Hydraulics and Pneumatics

Assignment: Major Problems in Pumps

Submitted by
Amjad Mehmood

2013-IM-10

Muddassir Raza

2013-IM-24

Ubair Waseem

2013-IM-25

Muhammad Yasir

2013-IM-33

Submitted to
Mr. Omer Asghar

Department of Industrial and Manufacturing Engineering

University of Engineering and Technology, Lahore

Major Problems in Pumps

Some problems arise with greater frequency than others. By understanding how and why, preventative
measures can be applied to reduce productivity loss, maintenance costs and operator frustration.

PUMP MOTOR FAILS TO START

Probable Cause

Blown fuse or tripped breaker

Low line current

Motor damage

Remedies

Replace fuse after correcting cause of overload

Reset after correcting cause of overload. If malfunction recurs, check heater size

Determine cause and correct

Check motor for physical damage that may hinder operation

PUMP RUNS BUT FAILS TO DELIVER

Probable Cause

Insufficient hydraulic oil

Check valve(s) lodged open by solids

Worn or dirty check valves

Suction or discharge line blocked

Pump is not primed

Remedies

Fill to proper level

Clean or replace

Clean line

Open valve

Allow suction line and pump head to fill with liquid before pumping against pressure

Remove and reinstall correctly

PUMP FAILS TO DELIVER RATED CAPACITY

Probable Cause

Incorrect capacity setting

Insufficient hydraulic oil

Starved suction

Leaky suction piping

Excessive suction lift

Liquid viscosity too high

Worn or dirty check valves

Remedies

Readjust capacity setting

Fill to proper level

Increase suction piping size or suction head

Repair piping

Cool liquid or increase suction head

Reduce viscosity of liquid; change ball material and/or size

Clean or replace

PUMP DELIVERS TOO MUCH CAPACITY

Probable Cause

Insufficient discharge pressure

Too much suction pressure

Remedies

Increase discharge pressure. (pump discharge pressure must be 15-30 psi greater than
suction pressure to assure proper ball check valve operation)
2

NOISY OPERATION OF BALL CHECK VALVES

Excessive gear wear

End play in worm (motor) shaft

Improper lubrication

Worn bearings

Ball valves make a clicking sound as they operate; rattling noises may also be heard under
certain conditions these noises are amplified by the natural resonance of piping. These noises
are normal and should not cause concern.

Repair gear set

Replace with correct oil

Replace bearings

PUMP LEAKING OIL

Probable Cause

Oil plug loose

Pump overfilled with oil

Breather cap loose or missing

Diaphragm head bolts not tightened

Remedies

Tighten

Drain oil to proper level

Tighten or replace

Tighten to specifications

AUXILIARY EQUIPMENT
Problems can also occur with accessories such as back pressure and safety relief valves,
pulsation dampers, calibration cylinders and controls. All must be accurately sized and
installed, since improperly matched components can adversely affect pump performance.
3

Problem: A leading computer chip manufacturer requested warranty service from the pump
manufacturer, claiming recently installed metering pumps with electronic controls were not
delivering the proper flow rate, based on instrument readings taken from a newly installed
PLC.
Solution: Visiting the job site, the service technician immediately determined that pump
performance was precisely to specifications. He then checked the signal readings from the
PLC and quickly determined that it was incorrectly calibrated, resulting in false signals to the
pumps electronic capacity control. After the PLC manufacturer recalibrated their unit, the
pumps operated properly.