1. “Pumps” Troubleshooting Guide

2. Pumps Troubleshooting Guide
Contents:
Pump leaks.
Pump leaks while running.
Pump leaks while not running.
Lube Seal Vapor leak.
No flow or low flow.
Noise and/or vibration is noticeable.
Motor runs hot or throws breaker.

3. Pumps Troubleshooting Guide
Pump Leaks
Whenever leakage is encountered and before removing your pump, determine when the leakage is occurring… while running, or while not running.
During these inspections you should try to determine the exact origin of the leak.
Special attention should be given to the shaft sleeve.
Once you have determined when the pump is leaking, refer to the guide below.

4. Pump Troubleshooting Guide
Pump Leaks While Running
Test
Test Results
Indicates
Action to Take
Visually determine the exact leakage point
Leakage from the seal area at shaft sleeve.
Pump suction pressure exceeds expeller capacity.
Check inlet pressure.
Wilfley offers free engineering to ensure your pump is matched to your service.
Excessive expeller wear, corrosion, clearance orplating between vanes.
Remove pump and inspect the expeller for wear.
Check the impeller clearances for your pump.
Pump running too slow.
Check sheaves, motor, and VFD limits.
Leakage comes from caseor gasket area.
Damaged seal surface, gasket failure or loose bolts.
Check bolt tightness.
Remove pump and check gaskets and o-rings for wear.
Be sure the Sealing surfaces are clean and undamaged.

5. Pump Troubleshooting Guide
Pump Leaks While NOT Running.
Test
Test Results
Indicates
Action to Take
Verify that leakage originates from the seal area.
Leakage comes from case or gasket area.
Damaged sealing surface gasket failure or loose bolts.
Check bolt tightness.
Remove pump and check gaskets and o-rings for wear.
Be sure the sealing surfaces are clean and undamaged.
Leakage is observed on seal or shaft sleeve.
Seal or actuator problem.
Disassemble seal and be sure that all parts operate freely.
Check for cleanliness and wear.
Replace parts as necessary.

6. Pump Troubleshooting Guide
Lube Seal Vapor Leak.
Test
Test Results
Indicates
Action to Take
Check for vapors coming from the seal area.
Vapors detected.
Lubricator is out of lubricant.
Lubricator has failed.
Replace lubricator.
Replace Lube Seal.

7. Pump Troubleshooting Guide
No Flow or Low Flow.
Test
Test Results
Indicates
Action to Take 1
Rotate motor shaft by hand.
Rotates freely.
Proceed to number 3.
Shaft won't turn or rubbing.
Pump or motor failure.
Proceed to number 2. 2
Remove coupling and rotate motor and pump shafts by hand.
Pump shaft won't turn or rubbing noise is present.
Pump problem.
Remove pump and repair.
Motor shaft won't turn or Motor bearing problem.
Motor bearing problem.
Replace motor and proceed to number 3. 3
Start motor and check direction of rotation.
Rotation correct.
Proceed to number 4.
Rotation incorrect.
Motor wiring reversed
Correct hookup.

8. Pump Troubleshooting Guide
No Flow or Low Flow.
Test
Test Results
Indicates
Action to Take 4
Check pump shaft speed.
Pump speed OK.
Proceed to number 4.
Pump speed incorrect.
Proceed to number 5. 5
If pump is geared or v-belt driven, check motor speed.
Motor speed OK.
Sheaves or gear ratio wrong.
Correct speed ratio.
Motor speed incorrect.
Wrong speed motor or low voltage.
Correct as required. 6
With pump not running, install pressure gauges at pump inlet and discharge.
Suction pressure OK.
Proceed to number 7.
Suction pressure low.
Suction valve closed or blocked.
Open valve or free blockage, and proceed to number 7.

9. Pump Troubleshooting Guide
No Flow or Low Flow.
Test
Test Results
Indicates
Action to Take 7
Start pump and motor - check suction pressure.
Suction pressure OK.
Proceed to number 8.
Low suction pressure.
Unit cavitating or not primes.
Bleed pump case. Check valves and piping.
Inlet line restricted or air leaks in inlet piping, excessive vapors (low NPSH), foaming of fluid.
Use defoamer, eliminate air leaks. Correct NPSH problems. 8
Check discharge pressure and compare with head – flow curve.
Pressure at pump OK.
Faulty flow instrumentation.
Proceed to number 9.
Pressure higher than normal.
Discharge valve or piping blocked.
Correct blockage.
Pressure lower than normal.
Excessive impeller clearance or impeller damage. (Could indicate excessive pump flow and delivery. Proceed to number 9.)
Remove pump and repair.
Process problem resulting in high viscosity, high solids content or entrained air.
Correct process problems. 9
Check flow Instrumentation vs. physical measurement.
Measurements do not correspond
Instrumentation error.
Check valving, instrumentation and piping.

10. Pump Troubleshooting Guide
Noise and/or Vibration is Noticeable.
Test
Test Results
Indicates
Action to Take 1
Visually check for loose or missing screws or bolts from coupling or tiedown points.
Bolt and screw OK.
Proceed to number 2.
Loose or missing bolts.
Improper or incomplete assembly.
Replace and tighten bolts. 2
Rotate unit by hand.
Unit free and clear.
Proceed to number 3.
Scraping, clunking or other unusual noise heard.
Proceed to number 4.
Unit won't turn freely and easily.

11. Pump Troubleshooting Guide
Noise and/or Vibration is Noticeable.
Test
Test Results
Indicates
Action to Take 3
With unit running, monitor type and location of noise. Use stethoscope or screwdriver held against pump and motor housing over bearings.
Grinding, scraping, rubbing noise heard from pump only.
Impeller or expeller rubbing inside case.
Remove and repair. Check clearances.
Scraping or rubbing noise heard from motor only.
Possibly motor fan blades loose or bent.
Consult motor manual.
Thumping or clicking noise or excessive vibration.
Bad bearing, damaged bearings. or excessive vibration. coupling or pump/motor misalignment.
Proceed to number 4. 4
Uncouple pump. Push and pull pump and motor shafts in both radial and axial directions.
No shaft movements observed.
Proceed to number 5.
Shaft wiggles or moves.
Failed bearings.
Remove and repair. Proceed to number 6.

12. Pump Troubleshooting Guide
Noise and/or Vibration is Noticeable.
Test
Test Results
Indicates
Action to Take 5
With coupling removed, turn on motor and listen for noise.
Motor quiet.
Proceed to number 6.
Motor noisy.
Motor failure.
Remove and replace motor. 6
Check pump and motor shaft align ment with dial indicator
Axial alignment and squareness within .005 – inch.
Correct alignment.
Proceed to number 7.
Axial alignment and squareness not within .005 – inch.
Poor alignment.
Align units. 7
Remove pump frame oil drain plug. Check for metallic particles on drain plug magnet.
No metal chips or particles.
Recheck tests.
Metallic chips or particles found.
Bearing failure.
Remove pump and repair.

13. Pump Troubleshooting Guide
Motor Runs Hot or Throws Breaker
Test
Test Results
Indicates
Action to Take 1
With motor and pump not running, verify that the units rotate freely without noise or drag by rotating the shaft by hand.
Shaft turns freely with no noise.
Proceed to number 2.
Shaft drags or noise is heard.
Mechanical problems.
Go to the problem section on noise and vibration. 2
Check breaker fuse size and motor nameplate rating.
Breaker fuse and motor rating correspond.
Correct motor and fuse.
Proceed to number 3.
Breaker fuse and motor rating do not correspond.
Incorrect fuse.
Install proper fuse.

14. Pump Troubleshooting Guide
Motor Runs Hot or Throws Breaker
Test
Test Results
Indicates
Action to Take 3
With motor and pump running, check pump and motor speed.
Speed and motor direction OK.
Correct motor and frequency.
Proceed to number 4.
Speed of pump wrong.
Incorrect motor or frequency.
Correct motor. 4
Measure pump output flow rate and/or discharge pressure.
Flow and pressure correct.
Proceed to number 5.
Flow too high (discharge pressure low).
Improper valving or system upset.
Correct system problems.
Flow and head high.
Impeller too large.
Reduce impeller or speed.

15. Pump Troubleshooting Guide
Motor Runs Hot or Throws Breaker
Test
Test Results
Indicates
Action to Take 5
Measure motor amperage or HP.
Amperage (HP) OK.
Proceed to number 6.
Amperage (HP) too high.
Mechanical failure of pump or motor.
Go to the problem section on noise and vibration.
Process problem resulting in high S.G. or viscosity.
Correct process problems. 6
Measure motor voltage at motor breaker.
Motor voltage OK.
Proceed to number 7.
Motor voltage low.
Incorrect voltage.
Correct voltage. 7
Check motor fan cooling and air flow.
Good air flow, cool temperature.
Motor problem.
Consult motor manual.
No air flow.
Motor fan difficulty or shroud blocked.
Improve air flow, consult motor manual.