PROBABLE FAULT REMEDY
Air vapour lock in suction line Stop pump and re-prime
Inlet of suction pipe insufficiently Ensure adequate supply of liquid
submerged
Pump not up to rated speed Increase speed
Air leaks in suction line or gland Make good any leaks or repack gland
arrangement
Foot valve or suction strainer Clean foot valve or strainer
PUMP DOES
choked
NOT DELIVER
RATED Restriction in delivery pipe-work or Clear obstruction or rectify error in
pipe-work incorrect pipe-work
QUANTITY
Head underestimated Check head losses in delivery pipes,
bends and valves, reduce losses as
required
Unobserved leak in delivery Examine pipe-work and repair leak
Blockage in impeller casing Remove half casing and clear
obstruction
Excessive wear at neck rings or Dismantle pump and restore
wearing plates clearances to original dimensions
Impeller damaged Dismantle pump and renew impeller
Pump gaskets leaking Renew defective gasket
PROBABLE FAULT
Impeller rotating in wrong direction Reverse direction of rotation
Pump not properly primed – air or Stop pump and re prime
PUMP vapour lock in suction line
DOES NOT Inlet of suction pipe insufficiently Ensure adequate supply of
DELIVER submerged liquid
LIQUID Air leaks in suction line or gland Make good any leaks or repack
arrangement gland
Pump not up to rated speed Increase speed
PROBABLE FAULT
Impeller rotating in wrong direction Reverse direction of rotation
PUMP Pump not up to rated speed Increase speed
DOES NOT
Impeller neck rings worn excessively Dismantle pump and restore
GENERATE ITS clearances to original dimensions
RATED
Impeller damaged or chocked Dismantle pump and renew
DELIVERY
impeller or clear blockage
PRESSURE
Pump gaskets leaking Renew defective gaskets
PROBABLE FAULT
Suction line not fully primed – air or Stop pump and reprime
vapour lock in suction line
Inlet of suction pipe insufficiently Ensure adequate supply of liquid
PUMP submerged at suction pipe inlet
LOSES LIQUID
AFTER Air leaks in suction line or gland Make good any leaks or renew
arrangement gland packing
STARTING
Liquid seal to gland arrangement logging Clean out liquid seal supply
ring (if fitted ) chocked
Logging ring not properly located Unpack gland and locate logging
ring under supply orifice
PROBABLE FAULT
Air or vapour lock in suction Stop pump and reprime
Fault in driving unit Examine driving unit and make
IRREGULAR good any defects
DELIVERY Air leaks in suction line or gland Make good any leaks or repack
arrangement gland
Inlet of suction pipe insufficiently Ensure adequate supply of
immersed in liquid liquid at suction pipe inlet
PROBABLE FAULT REMEDY
Air or vapour lock in suction line Stop pump and reprime
Inlet of suction pipe insufficiently Ensure adequate supply of liquid
submerged at suction pipe inlet
Air leaks in suction line or gland Make good any leaks or repack
EXCESSIVE arrangement gland
NOISE LEVEL
Worn or loose bearings Disconnect coupling and realign
pump and driving unit
Rotating element shaft bent Dismantle pump, straighten or
renew shaft
Foundation not rigid Dismantle pump and driving
unit, strengthen foundation
PROBABLE FAULT
Pump gaskets leaking Renew defective gasket
Serious leak in delivery line, pump Repair leak
PUMP delivering more than its rated
OVERLOADS quantity
DRIVING Speed too high Reduce Speed
UNIT
Impeller neck rings worn excessively Dismantle pump and restore
clearances to original dimensions
Gland packing too tight Stop pump, close delivery valve to
relieve internal pressure on packing,
slacken back the gland nuts and
retighten to finger tightness
Impeller damaged Dismantle pump and renew impeller
Mechanical tightness of pump Dismantle pump, check internal
internal components clearances and adjust as necessary
Pipe work exerting strain on pump Disconnect pipe work and realign to
pump
PROBABLE FAULT REMEDY
Pump and driving unit out of Disconnect coupling and realign
alignment pump and driving unit
Oil level too low or too high Replenish with correct grade of oil or
drain down to correct level
Wrong grade of oil Drain out bearing, flush through
BEARING bearings; refill with correct grade of
OVERHEATING oil
Dirt in bearing Dismantle, clean out and flush
through bearings; refill with correct
grade of oil
Moisture in oil Drain out bearing, flush through and
refill with correct grade of oil.
Determine cause of contamination
and rectify
Bearings too tight Ensure that bearings are correctly
bedded to their journals with the
correct amount of oil clearance.
Renew bearings if necessary
Too much grease in bearing Clean out old grease and repack
with correct grade and qty of grease
Pipe work exerting strain on Disconnect pipe work and realign to
pump pump
PROBABLE FAULT
Air or vapour lock in suction Stop pump and reprime
Inlet of suction pipe Ensure adequate supply of liquid at
insufficiently submerged suction pipe inlet
Pump and driving unit Decouple pump and driver, realign &
incorrectly aligned check alignment after coupling.
Worn or loose bearings Dismantle pump and renew bearings
EXCESSIVE
VIBRATION Impeller chocked or damaged Dismantle pump and clear or renew
impeller
Rotating element shaft bent Dismantle pump, straighten or
renew shaft
Foundation not rigid Remove pump, strengthen the
foundation and reinstall pump
Coupling damaged Renew coupling
Pipe work exerting strain on Disconnect pipe work and realign to
pump pump
PROBABLE FAULT
Pump and driving unit out of Disconnect coupling and realign
alignment pump and driving unit. Renew
bearings if necessary
Rotating element shaft bent Dismantle pump, straighten or renew
shaft. Renew bearings if necessary
Dirt in bearings Ensure that only clean oil is used to
BEARING WEAR lubricate bearings. Renew bearings if
necessary. Refill with clean oil
Lack of lubrication Ensure that oil is maintained at its
correct level or that oil system is
functioning correctly. Renew
bearings if necessary
Bearing badly installed Ensure that bearings are correctly
bedded to their journals with the
correct amount of oil clearance.
Renew bearings if necessary
Pipe work exerting strain on Ensure that pipe work is correctly
pump aligned to pump. Renew bearings if
necessary
Excessive vibration Refer excessive vibration
Symptom Diagnosis
CV As per pump curve Changed system
Open valve condition –
Q1 <Q, H1> H blockage pipe
Q1, H1 on pump curve friction,
filters, strainers,
etc
Symptom Diagnosis
CV As per pump curve Pump fault –
Open valve Blockage in
Q1 <Q, H1> H impeller,
increased
leakage loss
Symptom Diagnosis
CV As per pump curve Insufficient
Open valve Head lower NPSH leading to
in vicinity of the system cavitation break-
curve. down
Sudden break down of
H-Q
Symptom Diagnosis
CV Lower than pump Incorrect speed
curve Incorrect diameter
Lower Q, Lower H of impeller
Wrong direction of
rotation
TROUBLE SHOOTING
SYMTOMPS COMMON CAUSES REMEDY
PUMP NOT PRIMED FILL THE PUMP & SUCTION LINE COMPLETELY
WITH LIQUID
REMOVE AIR/GAS
ELIMINATE HIGH POINTS IN SUCTION PIPING
CHECK FOR FAULY FOOT VALVE, CHECK VALVE
INSTALLATION
AIR-POCKET IN SUCTION LINE CHECK FOR GAS, AIR IN
SYSTEM/SUCTION LINE
NO DELIVERY INSTALL GAS SEPERATION
OR CHAMBER
CHECK FOR AIR-LEAKAGE
DELIVERY NOT OPEN AIR-VENT VALVE IF ANY
UPTO THE
INSUFFICIENT IMMERSION OF LOWER SUCTION PIPE OR
EXPECTATION SUCTION PIPE, VORTEXING RAISE SUMP WATER LEVEL
SPEED OF PUMP TOO LOW OR WRONG DIRECTION CORRECT SPPED, CHECK RECORDS FOR
OF ROTATION PROPER SPEED
CHECK ROTATION WITH ARROW ON CASING -
REVERSE POLARITY ON MOTOR
CHECK IMPELLER
SYSTEM HEAD HIGHER THAN PUMP DESIGN HEAD DECREASE SYSTEM RESISTANCE
CHECK DESIGN PARAMETERS
INCREASE PUMP SPEED
INSTALL PROPER SIZE PUMP
TROUBLE SHOOTING
SYMTOMPS COMMON CAUSES REMEDY
WRONG IMPELLER SELECTION VERIFY PROPER IMPELLER SIZE
WRONG IMPELLER INSTALLATION CHECK IF THE IMPELLER IS INSTALLED
BACKWARD(DOUBLE SUCTION PUMP)
AIR-GAS ENTRAINMENT IN LIQUID CHECK FOR GAS, AIR IN
SYSTEM/SUCTION LINE
INSTALL GAS SEPERATION
CHAMBER
CHECK FOR AIR-LEAKAGE
OPEN AIR-VENT VALVE IF ANY
INSUFFICIENT SPEED OF PUMP TOO LOW OR CORRECT SPPED, CHECK RECORDS FOR
WRONG DIRECTION OF PROPER SPEED
DISCHARGE ROTATION CHECK ROTATION WITH ARROW ON CASING
PRESSURE - REVERSE POLARITY ON MOTOR
CHECK IMPELLER
IMPELLER CLOGGED CHECK FOR DAMAGE & CLEAN
IMPROPER PUMP SELECTION DECREASE SYSTEM RESISTANCE
CHECK DESIGN PARAMETERS
INCREASE PUMP SPEED
INSTALL PROPER SIZE PUMP
TROUBLE SHOOTING
SYMTOMPS COMMON CAUSES REMEDY
MISALIGNMENT CHECK ANGULAR & PRALLEL ALIGNMENT
BETWEEN PUMP & DRIVER
ELIMINATE STILT-MOUNTED BASE-PLATE
CHECK FOR LOOSE MOUNTING
CHECK FOR UNUNIFORM THERMAL
EXPANSION OF PUMP PARTS
BENT SHAFT CHECK TIR AT IMPELLER END (SHOULD NOT
EXCEED 0.002”)
REPLACE SHAFT OR BEARING IF NECESSARY
SHORT SEAL LIFE CASING DISTORSION DUE TO PIPE STRAIN CHECK ORIENTATION OF BEARING ADAPTER
CHECK FOR PIPE ALIGNMENT & ANALYZE PIPE
LOADS & SUPPORTS
PUMP CAVITATING CHECK FOR NPSHa/NPSHr MARGIN & TAKE
NECESSARY STEPS
CHECK FOR FLASH POINT MARGIN
CHECK FOR GAS ENTRAINMENT
IMPROPER OPERATING CONDITION INSTALL PROPER SEAL THAT SUITS PUMP
OPERATING CONDITIONS
UNBALANCE DRIVER RUN DRIVER DISCONNECTED FROM PUMP
UNIT - PERFORM VIBRATION ANALYSIS
TROUBLE SHOOTING
SYMTOMPS COMMON CAUSES REMEDY
BEARING FAILURES CHECK FOR PROPER LUBRICATION &
CONTAMINATION OF LUBRICANT
CHECK FOR PROPER BEARING INSTALLATION
CHECK FOR THE SUITABILITY OF BEARING
SELECTED
MISALIGNMENT CHECK ANGULAR & PRALLEL ALIGNMENT
BETWEEN PUMP & DRIVER
ELIMINATE STILT-MOUNTED BASE-PLATE
CHECK FOR LOOSE MOUNTING
CHECK FOR UNUNIFORM THERMAL
EXPANSION OF PUMP PARTS
SHORT BENT SHAFT CHECK TIR AT IMPELLER END (SHOULD NOT
EXCEED 0.002”)
BEARING REPLACE SHAFT OR BEARING IF NECESSARY
LIFE
CASING DISTORSION DUE TO PIPE STRAIN CHECK ORIENTATION OF BEARING ADAPTER
CHECK FOR PIPE ALIGNMENT & ANALYZE PIPE
LOADS & SUPPORTS
PUMP CAVITATING CHECK FOR NPSHa/NPSHr MARGIN & TAKE
NECESSARY STEPS
CHECK FOR FLASH POINT MARGIN
CHECK FOR GAS ENTRAINMENT
UNBALANCE DRIVER RUN DRIVER DISCONNECTED FROM PUMP
UNIT - PERFORM VIBRATION ANALYSIS
TROUBLE SHOOTING
SYMTOMPS COMMON CAUSES REMEDY
MOTOR TRIPPING-OFF CHECK STARTER
CHECK RELAY SETTING
CHECK FOR THE SUITABILITY OF MOTOR
SELECTED FOR CURRENT OPERAING CONDITION
SPEED TOO HIGH CHECK FOR SPEED OR PREVIOUS RECORDS FOR
PROPER SPEED
ELIMINATE STILT-MOUNTED BASE-PLATE
CHECK FOR LOOSE MOUNTING
CHECK FOR UNUNIFORM THERMAL EXPANSION
OF PUMP PARTS
ROTOR IMPELLER RUBBING ON CASING LOOSE IMPELLER FIT
EXCESSIVE WRONG ROTATION
POWER DEMAND REPLCE IF SHAFT IS BENT
HIGH NOZZLE LOADS
VERY SMALL INTERNAL RUNNING CLEARANCES
– CHECK FOR NECK RING DIMENSIONS
PUMP NOT DESIGNED FOR LIQUID DENSITY & CHECK DESIGN SP. GRAVITY
VISCOSITY BEING PUMPED CHECK MOTOR SIZE – USE LARGER DRIVER OR
CHANGE PUMP TYPE
HEAT UP THE LIQUID TO REDUCE VISCOSITY
BEARING FAILURES CHECK FOR PROPER LUBRICATION &
CONTAMINATION OF LUBRICANT
CHECK FOR PROPER BEARING INSTALLATION
CHECK FOR THE SUITABILITY OF BEARING
SELECTED
IMPROPER COUPLING SELECTION CHECK COUPLING SIZE
TROUBLE SHOOTING
SYMTOMPS COMMON CAUSES REMEDY
PUMP IS CAVITATING CHECK FOR NPSHa/NPSHr MARGIN & TAKE
NECESSARY STEPS
CHECK FOR FLASH POINT MARGIN
CHECK FOR GAS ENTRAINMENT
SUCTION OR DISCHARGE VALVE CLOSED OR CHECK FOR VALVE CONDITION
PARTIALLY CLOSED OPEN THE VALVES
MISALIGNMENT CHECK ANGULAR & PRALLEL ALIGNMENT
BETWEEN PUMP & DRIVER
ELIMINATE STILT-MOUNTED BASE-PLATE
CHECK FOR LOOSE MOUNTING
NOISE & CHECK FOR UNUNIFORM THERMAL
EXPANSION OF PUMP PARTS
VIBRATION
INADEQUATE GROUTING OF BASE PLATE CHECK GROUTING, CONSULT PROCESS INDUSTRY
PRACTICE RE-IE-686
IF STILT MOUNTED, GROUT BASEPLATE
BEARING FAILURES CHECK FOR PROPER LUBRICATION &
CONTAMINATION OF LUBRICANT
CHECK FOR PROPER BEARING INSTALLATION
CHECK FOR THE SUITABILITY OF BEARING
SELECTED
IMPROPER COUPLING SELECTION CHECK COUPLING SIZE, GRAESING , ALIGNMENT
