The Real Reason Your Pumps Fail

Source: HOMA Pump Technology

A common misconception when a pump goes down in wastewater applications is that the
pump is always the source of the problem. The reality is that many — if not most — failures
occur because of the system’s impact on the pump or because of other external
environmental/operational factors.

Pumps are only one part of a system consisting of many parts that impact their operation, and
continually repairing failed pumps without determining the root cause of the failure is all too
common. Doing so can be very expensive over time, and it can also lead to stressful
situations. In the common duplex pump station scenario, for example, a downed pump can
cause much concern because with one pump down, the single remaining pump is all that
stands between an operational station and a potential sewage overflow.

With pumps so critical to wastewater systems, it is wise to perform more system

troubleshooting on unusual or repetitive failures to find and solve the root cause issue(s) that
negatively impact the system. Beyond the assumption that the pump is the problem, operators
or maintenance staff may simply feel there isn’t enough time or resources to dig deeper into
problems.

Getting to the heart of issues is likely less expensive and time-consuming than one might
think, and good distributors who supplied the original equipment and the manufacturers’
applications engineering/service staff that support them are excellent resources available to
assist with this or to provide guidance.

This starts by investigating symptoms such as abnormal noises and strange episodes of
electrical trips, etc., that may accompany recurring pump failures. It is possible to
troubleshoot issues, or at least narrow down a problem to make a more targeted service call,
by examining key indicators and asking the right questions.

Getting Started

The root causes of pump failures generally fall under one of two categories - electrical or
mechanical.
Poor-quality power can lead to pump/motor failures, so begin by taking power readings. Are
the voltage and amperage values within normal range, and are they balanced between phases,
etc.? Voltage unbalance between phases on the supply side will cause a disproportionately
high current unbalance and motor temperature rise, shortening motor life; a 1% voltage
unbalance can create a current unbalance in the range of 6-10% , and with a 3% voltage
unbalance, the resulting motor temperature rise is increased by up to 18%. Voltage supply
unbalance can be caused by uneven single-phase loads on the three-phase grid, commonly
found in areas where residential single-phase air conditioning loads are prevalent. Also,
voltage drop and the corresponding current increase from being installed long distances from
the transformer can have a negative impact, as can a variety of factors arising from the use of
variable frequency drives. See the section on VFDs below.

For mechanical or performance issues, and also to determine potentially why the motor
current or input power is high, it is critical to know where the pump is operating on its curve.
The operational “duty point” of the pump is the intersection of the system curve and the
pump curve. In the design phase, the system curve of the pump discharge piping and force
main is typically calculated with some conservatism built in. Over time, the actual system
curve can change due to things like sedimentation buildup in the piping, air entrainment at
piping high points, scale buildup on pipe walls, etc. Older stations may have been sized based
on an anticipated increased future capacity that may or may not have come to pass.
Unfortunately, it is not uncommon for new equipment retrofits of older stations to be selected
based on the original system curve and design pump duty point, which, in reality, may be far
from the actual conditions, resulting in an incorrectly sized pump. 

Flow meter readings, if available, are optimal to determine the actual flow rate of the pump in
the system and allows the pump and actual system curves to be plotted, showing where the
pump is running compared to the design conditions. If a flow meter is not available, a
drawdown test can be used to determine the flow rate of the pump. A drawdown test is
performed by first calculating the volume of the sump as a function of sump level, then
recording the amount of time it takes to fill the sump between two specific sump levels
(inflow). Then, after the sump fills, recording the time to pump down to specific elevation.
Measuring over a smaller range - 1 to 2’ range is typically preferred, since a shorter duration
generally ensures that the inflow remains somewhat constant. Applying the formula [Pump
Flow = Gallons/Minute Inflow + Gallons/Minute Pump Down] provides a reasonable pump
flow rate measurement.

In many failure cases, the pump isn’t operating within specifications, so determining actual
pump flow offers an insight to pump health and may provide clues to problems, such as the
pump running off its curve or outside the prescribed Acceptable Operating Range (AOR),
where recirculation cavitation and/or excessive vibration may occur. Pressure measurements
from a pressure gauge on the discharge line corrected back to the pump discharge elevation
are also valuable for determining where the pump is operating.

Once there is a low-flow indication, dig deeper by running down this checklist:

 Is there more head on the pump than was originally designed?

 Is the check valve not opening all the way?
 Is there cavitation (low-pressure condition where the liquid turns into a vapor at the
eye of the pump impeller) due to inadequate Net-Positive Suction Head Available
(NPSHA)?
  Is there enough NPSHA at the site compared to pump requirements?
 Is the impeller showing premature wear?
 Is there a clog in the piping?
 Is air entrainment occurring from cascading flows in the sump?
 Does the measured flow and pressure correspond to the pump curve? If not, look for
unanticipated inlet losses.

If you’ve checked out the basics above but still have not identified a definitive problem,
consider diagnostic testing. A full-service testing organization will be able to bring
equipment to your site that measures power quality and can dig deeper into mechanical
problems by performing vibration testing and other tests.

VFDs Can Also Present Problems

Variable frequency drives (VFDs) are popular because they allow for a range of flows by
varying the pump curve though speed regulation, perform as soft starts for a gentler ramp-up
avoiding the high initial motor inrush currents, and allow. However, VFDs present their own
set of issues that can lead to pump failures.

Some common VFD-related issues include low operational speed. If the pump is oversized,
or if the duty point is based on maximum station inflow conditions, then the majority of its
operation may be at reduced speed. In those cases, it is critical that the minimum speed
setting is set such that the flow velocity though the piping system is high enough to prevent
sedimentation from settling out and that enough pressure is generated to be able to overcome
the static head. If the wastewater is heavily concentrated with rags or stringy materials, low-
speed operation can cause rag balls or fouling buildup to form in the eye of the impeller,
which can lead to a multitude of problems. Consider ramping the pump speed up to full speed
operation for a short period upon start-up and shutdown in this case to “flush” the pump at
the beginning and end of its pumping cycle.

There are several factors with VFD use such as length of cable, cable size, and type of VFD
that can cause voltage distortion in the form of spikes or harmonics which can destroy the
motor stator, or cause common mode voltages and shaft voltages which result in bearing
currents. Bearing currents create heat and degrade bearing grease and races, potentially
causing catastrophic failure. In such cases sine wave filter, or dV/dT filter may be required.

There are many system and operational/environmental aspects of a pump application that can
lead to pump failures in wastewater applications, so fixing repeat failures without digging
deeper is a substandard approach. For long-term operational security and savings, it is best to
investigate and cure the root cause.

Need More Information? Just Ask.

Click the button below to directly contact the supplier. Use it to:

 Ask a question.
 Request more detailed information or literature.
 Discuss your current project/application.
 Request a quote.
 Locate a distributor in your area.
  Schedule a demo.

Request Info 
  Free Water Online Newsletter

HOMA Pump Technology

 Request Info 
 Contact Details
 Company Profile

MORE FROM HOMA Pump Technology

Hot Under The Collar? – Why Your Pump Motors Overheat

An overheating pump motor can be a worrying issue for operators and engineers
alike, but like many pump issues, it is usually a symptom that can be traced to a
problem in the system. These common...

 Important Considerations For Pump Station Retrofits

Everyone involved with wastewater pump applications — operations managers, in-

house engineers, and consulting engineers — wants their newly retrofitted station to
operate reliably and...

 Variable Speed Pumping With Variable Success – Potential Pitfalls When Using Variable
Frequency Drives

Variable speed pumping using a variable frequency drive (VFD) can be a powerful
tool in a pump system. Incorrect application can do more harm than good. Here’s
how.

 Operation And Maintenance Realities Of Non-Clog Sewage Pumps

Pump clogs cause sanitary sewer overflows (SSOs) and backed up lift stations that
damage the environment. They also put the public health at risk and lead to regulatory
fines for the utility.

 Decreasing Lifecycle Costs: Don't Lose Dollars Chasing After Cents

 This article exploressome of the best practices to ensure overall station reliability, i.e.,
“total station efficiency,” in order to keep operating costs and downtime at a
minimum.

 Evaluating Low-HP Pump Technology To Run Cool In Hot Environments

 A Tool For Every Job – Selecting The Right Impeller For Your Application
 Low-Maintenance, Low-HP Pumps For Packaged Wastewater Treatment Plants
 HOMA EffTec Initiative For Enhanced Station Efficiency
 HRS Submersible Mixers
 Submersible A Series Wastewater Pumps
 Submersible A Series Wastewater Pumps Brochure

This website uses cookies to ensure you get the best experience on our

website. Learn more

Got it!

Explore Water Online

 From The Editor

 Water Online Newsletters
 Latest Water and Wastewater News
 Article Archives

Popular Features

 Water Talk Podcasts

 Water Talk Webinars
 Water Online TV
 Water Innovations Digital Magazine Archive
 Upcoming Events

Beyond Water Online

 Water Online On Twitter

 Water Online On LinkedIn
 Sign-Up For Our Newsletter
 Partners

Advertise On Water Online

 Request A Demo
 Water Online Media Kit
 2022 Water Online Editorial Calendar