“Pumps”

Troubleshooting Guide
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.
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.
 Pump Troubleshooting Guide
 Pump Leaks While Running

Test Test Results Indicates Action to Take

 Visually  Leakage from  Pump suction  Check inlet pressure.

determ the seal area pressure exceeds  Wilfley offers free
ine the at shaft expeller capacity. engineering to ensure
exact sleeve. your pump is matched to
leakag your service.
e point
 Excessive expeller  Remove pump and inspect
wear, corrosion, the expeller for wear.
clearance  Check the impeller
orplating between clearances for your pump.
vanes.
 Pump running too  Check sheaves, motor,
slow. and VFD limits.

 Leakage  Damaged seal  Check bolt tightness.

comes from surface, gasket  Remove pump and check
caseor gasket failure or loose gaskets and o-rings for
area. bolts. wear.
 Be sure the Sealing
surfaces are clean and
undamaged.
 Pump Troubleshooting Guide
 Pump Leaks While NOT Running.

Test Test Results Indicates Action to Take

 Verify that  Leakage comes  Damaged  Check bolt tightness.

leakage originates from case or sealing surface  Remove pump and
from the seal area. gasket area. gasket failure check gaskets and o-
or loose bolts. rings for wear.
 Be sure the sealing
surfaces are clean and
undamaged.

 Verify that  Leakage is  Seal or actuator  Disassemble seal and

leakage originates observed on seal problem. be sure that all parts
from the seal area. or shaft sleeve. operate freely.
 Check for cleanliness
and wear.
 Replace parts as
necessary.
 Pump Troubleshooting Guide
 Lube Seal Vapor Leak.

Test Test Results Indicates Action to Take

 Check for  Vapors  Lubricator is  Replace

vapors coming detected. out of lubricator.
from the seal lubricant.
area.
 Lubricator  Replace Lube
has failed. Seal.
Pump Troubleshooting Guide
 No Flow or Low Flow.

Test Test Results Indicates Action to Take

1 Rotate motor Rotates freely. Proceed to number 3.

shaft by hand.
Shaft won't turn or Pump or motor Proceed to number 2.
rubbing. failure.

2 Remove Pump shaft won't turn or Pump problem. Remove pump and
coupling and rubbing noise is present. repair.
rotate motor
and pump Motor shaft won't turn or Motor bearing Replace motor and
shafts by Motor bearing problem. problem. proceed to number 3.
hand.

3 Start motor Rotation correct. Proceed to number 4.

and check
direction of Rotation incorrect. Motor wiring Correct hookup.
rotation. reversed
 Pump Troubleshooting Guide
 No Flow or Low Flow.

Test Test Results Indicates Action to Take

4 Check pump shaft Pump speed OK. Proceed to number 4.

speed.
Pump speed Proceed to number 5.
incorrect.

5 If pump is geared or Motor speed OK. Sheaves or gear Correct speed ratio.
v-belt driven, check ratio wrong.
motor speed.
Motor speed Wrong speed Correct as required.
incorrect. motor or low
voltage.

6 With pump not Suction pressure Proceed to number 7.

running, install OK.
pressure gauges at
pump inlet and Suction pressure Suction valve Open valve or free
discharge. low. closed or blocked. blockage, and
proceed to number 7.
Pump Troubleshooting Guide
 No Flow or Low Flow.

Test Test Results Indicates Action to Take

7 Start pump and Suction pressure Proceed to number 8.
motor - check OK.
suction
Low suction Unit cavitating or not primes. Bleed pump case. Check
pressure.
pressure. valves and piping.

Inlet line restricted or air leaks Use defoamer, eliminate air

in inlet piping, excessive vapors leaks. Correct NPSH
(low NPSH), foaming of fluid. problems.
8 Check discharge Pressure at pump Faulty flow instrumentation. Proceed to number 9.
pressure and OK.
compare with
Pressure higher Discharge valve or piping Correct blockage.
head – flow
than normal. blocked.
curve.
Pressure lower Excessive impeller clearance or Remove pump and repair.
than normal. impeller damage. (Could
indicate excessive pump flow
and delivery. Proceed to number
9.)
Process problem resulting in Correct process problems.
high viscosity, high solids
content or entrained air.
9 Check flow Measurements do Instrumentation error. Check valving,
Instrumentation not correspond instrumentation and piping.
vs. physical
measurement.
 Pump Troubleshooting Guide

 Noise and/or Vibration is Noticeable.

Test Test Results Indicates Action to Take

1 Visually check for loose Bolt and screw OK. Proceed to number 2.
or missing screws or
bolts from coupling or
tiedown points.
Loose or missing Improper or Replace and tighten
bolts. incomplete bolts.
assembly.

2 Rotate unit by hand. Unit free and clear. Proceed to number 3.

Scraping, clunking Proceed to number 4.

or other unusual
noise heard.

Unit won't turn Proceed to number 4.

freely and easily.
 Pump Troubleshooting Guide
 Noise and/or Vibration is Noticeable.

Test Test Results Indicates Action to Take

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

Test Test Results Indicates Action to Take

5 With coupling Motor quiet. Proceed to number 6.

removed, turn on
motor and listen Motor noisy. Motor failure. Remove and replace
for noise. motor.

6 Check pump and Axial alignment and Correct alignment. Proceed to number 7.
motor shaft align squareness within
ment with dial .005 – inch.
indicator
Axial alignment and Poor alignment. Align units.
squareness not
within .005 – inch.

7 Remove pump No metal chips or Recheck tests.

frame oil drain particles.
plug. Check for
metallic particles Metallic chips or Bearing failure. Remove pump and
on drain plug particles found. repair.
magnet.
 Pump Troubleshooting Guide

 Motor Runs Hot or Throws Breaker

Action to
Test Test Results Indicates
Take
1 With motor and pump not Shaft turns freely Proceed to
running, verify that the with no noise. number 2.
units rotate freely without
noise or drag by rotating
the shaft by hand. Shaft drags or Mechanical Go to the
noise is heard. problems. problem section
on noise and
vibration.

2 Check breaker fuse size Breaker fuse and Correct motor Proceed to
and motor nameplate motor rating and fuse. number 3.
rating. correspond.

Breaker fuse and Incorrect fuse. Install proper

motor rating do not fuse.
correspond.
 Pump Troubleshooting Guide
 Motor Runs Hot or Throws Breaker
Action to
Test Test Results Indicates
Take

3 With motor and pump Speed and motor Correct motor and Proceed to
running, check pump direction OK. frequency. number 4.
and motor speed.
Speed of pump Incorrect motor or Correct motor.
wrong. frequency.

4 Measure pump output Flow and pressure Proceed to

flow rate and/or correct. number 5.
discharge pressure.
Flow too high Improper valving Correct
(discharge pressure or system upset. system
low). problems.

Flow and head high. Impeller too Reduce

large. impeller or
speed.
 Pump Troubleshooting Guide
 Motor Runs Hot or Throws Breaker
Test Test Results Indicates Action to Take
5 Measure motor Amperage (HP) OK. Proceed to number 6.
amperage or HP.

Amperage (HP) too Mechanical Go to the problem

high. failure of pump section on noise and
or motor. vibration.

Process problem Correct process

resulting in high problems.
S.G. or
viscosity.
6 Measure motor Motor voltage OK. Proceed to number 7.
voltage at motor
breaker.
Motor voltage low. Incorrect Correct voltage.
voltage.
7 Check motor fan Good air flow, cool Motor problem. Consult motor
cooling and air flow. temperature. manual.

No air flow. Motor fan Improve air flow,

difficulty or consult motor
shroud blocked. manual.