2014-0708presentationslideshow-140709005449-phpapp02.pdf
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Transcript of 2014-0708presentationslideshow-140709005449-phpapp02.pdf
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PUMP TROUBLESHOOTING
Brian GongolDJ Gongol & Associates, Inc.
July 14, 2014
Ankeny Annual Water ConferenceDMACC/Ankeny
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Quick survey
Are you here for water, wastewater, or both?
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Sir Arthur Conan Doyle (as Sherlock Holmes)
"Once you eliminate the impossible,whatever remains, no matter how improbable,
must be the truth."
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Handout
Pump troubleshooting flowchart
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All pump problems are either mechanical...
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...or hydraulic
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Secondarily, they are either internal...
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...or external to the pump
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How to tell a mechanical problem
Take away the water
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How to tell a hydraulic problem
Take measurements
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Mechanical problems - internal to the pump
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Bearings
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Seals
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Packing
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Tightness of fit
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Suction flap valves
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Debris
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Internal rubbing
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Friction
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Mechanical problems - external to the pump
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Motors
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Controls
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Alignment
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Balance
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Transmission
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Belts
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Sheaves
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Couplings
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Valves (throttling)
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Valves (isolation)
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Valves (air-release)
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Piping
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Rotation
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Jay-Z had 99 problems
We've come up with about 50...and this is halftime
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Hydraulic problems - internal to the pump
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Recirculation
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Clearances
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Wearplate wear
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Wear ring wear
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Volute wear
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Impeller wear
In at least three flavors...
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Chemical attack
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Abrasion
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Cavitation*
Cavitation damage happens inside the pump...but it's almost always caused outside the pump
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Hydraulic problems - external to the pump
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Suction side or discharge side
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Hydraulic problems - external - suction
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NPSH
NPSHa (net) = Atmospheric pressure- vapor pressure- safety factor- total dynamic suction lift- NPSHr for the pump
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Atmospheric pressure
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Heat/vapor pressure
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Air entrainment
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Air in high spot
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Turbulence
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Vortexing
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Minimum submergence
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Plugged suction
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Debris
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Horizontal runs
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Valves
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Leaks
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Changes to fluid properties
For instance...
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Gases in solution
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Surfactants
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Viscosity
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Specific gravity
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Froth/foam/bubbles
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Hydraulic problems - external - discharge
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Handout
Engineering data booklet
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Valves
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Leaks/breaks
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Sediment
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Debris
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Changes to effective pipe diameter
Caused by...
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Air
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Ice
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Corrosion
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Scaling
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Buildup
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Tools to assist in your investigation
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Impeller condition: Excess wear
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Impeller condition: Suction cavitation
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Impeller condition: Discharge cavitation
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Shaft breakage
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Seal failure
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Strange or unwelcome noises
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Strange or unwelcome noises
Suction cavitation
Discharge cavitation
Surges
The scream
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Use all of your available senses (minus taste)
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Record performance
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Keep pump curves handy
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Gauge readings make a huge difference
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Gauge readings make a huge difference
Look in the direction of change
Was the change gradual or abrupt?
Some are dead giveaways,others just point in the right direction
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Gauge case studies
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Gauge case studies
The prime that took forever
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Gauge case studies
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Gauge case studies
The prime that took forever The hole in the suction line
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Gauge case studies
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Gauge case studies
The prime that took forever The hole in the suction line The plugged suction
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Gauge case studies
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Gauge case studies
The prime that took forever The hole in the suction line The plugged suction
The forcemain failure
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Gauge case studies
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Gauge case studies
The prime that took forever The hole in the suction line The plugged suction
The forcemain failure The sedimentation
inclination
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Gauge case studies
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Gauge case studies
The prime that took forever The hole in the suction line The plugged suction
The forcemain failure The sedimentation
inclination The bubble, bubble, toil,
and trouble
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Gauge case studies
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Gauge case studies
The prime that took forever The hole in the suction line The plugged suction
The forcemain failure The sedimentation
inclination The bubble, bubble, toil,
and trouble The surge-and-slam
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Gauge case studies
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Always divide and conquer
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Questions?
Thank you for coming!
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Thank you for your attention!
Contact us anytime with questions
Brian Gongol DJ Gongol & Associates 515-223-4144 [email protected]
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References:
Photo: Mechanic tightening nut (public domain) http://loc.gov/pictures/resource/fsac.1a35263/
All other photos are original work by and copyright reserved to Brian Gongol
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