According to various researches, the world’s industrial market share will be split into five groups by 2026: construction, chemicals, oil and gas, water and wastewater, and power. The need for chemical products from manufacturing, automotive, and construction is continuously increasing globally to keep up with the increased demand for power and energy along with ongoing population growth, industries and municipalities must use more different types of Centrifugal pumps. Most facilities depend on pumps to perform effectively and produce their intended products with the expected system reliability. Learn about frequent pumping problems or common pump mistakes in this article, along with solutions!!
Overview
Too gain or keep a competitive advantage, users must maintain pumps at the plant level with effective and efficient preventative maintenance (PM). Numerous potential problems must be examined. Examples include excessive vibration or noise, shaky mounting points, high or low bearing temperatures, leaky gaskets, pump flanges, and weak electrical connections.
The biggest problem, still today, is probably a human mistake. Most pumping problems are caused by corrosion, cavitation, wear, etc., and begin long before they are noticed. A lack of resources, incorrect maintenance frequencies, a lack of precision maintenance training, and a lack of utilisation of condition-based monitoring and predictive technology cause this.
Several Common Pump Mistakes
The idea that packing is less expensive and forgiving than mechanical seals is popular. Replacement cost is frequently the only cost taken into account in this comparison. Mechanical seals may be less expensive when packing expenses are considered, such as the regular (nearly daily) adjustments required, high flush water use, damage to shafts, base corrosion, etc. Some states offer incentives based on decreased water use.
Maintain seal flush system correctly
Inadequate maintenance of the seal flush system is the most frequent cause of seal and packing failure. Use the proper flush plan for the application, and make sure the flush medium is clean. The packing will be negatively impacted immediately if the seal flush fails. Depending on the use, mechanical seals can last for several hours.
Double pumping
Most two-pump pumping systems are built to work with a single-duty pump and a backup pump. The piping systems are made to handle the flow from one pump located near the BEP. When two pumps are operated in parallel into a system built to handle the flow from only one pump, both pumps run very far back on their curves, leading to poor reliability due to various flow-related issues.
Specifying pumps
Users frequently choose the same size pumps as the one being replaced when buying or specifying pumps or choose based on efficiency, thinking these factors are related to quality. When a pumps needs to be replaced, a new pump should be matched to the system circumstances by reviewing the real requirements (flow head, piping system, etc.). A typical inclination is to have too much pump for the application, which causes a pump to flow backward on its curve.
Troubleshooting pumps
The piping system in a centrifugal pump regulates pump performance. Therefore, check the system and piping for the pumping problem before conducting any investigation while troubleshooting pumps.
Best Practices To Avoid Pump Mistakes
Suction piping
The distance between the pump’s suction and the first elbow should be at least ten diameters. It is particularly important for double-ended pump designs since the turbulent input flow might result in bearing issues later on in the form of shaft thrusting. To prevent an uneven flow to both sides of a twin suction pump impellers, if an elbow must be fitted, ensure it is in a plane and at a right angle to the pump shaft. The suction flange should receive the top of the reducer directly.
Piping installation
Instead, run the pipe from the pump’s suction flange to the pipe rack instead of the other way around. It lessens the possibility of pipe strain.
Pump selection
Make sure the system curve and the pump curve connect at a sharp angle for a system that will have variable flow. An unstable system with problems with flow control will emerge from the pump and system curve intersecting at an acute angle.
Pump assembly
Ensure the whole pump rebuild, including all bearing fits, shaft run-outs, and clearances, is documented. For simple oil level confirmation, ensure the proper oil level (the centerline of the lowest ball) is marked on the outside of the housing.
Pump housing seals
Always use a high-quality desiccant breather and a good quality labyrinth or end face-linear bush bearing housing seal to prevent and regulate moisture entry.
Lastly,
Whether you are at home or working in a vast enterprise, a problem that rarely enters our minds yet significantly impacts our daily activities is the issue with the pump! The tasks we execute regularly are made possible by sound engineering, and if that engineering goes wrong, it might cause issues. Hopefully, this essay has provided you with some helpful knowledge. Also, don’t hesitate to contact Microcare Group if you have any questions!
One of India’s top pump spare parts manufacturers is Microcare. Microcare has more than 30 years of experience, knowledge, dedication, and a clear vision to be a change agent, a pioneer of new technologies, and a quality standard-setter. The fabrication of pump spares by Microcare is well renowned for using cutting-edge technology and methods. When it comes to quality, effectiveness, and on-time delivery, Microcare has always set the standard.
