abnormal change in voltage and current,
and temperature. The alignment of the pump unit should be checked occasionally. The
bearings that require lubrication should be given a regular attention.
 
32.2.2 Half-yearly Maintenance
At least once in six months, the shaft packing should be checked by observing leakage
from it. Generally, a leak of 15-30 drops of liquid per minute from the stuffing box is
desirable. If the leakage from the stuffing box is excessive or the packing is worn, the
entire packing in the box will have to be replaced. Replacing just a ring or two will not
result in an effective sealing. While overhauling the stuffing box, all the old packing rings
are removed and the interior of the stuffing box cleaned thoroughly. The shaft and shaft
sleeve surface are properly cleaned before inserting the packing rings. There should not
be any burrs or scores on the working surface. If the shaft sleeve is badly worn or scored,
it is replaced. Similarly, the straightness of the shaft is ensured. 
The radial clearance between the shaft and the stuffing-box bore is measured for
determining the size of a new gland packing to be provided. The packing should not be
inserted in a spiral form; rather it is installed in individual rings. The rings are carefully
cut to the exact size by wrapping the packing around the shaft. The packing rings are
fitted carefully, opening them radially until the ends are as wide apart as half the shaft
diameters, then the ends are turned apart in an axial direction, until the rings slide over
the shaft. Then, each ring is pushed into the stuffing box, inserting the joint first. It should
be ensured that the joints of succeeding packing rings are staggered. This is followed by
assembling the gland ring and tightening the nuts by hand or a spanner. When the pump
is in operation, the nuts are again adjusted to achieve the desired leakage from the
stuffing box.   
The pumps installed on cavity wells require half-yearly checking. Sometimes, pieces of
stones or gravel get into the pump casing owing to overpumping which results in the
decrease of discharge. In such situations, the pump is opened and cleaned.
 
32.3 Preventive Maintenance Techniques
A brief description of the salient techniques for preventive maintenance of pumps is
provided below. 
(1) Standby units: In most major industries failure of an essential item of equipment can
result in a total emergency shut-down of the complete plant. It is for this reason that on
the more vulnerable possible points of failure, such as rotating machinery, it has become
normal practice to employ a working machine with a 100% standby machine standing
alongside to take over the function in the event of failure occurring (Myles and
Associates, 2003). If such an occurrence takes place, immediate action must be taken to
restore the damaged unit to service with minimum downtime to ensure continuity of
service in the event of a repeat occurrence. 
(2) Regular routine checks: Despite the above precautions, regular checks on all the more
vital items of equipment, including almost without exception any installed pump units
should be made to identify in good time, possible developing problems which will have
to be faced at the first opportunity. 
(3) ‘OEM’ parts and service: To minimise failures in service, the repairs which are
carried out on pumps and motors should be in strict accordance with the manufacturer’s
original standards in all respects, and should incorporate only ‘Original Equipment
Manufacturers (OEM)’ replacement components. The ideal would, of course, be to return
the unit for periodic servicing to the maker’s workshop. 
(4) Cost of plant shutdown: It must be realized that the cost of possible plant shutdown
can totally outweigh possible obvious saving in price by purchase of substandard parts,
not of original design standards from pirate suppliers. 
(5) Cost of power: If the original maker’s efficiency levels are not maintained by the use
of ‘OEM’ components, the costs of power consumption are also a most significant item
in the total production costs, and again this emphasizes the need for use at all times of
‘OEM’ parts. Taking the equivalent capital cost of power from a calculation undertaken
by a major South African Water Board for application in a contract, awarded in 1986, the
equivalent capital cost of 1 kW consumption was calculated at Rs. 2300.00 (Myles and
Associates, 2003). 
(6) Danger to life and limb: The most important of all reasons for maintaining original
standards by use of original manufactures’ components and facilities is the possibilities of
pump failure creating a hazardous situation, where the operating staff may, as a result, be
subjected to unnecessary dangers. 
(7) Quality assurance: The design, manufacturing, inspection and quality assurance
standards and limitations set by the original manufacturer are a vital ingredient mix in
ensuring that the above standards of performance, reliability in service, continued high
efficiency and safety in operations are maintained. This is the foundation of preventive
maintenance (Myles and Associates, 2003).
 
32.4 Overhauling of Centrifugal Pumps
Centrifugal pumps have two basic types of parts: rotating and stationary. Rotating parts
include the impeller, shaft, wearing rings, shaft sleeves, and bearings. Stationary parts
include the casing with the suction and discharge flanges, bearing housing and packing.
Most overhaul work on centrifugal pumps is concerned with the rotating parts. 
It is desirable that the pump is completely overhauled annually or once in two years.
However, in many situations, the operating conditions do not permit annual shutdown
periods for overhaul. In such cases, overhauling is done when it is absolutely essential, on
the basis of pump performance and symptoms indicating major problems. The following
situations call for a shutdown of the pumping plant for troubleshooting, repair and
possible overhaul (Michael and Khepar, 1999):
 1. Fall-off in pump performance,
2. Excessive noise during pump operation,
3. Excessive vibration of pump, and
4. Symptoms of corrosion or erosion trouble.
 
32.4.1 Dismantling of Centrifugal Pumps
The pump has to be dismantled for overhauling. As discussed in earlier lessons, there are
different types of horizontal centrifugal pumps such as monoblock or close-coupled
pumps, belt-driven pumps and directly-coupled pumps. The dismantling and
reassembling procedure of a belt-driven pump is discussed in this section. However, the
basic principles are the same, irrespective of the types of centrifugal pumps. 
The pump is first disconnected from the piping system (if the pump is directly coupled, it
is uncoupled by removing the coupling bolts and rubber bushes). The steps involved in
dismantling a belt-driven centrifugal pump are as follows (Michael and Khepar, 1999):
1. Remove the inlet and outlet flanges.
2. Remove the bearing cap by removing the bolts holding it.
 3. Remove the grease cup and bearing lock nut.
4. Remove the pedestal and take out the ball bearing, using a bearing puller.
5. Remove the belt shifter.
6. Remove the nuts and bolts joining the casings and remove the casing slowly, taking
care not to damage the impeller and casing rings.
7. Remove the impeller nut.
8. Dismantle the rotating unit and remove the impeller slowly by gently hammering
back the shaft using a wooden block.
9. Remove the impeller from the rotating unit.
10. Remove the pulleys using a pulley puller.
11. Finally, dismantle the stuffing box.
 The detailed description about the above steps can be found in Michael and Khepar
(1999).
 
32.4.2 Reassembling of Centrifugal Pumps
After overhauling, the pump is reassembled. The procedure of reassembling is more or
less the reverse of dismantling. The following are the major steps involved in
reassembling a centrifugal pump with pulley (Michael and Khepar, 1999):
1. Mount the pulleys on the shaft.
2. Mount the casing and stuffing box bushes on the shaft.
3. Gently mount the impeller on the shaft.
4. Insert the impeller key carefully.
5. Adjust the impeller at its correct position and tighten the impeller unit.
6. Insert the gasket and grease it properly.
7. Mount the casing by tightening its nuts and bolts.
8. Insert the belt shifter at its correct position.
9. Insert the shaft sleeve and tighten it properly.
10. Mount the pedestal and align it properly by inserting the desired packing.
11. Mount the ball bearing using hand press and tighten the bearing locking nut. Do not
hammer the ball bearing!
 12. Finally, mount the bearing cap. 
 
32.5 Centrifugal Pump Troubles and Remedies
Troubles in centrifugal pumps can be grouped into two classes: mechanical troubles and
hydraulic troubles. Mechanical troubles include breakage of the pump coupling or shaft.
These troubles are easily traceable and can be attended to promptly. However, hydraulic
troubles such as failure to deliver water, reduction in discharge and overloading of the
prime mover are more difficult to rectify. The major troubles encountered in a centrifugal
pump and their remedial measures are discussed below, which can serve as guidelines for
the pump users.
Table 32.1. Summary of troubles encountered in centrifugal pumps and their remedies
(Source: Myles and Associates, 2003)

SYMPTOM PROBABLE FAULT REMEDY

1.  Pump does not deliver  Impeller rotating in wrong Reverse direction of rotation.
water direction.
 Pump not properly primed ¾ air Stop pump and reprime.
or vapor lock in the suction line.
  Inlet of suction pipe Ensure adequate supply of liquid.
insufficiently submerged.

 Air leaks in suction line or gland Make good any leaks or repack
arrangement. gland.

 Pump not up to rated speed. Increase speed.

2.   Pump does not deliver  Air or vapor lock in the suction Stop pump and reprime.
rated line.
 Inlet of suction pipe Ensure adequate supply of liquid.
insufficiently submerged.

 Pump not up to rated speed. Increase speed.

 Air leaks in suction line or gland Make good any leaks or repack
arrangement. gland.

 Foot valve or suction strainer Clean foot valve or strainer.

choked.
  Restriction in delivery pipework Clear obstruction or rectify error in
or pipework incorrect. pipework.

Check head losses in delivery

 Head underestimated. pipes, bends and valves, reduce
losses as required.

 Unobserved leak in delivery. Examine pipework and repair leak.

Remove half casing and clear

 Blockage in impeller or casing. obstruction.

quantity  Excessive wear at neck rings or Dismantle pump and restore

wearing plates. clearances to original dimensions.

Dismantle pump and renew

 Impeller damaged. impeller.

 Pump gaskets leaking. Renew defective gaskets.

  Impeller rotating in wrong Reverse direction of rotation.
direction.

 Pump not up to rated speed. Increase speed.

3.   Pump does not  Impeller neck rings worn Dismantle pump and restore
generate its rated delivery excessively. clearances to original dimensions.
pressure
Dismantle pump and renew
 Impeller damaged or choked. impeller or clear blockage.

 Pump gaskets leaking. Renew defective gaskets.

4.  Pump loses liquid after  Suction line not fully primed 

starting ¾ air or vapor lock in the Stop pump and reprime.
suction line.
 Inlet of suction pipe Ensure adequate supply of liquid
insufficiently submerged. at suction pipe inlet.
  Air leaks in suction line or Make good any leaks or renew
gland arrangement. gland packing.

 Liquid seal to gland

arrangement logging ring (if Clean out liquid seal supply.
fitted) choked.
Unpack gland and relocate
 Logging ring not properly logging ring under supply
located. orifice.

5.  Pump overloads driving unit  Pump gaskets leaking. Renew defective gaskets.

 Serious leak in delivery line,

pump delivering more than Repair leakage.
its rated quantity.

 Speed too high. Reduce speed.

 Impeller neck rings worn Dismantle pump and restore

excessively. clearance to original dimensions.
 Stop pump, close delivery valve
to relieve internal pressure on
 Gland packing too tight. packing, slacken back the gland
nuts and retighten to finger
tightness.

Dismantle pump and renew

 Impeller damaged. impeller.

Dismantle pump, check internal

 Mechanical tightness at clearance and adjust as
pump internal components. necessary.

 Pipework exerting strain on Disconnect pipework and realign

pump. to pump.

  6.  Excessive  Air or vapor lock in suction. Stop pump and reprime.

 
vibration
   Inlet of suction pipe Ensure adequate supply of liquid
insufficiently submerged. at suction pipe inlet.
  Pump and driving unit Disconnect coupling and realign
incorrectly aligned. pump and driving unit.

 Worn or loose bearings. Dismantle and renew bearings.

 Impeller chocked or Dismantle pump and clear or

damaged. renew impeller.

Dismantle pump and straighten

 Rotating element shaft bent.
 
or renew shaft.

Remove pump, strengthen the

 Foundation not rigid.
foundation and reinstall pump.

 Coupling damaged. Renew coupling.

 Pipework exerting strain on Disconnect pipework and realign

pump. to pump.

7. Bearing    overhauling  Pump and driving unit out of Disconnect coupling and realign
 alignment. pump and driving unit.

 Oil level too low or too high. Replenish with correct grade of
oil or drain down to correct level.

 Wrong grade of oil. Drain out bearing, flush through

bearings; refill with correct grade
of oil.

 Dirt in bearings. Dismantle, clean out and flush

through bearings; refill with
correct grade of oil.

 Moisture in oil. Drain out bearing, flush through

and refill with correct grade of
oil. Determine cause of
contamination and rectify.

 Bearings too tight. Ensure that bearings are correctly

bedded to their journals with the
correct amount of oil clearance.
 Renew bearings if necessary.

 Too much grease in bearing. Clean out old grease and repack
with correct grade and amount of
grease.

 Pipework exerting strain on Disconnect pipework and realign

pump. to pump.

8. Bearing     wear  Pump and driving unit out of Disconnect coupling and realign
alignment. pump and driving unit. Renew
bearings if necessary.

 Rotating element shaft bent. Dismantle pump, straighten or

renew shaft. Renew bearings if
necessary.

 Dirt in bearing. Ensure that only clean oil is used

to lubricate bearings. Renew
bearings if necessary. Refill with
 clean oil.

 Lack of lubrication. Ensure that oil is maintained at

its correct level or that oil system
is functioning correctly. Renew
bearings if necessary.

 Bearing badly installed. Ensure that bearings are correctly

bedded to their journals with the
correct amount of oil clearance.
Renew bearings if necessary.

 Pipework exerting strain on Ensure that pipework is correctly

pump. aligned to pump. Renew bearings
if necessary.

 Excessive Vibration. Refer to symptom 6.

9. Irregular delivery  Air or vapor lock in the Stop pump and reprime.
suction line.
  Fault in driving unit. Examine driving unit and make
good any defect.

 Air leaks in suction line or Make good any leaks or repack

gland arrangement. gland.

 Inlet of suction pipe Ensure adequate supply of liquid

insufficiently immersed in at suction pipe inlet.
liquid.

10. Excessive noise level  Air or vapor lock in suction Stop pump and reprime.
line.

 Inlet of suction pipe Ensure adequate supply of liquid

insufficiently submerged. at suction pipe inlet.

 Air leaks in suction line or Make good any leaks or repack

gland arrangement. gland.

 Pump and driving unit out of Disconnect coupling and realign

 alignment. pump and driving unit.

 Worn or loose bearings. Dismantle and renew bearings.

 Rotating element shaft bent. Dismantle pump, straighten or

renew shaft.

 Foundation not rigid. Remove pump and driving unit,

strengthen foundation.