Case Study / Troubleshooting of Pump

 

Case Study 1 : Severe Vibration on Pump


The issue at hand concerns severe vibration experienced by the pumps while operating, which persists until the unit are shut down. Those pumps with high vibration are the VS-4 type vertical sump pumps and they are fabricated with extended shafts of 2 meters in length. According to the pump's nameplate, it is designed to deliver a rated flow of 10.8 m3/h at a head of 22 meters. Unfortunately, those pumps had experienced a breakdown after 6 months of operation.

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Case-Studies Relating to Pump Issues



With over 30 years of experience in providing training and conducting commissioning for centrifugal and process pumps, our observations reveal that more than 95% of issues stem from operational negligence or system-related problems like dry-running, cavitation due to air-lock or air-ingression, insufficient NPSHa (Net Positive Suction Head available), misalignment of flexible coupling, and pipe stress are common challenges encountered. Remarkably, less than 5% of problems are attributed to product or manufacturer defects.


To enhance the longevity of pumps and minimize costly production shutdowns, we aim to share our extensive experiences. Our focus is on equipping users and operators with comprehensive pump knowledge and the correct operating procedures. Our expertise extends beyond centrifugal and process pumps to include vacuum pumps and systems. Through case studies, analysis, and solutions, we strive to contribute to the improvement of pump performance and reliability in various industrial settings.


The following shows several examples of the pump issues that our customers confronted in the past:


Case Study 2: Cavitation due to "High Air Ingression" into Pump Suction


In an edible oil refinery, 2 units of cooling water circulation pumps were having some leaking issues. These pumps are BB-1 horizontal split-case pumps, where their sizes are 150-460 and are equipped with 110 kW (4-pole) motors. However, a problem arose for these both pumps when the water leaked or sprayed through the casing near to the pump outlet after running for less than two weeks. It was later found that the occurrence of leaking was mainly due to the cavitation issue. The problem of leaks in the pump casings was investigated.

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Case Study 3 : Importance of Pressure Gauge


Pressure, vacuum, and temperature gauges are essential and significant accessories in any pumping system, whether they are positioned at the suction or inlet, or at the discharge or outlet (located before the discharge valve) of a process or vacuum pump. These gauges play a crucial role in helping engineers, technicians, and operators gain a better understanding of the systems.

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Case Study 4:  Comparison on DIN 24255/ EN 733 vs ISO 2858/ 5199 vs API 610 Standard on End Suction Centrifugal Pumps


The standards DIN 24255/EN 733, ISO 2858/5199, and API 610 outline specifications for various types of centrifugal pumps, each serving different purposes in design, manufacturing, and testing

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