Problem Solving Centrifugal Pumps

Inside View
This document has been produced to support pump users at all levels, providing an invaluable
reference tool. It includes information on general Centrifugal pump problems and their effect on
Centrifugal pumps with suggestions as to probable causes and solutions.
Main sections are as follows:
1. Introduction
2. Centrifugal Pump Problems
3. Alfa Laval Solutions to Specific Centrifugal Pump Problems
4. How correct System Design and Installation can avoid potential problems
5. Problem Solving Table

The information provided in this document is given in good faith,

but Alfa Laval is not able to accept any responsibility
for the accuracy of its content, or any consequences
that may arise from the use of the information
supplied or materials described.

Contents
Section 1.0: Introduction

Page
3

Introduction to problem solving Centrifugal pumps.

Section 2.0: Centrifugal Pump Problems

Overview of pump problems typically found on Centrifugal pumps.

2.1
No or low flow
2.2
No or low pressure
2.3
Excessive power consumption
2.4
Excessive noise or vibration
2.5
Seal leakage

7
14
15
16
20

Section 3.0: Alfa Laval Solutions to Specific Centrifugal Pump Problems

31

How Alfa Laval can provide solutions to specific pump problems.

3.1
Ability to self-prime
3.2
Ability to handle high inlet pressures
3.3
Rouging

31
32
33

Section 4.0: How correct System Design and Installation can avoid
potential problems

35

Advises guidelines relating to correct pump installation, system design and pipework layout.
4.1
Pipework
4.2
Protection
4.3
Operation
4.4
Pre-start up Checks

35
35
36
36

Section 5.0: Problem Solving Table

37

Provides summary of probable causes and solutions to the most common problems.

1.0 Introduction
In most pumping systems, the pump is likely to be one of the most vulnerable components and systems
frequently show the pump to be at fault regardless of what may be wrong.
Upon investigation the likely causes of the problem are inadequate control of the pumped fluid or a change in
operating requirements of which the system or pump is not capable of handling.
Pumps that are correctly installed and operated within their design parameters will give typically long troublefree service of >10 years, unless on very arduous duties.
In order to correctly identify the problem it is important to gather as much information relating to the process as
follows:

Reconfirm original duty requirements and/or system design.

Check for any process changes i.e. pressure, temperature, fluid viscosity etc.

Check whether the system was undergoing routine maintenance.

How long did the pump operate before the problem.

Check the appearance and condition of the pump internal components.

Check when the pump was last serviced.

Check for any changes in pump noise or vibration.

This will save considerable time and effort in leading to the most appropriate solution. The most common
problems associated with Centrifugal pumps are shown herein with particular effects on our range of Centrifugal
pumps.

2.0 Centrifugal Pump Problems

Typical pump problems include:

No or low flow
No or low pressure
Excessive power consumption
Excessive noise or vibration
Seal leakage

These are common for all Centrifugal pump types shown as follows:

Pumps

Rotodynamic

Positive
Displacement

Reciprocating

Rotor

Single Stage

Multi-Rotor

Single Rotor

Screw

Piston

Simplex

Process

Circumferential
Piston

Archimedian
Screw

Multiplex

Rubber Lined

Gear Internal

Flexible
Member

Submersible

Gear External

Peristaltic

General

Rotary Lobe

Vane

Diaphragm

Progressing
Cavity

Plunger

Multi-Stage

End Suction

Double Entry

Typical causes are as follows:

No or low flow

Pump is not primed

The motor is turning pump in the wrong direction
Valves are closed or there is an obstruction in the suction or discharge pipework
The end of the suction pipework is not submerged
A strainer or filter is clogged
Insufficient Net Positive Suction Head available (NPSHa)
Air leak in the suction pipe
No power to the pump
Pump speed too low
Pumped media viscosity is higher than expected
Pressure is higher than calculated
Flow switch faulty

No or low pressure

Valves are closed or there is an obstruction in the suction or discharge pipework

A strainer or filter is clogged on the inlet
Flow is higher than calculated
The motor is turning pump in the wrong direction
Insufficient Net Positive Suction Head available (NPSHa)
No power to the pump
Pump speed too low
Pumped media viscosity is higher than expected

Excessive power consumption

Flow is higher than calculated with low outlet pressure

Viscosity too high
Mechanical contact in the pumphead

Excessive noise or vibration

Pipework is not properly supported

Pump is cavitating
Impeller contact with casing/backplate
Gas entrainment
Loss of shaft support (bearing failure in motor)
Pumped media contains unexpected abrasive particles
Poor pipework / system design
Dry running of seal

Seal leakage

Pumped media contains unexpected solids

Chemical corrosion / attack
Pump is cavitating
Too high discharge pressure
Too high temperature
Pump / shaft vibration
Incorrect fitting
Incorrect selection of seal materials
Pump allowed to run dry
Insufficient or no auxiliary flushing services

2.1

No or low flow

2.1.1

Pump is not primed

Centrifugal pumps are capable of evacuating (pumping) a modest amount of air from the suction side of
the pump to the discharge side of the pump. Filling the inlet system with fluid or at least filling the pump
(wetted pumping elements) will make a major improvement in the pumps priming capability.

2.1.2

The motor is turning pump in the wrong direction

Centrifugal pumps should never be allowed to operate in the wrong direction of rotation. If the pump is
not fitted with an impeller screw the impeller may unscrew from the shaft making contact with the
casing, thereby causing seizure.

Impeller damage

To ensure correct direction of rotation the motor can be started and stopped momentarily to check the
motor fan is rotating clockwise as viewed from the rear end of the motor.

Fluid Out
Correct
rotation

Fluid In
View from rear end

If an impeller screw is fitted, the pump is still capable of achieving low flow with the motor turning in
wrong direction.

Impeller screw

If pump is operating in reverse rotation, use motor manufacturers instructions to ensure appropriate
direction.

2.1.3

Valves are closed or there is an obstruction in the suction or discharge pipework

Any obstruction in the pipework and/or valves being closed can significantly increase pressure. An
increase in pressure on the outlet will have the effect of a decrease in flow, highlighted in curve below:

Duty point

Increase in
pressure

Pump curve

Resultant
decrease
in flow

The following symptons may occur:

Low outlet pressure (see 2.2.1)
Seal dry running (see 2.5.4)
Increase in noise/vibration (see 2.4)
Reduced NPSHa (see 2.1.6)

2.1.4

The end of the suction pipework is not submerged

In this situation no fluid will be allowed to enter the pump, cavitation may occur (see 2.1.6 below) and
potential for dry running of seal (see 2.5.4).

2.1.5

A strainer or filter is clogged

If a strainer or filter is clogged in the suction pipework, this will have the effect of increasing pressure
loss thereby decreasing flow as described in 2.1.6 below. If a strainer or filter is clogged in the discharge
pipework, this will have the effect of increasing pressure loss thereby decreasing flow as described in
2.1.3 above.

2.1.6

Insufficient Net Positive Suction Head available (NPSHa)

For satisfactory pump operation the condition at the inlet of a pump is critical. The system on the inlet
side of the pump must allow a smooth flow of fluid to enter the pump at a sufficiently high pressure to
avoid cavitation. This is called the Net Positive Suction Head, generally abbreviated NPSH.
It is critical that the net positive suction head available (NPSHa) in the system is greater than the net
positive suction head required (NPSHr) by the pump. The value of NPSHa in the system is dependent
upon the characteristic of the fluid being pumped, inlet piping, the location of the suction vessel, and the
pressure applied to the fluid in the suction vessel. This is the actual pressure seen at the pump inlet. It is
important to note, it is the inlet system that sets the inlet condition and not the pump.
NPSHa is calculated as follows:
NPSHa (metres) =
Pressure action on
Surface of liquid (Pa)

Static suction
head (hs)

Pressure drop
(hfs)

+ve -ve +ve -ve

Where:
Pa
hs
hfs
Pvp

=
=
=
=

Pressure absolute above fluid level (bar)

Static suction head (m)
Pressure drop in suction line (m)
Vapour pressure (bar a)

Vapour pressure
(Pvp)

The term cavitation is derived from the word cavity, meaning a hollow space. In pump terminology,
cavitation is an undesirable vacuous space in the inlet port of the pump normally occupied by fluid. The
lowest pressure point in a pump occurs at the pump inlet - due to local pressure reduction part of the
fluid may evaporate generating small vapour bubbles known as vacuoles. These vacuoles are carried
along by the fluid and implode instantly when they get into areas of higher pressure which will damage
pump components.
For many pump application problems, cavitation is the most commonly encountered. It occurs with all
types of pumps, rotary, centrifugal or reciprocating, caused by insufficient system inlet pressure to the
pump. This can be due to an inlet system restriction, excessive fluid viscosity or excessive pump speed.
Inlet restrictions can include dirty or clogged inlet strainers, debris floating in the fluid supply that covers
the inlet piping intake, or rags. If the fluid is cooler than design temperature, its viscosity may be too
high causing excessive friction (pressure loss) in the inlet piping system. Adversely if the product is too
hot there is risk of product vaporisation.
Cavitation is frequently accompanied by noise, vibration and significant increase in discharge pressure,
pulsation and/or loss of flow. If a pump is allowed to cavitate over long periods, this will cause damage
to the pumphead components, seals and drive train. The surface of these components are typically
perforated and pitted as material is eroded by implosive forces.

Vapour bubbles forming

Damage due to cavitation

10

Suggestions for avoiding cavitation:

Keep pressure drop in the inlet line to a minimum i.e. length of line as short as possible,
diameter as large as possible, and minimal use of pipe fittings such as tees, valves etc.
Maintain a static head as high as possible.
Reduce fluid temperature, although caution is needed as this may have an effect of increasing
fluid viscosity, thereby increasing pressure drop.
Size the pump correctly ensuring NPSHa > NPSHr

2.1.7

Air leak in the suction pipe

Air in the suction pipework or entrained gas in the pumped media has the effect of reduced pump
performance and creates the same symptoms as cavitation. This can occur under other circumstances
such as a pump operating at an inlet pressure below local atmospheric pressure. In this instance it is
quite likely that air is being drawn into the pipework through a loose pipe connection or pump casing
joint, leaking inlet valve stem, defective or otherwise damaged joint gasket in the pipework system.

2.1.8

No power to the pump

In this situation the cause is mainly due to incorrect wiring of the electric motor, check motor
manufacturers instructions.
Other factors to be taken into consideration:
Check switchgear
Check starting current
Check thermistor motor protection
Check programming of the frequency inverter (if used) is correct.
Check flow switch (if used) is operating correctly

2.1.9

Pump speed too low

If the pump is equipped with a star/delta starting method and it does not shift between the star and delta
connection the pump will remain on low speed in the star connection.

Torque

I = Current in delta connection

I = Current in star connection
M = Torque in delta connection
M = Torque in star connection
Mb = Load from centrifugal pump

Speed

11

If the soft start is not correctly programmed the pump will not reach the design speed. The soft start
provides a smooth start at the time, as the starting current is limited. The magnitude of the starting
current is directly dependent on the static torque requirement during a start and on the mass load that is
to be accelerated. In many cases the soft starter saves energy by automatically adapting the motor
voltage continually to the actual requirement. This is particularly important when the motor runs with a
light load.

2.1.10 Pumped media viscosity is higher than expected

Centrifugal pumps typically handle low viscosity pumped media i.e. 800 cP max. Above this figure the
power will exceed the maximum rating of the motors and the performance of the pump will be greatly
affected.
Viscous drag will decrease the pumps efficiency resulting in a reduced performance and a higher power
requirement which may exceed the maximum power rating of the motor.
Poor pump performance may be attributed to an unexpected change in fluid viscosity. In some fluids the
viscosity is constant regardless of the shear forces applied to the layers of fluid. These fluids are known
as Newtonian fluids whereby at a constant temperature the viscosity is constant with change in shear
rate or agitation.
Newtonian Fluid Behaviour

Viscosity

Typical Newtonian fluids are:

Water

Beer

Hydrocarbons

Milk

Mineral Oils

Syrups

Shear rate

However, there are many fluids which do not follow this linear law, these fluids are named NonNewtonian fluids. Of these, Psuedoplastic fluids can have an affect on pump performance if not taken
into consideration upon initial pump sizing. With Psuedoplastic fluids the viscosity decreases as shear
rate increases, but initial viscosity may be so high as to prevent start of flow in a normal pumping
system.
Psuedoplastic Fluid Behaviour

Viscosity

Typical Psuedoplastic fluids are:

Blood

Emulsions

Gums

Lotions

Soap

Toothpaste

Yeast

Shear rate

12

In general terms, low viscosity Newtonian fluids are best handled with Centrifugal type pumps and
Psuedoplastic fluids are best handled with Positive Displacement Rotary Lobe type pumps.

2.1.11 Pressure is higher than calculated

Any increase in viscosity will increase pressure losses in the system. This will affect the system curve
resulting in less flow. To overcome this, the solution will be to increase pump speed. However care must
be taken as this will increase NPSHr which may affect the NPSHa of the system as described in 2.1.6.

2.1.12 Flow switch faulty

A faulty flow switch can result in no power getting to the pump, hence no pump operation.

13

2.2

No or low pressure

2.2.1

Valves are closed or there is an obstruction in the inlet pipework

See 2.1.3

2.2.2

A strainer or filter is clogged on the inlet

See 2.1.5

2.2.3

Flow is higher than calculated

If the delivered flow from the pump is higher than calculated it can be related to the system pressure
being lower than expected.

2.2.4

The motor is turning in the wrong direction

See 2.1.2

2.2.5

Insufficient Net Positive Suction Head available (NPSHa)

See 2.1.6

2.2.6

No power to the pump

See 2.1.8

2.2.7

Pump speed too low

See 2.1.9

2.2.8

Pumped media viscosity is higher than expected

See 2.1.10

14

2.3

Excessive power consumption

2.3.1

Flow is higher than calculated with low outlet pressure

This will increase the flow rate, thereby increase in power consumption. Throttling the discharge
pressure by the addition of an orifice or valve will increase the system pressure and thereby reduce the
flow.

2.3.2

Viscosity too high

Any increase in fluid viscosity will increase the pressure losses and reduce pump efficiency, thereby
increasing the power absorbed. Too much power can overload the motor protection.

2.3.3

Mechanical contact in the pumphead

See 2.4.3.

15

2.4

Excessive noise and vibration

2.4.1

Pipe work is not properly supported

The pump must not be allowed to support any of the pipework weight and correct installation guidelines
should be followed.

2.4.2

Pump is cavitating
See 2.1.6
Cavitation is frequently accompanied by noise, vibration, pulsation and/or loss of flow. If a pump is
allowed to cavitate over long periods, this will cause damage to the pumphead components, seals and
drive train. The surface of these components are typically perforated and pitted as material is eroded by
forces of the vacuoles imploding.

Damage due
to cavitation

Suggestions for avoiding cavitation:

Keep pressure drop in the inlet line to a minimum i.e. length of line as short as possible,
diameter as large as possible, and minimal use of pipe fittings such as tees, valves etc.
Maintain a static head as high as possible.
Reduce fluid temperature, although caution is needed as this may have an effect of increasing
fluid viscosity, thereby increasing pressure drop.
Size the pump correctly ensuring NPSHa > NPSHr

16

2.4.3

Impeller contact with casing/backplate

Contact is mainly attributed to:
Incorrect clearance between impeller and backplate
Worn bearings on motor
Excessive high inlet pressure
Foreign object
Pressure shock
Incorrect rotation
Incorrect clearance between impeller and backplate
It is important the correct distance is set between the impeller and the backplate (refer to Instruction
Manual).

Initial contact between front

of impeller and pump casing

Here the impeller position was adjusted so as

not to rub on the pump casing but instead
began to rub on the backplate

17

Damage to backplate and back of impeller due to constant rubbing. Initial contact may have damaged
the motor bearings so clearances cannot be reset correctly as the shaft and impeller are floating.

Worn bearings on motor

See 2.4.5
Excessive high inlet pressure
???????
Foreign object
Fitting a strainer in the suction pipework prior to pump inlet will eliminate and foreign objects being
allowed to enter the pump.
Pressure shock
???????
Incorrect rotation
See 2.1.2

2.4.4

Gas entrainment
Gas in the inlet pipework or entrained gas in the pumped media has the same impact on pump
operation and creates the same symptoms as cavitation. This can occur under other circumstances
such as a pump operating at an inlet pressure below local atmospheric pressure. In this instance it is
quite likely that air is being drawn into the pipework through a loose pipe connection or pump casing
joint, leaking inlet valve stem, defective or otherwise damaged joint gasket in the pipework system.

2.4.5

Loss of shaft support (bearing failure in motor)

Bearing failure can occur for a number of reasons such as:
Excessive high inlet pressure
Temperature exceeding pump design limits
Cavitation
Coupling/Shaft mis-alignment
Inadequate lubrication
Excessive pressure surges

18

Examples of motor bearing failure

2.4.6

Pumped media contains unexpected abrasive particles

If any hard solid particle is allowed to enter the pump it is likely to cause damage to pumphead
components. Use of a strainer or filter prior to pump suction will avoid this problem.

Scoring marks due to ingress of hard foreign object

2.4.7

Poor pipe work / system design

See 4.0
It is important that installation guidelines are followed.

2.4.8

Dry running of seal

See 2.5.4

19

2.5

Seal Leakage
Mechanical seals are precision designed and manufactured, yet one of the most common causes of
failure in Centrifugal pump types. By design mechanical seals are friction contact devices and can be
subjected to a very wide range and often hostile operating environments. Selecting the correct
mechanical seal is imperative to avoid any seal leakage i.e. mounting attitude, seal face combination
and elastomer selection.
To assist in identifying why a particular mechanical seal has leaked it is important to record as much
information as possible:
How long has the seal been in operation (months, days, hours)? Is the seal subject to continuous or
intermittent running?
Check for any process changes i.e. pressure, speed, temperature and pumped media details.
Where is the seal leaking from? i.e. seal faces and/or elastomers.
How badly is the seal leaking? i.e. constant or variable, only when shaft is stationary.
Check seal flush flow rate and pressure if single flushed or double flushed mechanical seals are
used.
Check for any pump cavitation and/or vibration.
For solving any seal leakage problem it is advisable to adopt a systematic approach as follows:

Inspect the entire seal

Examine the wear track

Examine the faces

Signs of heat

Inspect the seal drive

Check the springs

Check the elastomers

Check for rubbing

20

2.5.1

Inspect the entire seal

Do not try to solve a seal leakage problem by looking at only the parts that look important. Both the
primary rotating and stationary seal faces should be inspected, as well as secondary seals such as O
rings, cups or gaskets. The shaft sleeve and inside of the seal housing/casing should also be inspected.
Look for any deposits, chips or broken components. Look for any wear debris near to seal faces.

2.5.2

Examine the wear track

Normal wear pattern
Cause:
If leakage is present it is probably due to problems with elastomeric
secondary seals.
Solution:
Replace both primary seal faces and secondary seals.

Wide wear pattern

Cause:
This indicates that the pump shaft is running eccentrically due to being
bent from misalignment, bearing failure, shaft deflection or severe pipe
strain.
Solution:
Replace shaft, seal and motor bearings if applicable. Check shaft is
correctly aligned, and check system pressures and alleviate any pipe
strain.
Off centre wear pattern
Cause:
This indicates that the seal faces are not running concentric to one
another or the stationary face is not central in the gland area.
Solution:
Replace seals and install correctly by referring to the seal manufacturers
fitting instructions and check shaft alignment.

Non contact pattern

Cause:
This indicates that the rotary face is not mating with the stationary face.
This can be due to incorrect installation, slipping of the drive mechanism or
loss of anti-rotation devices.
Solution:
Install seals correctly by referring to the seal manufacturers fitting
instructions and check that anti-rotation devices are present.

21

Partial wear pattern

Cause:
This indicates that the rotary face is not fully mating with the stationary
face. This can be due to incorrect installation, excessive tightening of the
stationary face or thermal expansion in the pipework.
Solution:
Install seals correctly by referring to the seal manufacturers fitting
instructions and prevent thermal expansion entering the pump.

2.5.3

Examine the faces

Cracked silicon carbide face
Cause:
Over tightening or mishandling.
Solution:
Replace seals and install correctly by referring to the seal manufacturers
fitting instructions and handle with care.

Cracked carbon
Cause:
This is usually caused by over compression, vibration or the
swelling of an elastomer on the inside diameter, putting the
carbon in tension. Problem could also be mishandling.
Solution:
Replace seals and install correctly by referring to the seal
manufacturers fitting instructions and handle with care.
Check elastomers are compatible with the pumped media from
seal manufacturers recommendations.

Heavy wear or scoring

Cause:
This often occurs with seals in severe abrasive service with the seal faces
separating, letting in large particles between the seal faces. These particles
then embed in the soft face (carbon) and grind the hard face.
Solution:
Replace seals with a hard face combination such as silicon carbide and/or
provide a flush to the seal area.

22

Example of excessive wear due to

abrasive application i.e. UHT
chocolate milk.
Solution would be to use a double
flushed mechanical seal

Chipping on outside diameter

Cause:
This is evident in soft seal face material (carbon) due to the
solidification of pumped media on the face outside diameter
causing breakage upon start up. Severe cavitation could also
cause this problem.
Solution:
Replace seals and provide a flush to the seal area and/or
eliminate any pump cavitation problems (see 2.1.6).

Example of chipping on
outside diameter of seal face

23

Chipping on inside diameter

Cause:
This is evident in soft seal face material (carbon) due to
abrasive particles in the pumped media damaging the seal
face. Severe cavitation could also cause this problem.
Solution:
Replace seals with a hard face combination such as silicon
carbide and provide a flush to the seal area and/or eliminate
any pump cavitation problems (see 3.1.4).

Pitting, blistering or corrosion

Cause:
Mechanical seals are selected for particular applications and
should not be subject to these problems. However severe
corrosion can occur if used on incompatible pumped media.
Also this can occur when a poor grade of carbon is being used,
or when retrofitted by someone other than the original
manufacturer - here gases are trapped within the material
which vaporise during operation, thereby allowing solidification
of pumped media on the seal faces giving shearing and tearing
effects.
Solution:
Replace seals with faces that are compatible with pumped
media.

Example of crevice
corrosion on a
stainless steel face

Example of pitting corrosion

on stainless steel

24

Example of electro-chemical corrosion on WFI

application (LKH UltraPure pump) using incorrect
seal face material
Solution would be to ensure use of designated
high grade silicon carbide seal faces for LKH
Ultrapure pumps

Example of seal faces

being subject to
chemical attack

Product solidification/burning
Cause:
Product solidification/burning on the seal faces can
cause wear on start-up reducing seal life.
Solution:
Fitting a flushed mechanical seal arrangement can alleviate
this problem.

An example of mechanical seal

failure whereby the pumped media
has been allowed to solidify on the
seal faces causing leakage.

25

Example of seal failure from milk application

whereby at temperatures >45C the lactose and
protein of the milk will burn on the seal faces due
to insufficient cooling and lubrication hence
damage on faces.

2.5.4

Signs of heat
If any discoloration of the seal parts is observed, then high friction between the seal faces has been
created. Further evidence in O ring hardening and setting may support this. The seal faces will also
show signs of excessive wear and possible heat distress in the form of thermal cracking.
Cause:
The most probable causes are dry running, flashing, or very poor face lubrication. Flashing being
boiling of the fluid film on the seal faces. Other causes could be incorrect fitting of the seal causing high
friction and thereby high temperatures within the seal or the pump is operating at excessive pressures
or speed.
Solution:
Ensure seal does not run dry in the application. If this cannot be avoided a single seal with
flush or a double seal with a barrier fluid should be considered ensuring proper lubrication of the
seal.
Ensure the seal is properly installed as per seal manufacturers fitting instructions.
Ensure the pump operates at specified pressure and/or speed.
An example of a mechanical seal
where the seal faces have been
allowed to run dry

The sealing surface is scored

Burnt debris found on the inner

diameter

O ring is deformed (being axially

moved from the fitted position
close to the shaft step)

Burnt o ring residues on the

outer diameter

26

Further example of mechanical

seal faces being allowed to run dry

2.5.5

Inspect the seal drive

Mechanical seal designs all use some method to transmit torque from the shaft to the rotary seal face.
For the mechanical seals used on the LKH and SolidC centrifugal pumps this takes the form of a drive
pin on the rotating part correctly engaging in the slot of the stationary part.

Drive pin

2.5.6

Check the elastomer

Swollen, sticky or disintegrating
Cause:
This is generally caused by chemical incompatibility with pumped media.
Solution:
Replace with different elastomer material that is compatible from seal
manufacturers recommendations.

27

Hard or cracked
Cause:
This is generally caused by excessive heat and/or chemical attack. Usually the
source of heat is the face or a metal to metal contact of two parts. Excessive
face heat is caused by lack of lubrication and subsequent high friction. It could
also be a sign that the pump has run dry.
Solution:
Ensure seal does not run dry in the application. If this cannot be avoided a
single seal with flush or a double seal with a barrier fluid should be considered
ensuring proper lubrication of the seal.
Replace with different elastomer material that is compatible from seal
manufacturers recommendations.
Compression set
Cause:
This is caused where the O ring has been unable to withstand the temperature of
the pumped media - the O ring loses its roundness and becomes square in section.
This may also occur if too much heat is generated at the seal faces.
Solution:
Reduce pumped media temperature and/or replace with different elastomer material
that is compatible from seal manufacturers recommendation and can withstand
high temperature required.

Extruded
Cause:
This is caused by excessively high pressure and/or the size of the seal O
ring groove being incorrect. As the o ring extrudes it will tear in the gap
between shaft and seal ring.
Solution:
Replace elastomer and reduce system pressures. Also check that the O
ring groove size is correct by referring to seal manufacturer.

Example of O ring damaged

by excessive pressure

28

Cuts or nicks
Cause:
This is the most common failure and normally occurs during installation.
Solution:
By its nature elastomers slide on to the shafts with some interference and care
should be taken when sliding new elastomers over any sharp edges, shoulders
or old grub screw marks to avoid damage.

2.5.7

External Symptoms of Seal Failure

Symptoms

Possible Causes

Seal squeals

No seal lubrication.

Carbon deposits

Lack of lubrication causes carbon to grind away.

Liquid film vaporising/flashing between the faces.

Seal spits and sputters (popping)

Liquid film vaporising/flashing between the faces.

Seal drips steadily (heavy leakage is

normally from the faces rather than
the o rings)

Primary:
Faces not flat.
Faces cracked, chipped or blistered.
Distortion of seal faces for thermal or mechanical reasons.
Secondary:
Seals nicked or scratched during installation.
Leakage of fluid under pump shaft sleeve.
O rings have been compression set (hard and brittle).
O rings subjected to chemical attack (soft and sticky).
Incorrect seal materials specified.

Pump/Shaft Vibration

Shaft misalignment.
Cavitation.
Bearing failure.
Dry running

29

3.0 Alfa Laval Solutions for Specific Centrifugal Pump Problems

Specific pump problems include:

3.1

Ability to self-prime
Ability to handle high inlet pressures
Rouging

Ability to self-prime
The Alfa Laval LKHSP self-priming centrifugal pump is specifically designed for pumping liquids
containing air or gas without losing its pumping ability.
The LKHSP self-priming pump can be used for
emptying tanks, as CIP return pump and
similar applications where there is a risk of air
or gas mixing with the liquid in the suction line.

LKHSP
Self-Priming Pump

Tank

During operation the water in the pump recirculates within the confines of the system
with the ball valve open. The recirculation
creates negative pressure which opens the
non-return valve letting in fluid and air. As the
pump is now delivering fluid, the pressure
increases and closes the ball valve. The pump
subsequently functions as a standard
centrifugal pump.

Ball valve
Spring

Non-return
valve

31

For satisfactory operation the static head on discharge line should be less than 8 metres. If the static
head is higher than this figure, the spring in the ball valve between the tank and the inlet of the pump
cannot open which will result in the pump being unable to prime.

3.2

Ability to handle high inlet pressures

The Alfa Laval LKHP, LKHI and Multi-Stage centrifugal pumps have motors fitted with special bearings
to handle high inlet pressures. It is important to ensure the motors lubrication is regularly maintained to
avoid total bearing/pump failure.

LKHP Pump for

inlet pressures
up to 40 bar

LKHI Pump for

16 bar inlet pressure

LKH Multi-Stage Pump

32

3.3

Rouging
Rouging refers to a form of corrosion found in stainless steel. Rouging is a thin film, usually reddishbrown or golden in color, of iron oxide or hydroxide, typically on found on stainless steels. The contrast
between this film and shiny metal accentuates this aesthetics problem. The rouge film typically wipes off
easily with a light cloth, but it reforms while the process fluid is in contact with the stainless steel. This
problem is most chronic in the pharmaceutical industry on the interior surfaces of high purity water (i.e.
water for injection, WFI) distillation units, storage tanks, distribution systems (piping, valves, pump
housings, fittings, etc.) and process vessels.
As stated, rouge is ferric oxide (i.e. rust), but the film may contain not only iron but also chromium and
nickel compounds in various forms, and hence the film may vary in colour and tenacity. Rouging is
experienced more on type 304/304L stainless steel than on type 316/316L, and less on electropolished
surfaces than mechanically polished surfaces. Particles of rust can become dislodged and be dispersed
throughout a piping distribution system, often collecting on in-line filters.
Stainless steel is stainless owing to the fact that the alloy forms a thin, protective, tenacious,
transparent oxide film that protects it against destructive corrosive elements in aqueous solutions. This
film is composed of chromium oxide, and is said to make the steel passive against corrosion. Exposure
to moist air will provide this passivation within a matter of minutes, and the film will thicken with time.
The passive layer on the surface of stainless steels can breakdown by the interaction of ultra pure
water, which is devoid of ionic elements, leading to rouging. The ionic pull of the water is strong enough
to strip the protective chromium oxide off the steel surface. This results in the stainless steel having to
re-passivate by reforming another layer of chromium oxide film, which incorporates the rouge causing
discoloration. During the brief time it takes to re-passivate, a thin layer of the stainless steel dissolves, or
corrodes. The major elements composing stainless steel are iron, chromium and nickel. The chromium
and nickel ions are soluble and go into the bulk solution. The iron, however, precipitates above a pH of
3 as iron hydroxide that readily oxidizes to ferric oxide, which is red in colour (i.e. rouge). If this
progresses uniformly across the surface of the steel, and the de-passivation / re-passivation process is
cycled many times, then the surface of the stainless steel takes on a light golden to dark brown
appearance depending on the ionic state of the various oxide layers and their depth.

Discoloration effect
of rouging

33

In high purity water systems the rouge may be of three types:

Class I Rouge originating from external sources, usually by erosion or cavitation of pump
surfaces.
Class II Rouge originating from chloride induced corrosion of the stainless steel surfaces.
Class III Rouge, either blue or black, found in high temperature steam systems.
Rouging can take place in pure water, ultra-pure water, steam, treated potable water or untreated
process water.
The Alfa Laval LKH UltraPure centrifugal pump has
the option of having the product wetted components
manufactured from stainless steel with <1% delta
ferrite level to alleviate this problem.

LKH UltraPure Pump

34

4.0 How correct System Design and Installation can avoid

potential problems
To ensure optimum pump operation it is important that any pump unit is installed correctly. When designing a
pumping system consideration should be given to the pipework, pump protection and operation.

4.1

Pipework

Have short straight inlet pipework.

o This will reduce friction losses in the pipework, thereby improving the NPSH available.

Avoid bends, tees and any restrictions close to either suction or discharge side of pump. Use long
radius bends wherever possible.
o This will minimise pressure losses and/or turbulence in the pipework.

Keep pipework horizontal where applicable.

o This will reduce possibility of air locks.

Confirm the Net Positive Suction Head (NPSH) available from the system exceeds the NPSH required
by the pump (see 2.1.6).
o This is crucial for ensuring the smooth operation of the pump and preventing cavitation.

Avoid suction lifts and manifold/common suction lines for two centrifugal pumps running in parallel
o This will prevent vibration or cavitation.

Include eccentric reducers on suction lines.

o This will minimise pressure losses and/or turbulence in the pipework.

Avoid the use of blind tees.

o This will avoid pressure pulsing and thereby noise and possible pump damage.

Include for seal flushing pipework where applicable.

o This will ensure satisfactory seal operation.

All pipework must be supported. The pump must not be allowed to support any of the pipework weight.

4.2

Protection

Protect the pump against blockage from hard solid objects e.g. nuts, bolts, welding slag etc.
o This will prevent possibility of pumphead seizure.

Protect the pump from accidental operation against closed inlet and outlet valves.
o This will prevent catastrophic pumphead seizure.

35

4.3

4.4

Operation

Ensure pumped media is maintained at the correct temperature.

o This will avoid dramatic increase in viscosity leading to possible over pressurisation and/or
cavitation.

Try to allow at least 0.5 m for pump access.

o This will ease maintenance all round the pump.

Ensure fluid flow velocity is sufficient.

o This will avoid pumped media settling out, thereby restricting flow and increasing pressure.

Pre-start up Checks
Before the pump unit is started it is important to ensure that pre-start up checks are made as follows:

Check that the pipework system has been purged to remove welding slag and any other debris. For
purging purposes a bypass should be installed around the pump. Dependent upon the
cleaning/purging velocity this may need to be done more than once.
Minimum recommended velocity 1.5 - 3.0 m/s.

Check that all obstructions have been removed from the pipework and pump.

Check that all the pump connections and pipework joints are tight.

Check that seal flushing is connected if applicable.

Check that all valves in the system are open.

Check that the motor rotation is correct.

36

5.0 Problem Solving Table

The table shown below offers probable causes and solutions to the most common problems encountered:

Seizure

Mechanical seal leakage

Pump element wear

Noise and vibration

Motor overheats

Excessive power absorbed

Pump overheats

Prime lost after starting

Pump stalls when starting

Pump will not prime

Irregular discharge

Low discharge pressure

No flow

Under capacity

Problem

Probable Causes

Incorrect direction of rotation

Pump not primed

Insufficient NPSH available

Fluid vaporising in suction line

Air entering suction line
Strainer or filter blocked
Fluid viscosity above rated figure
Fluid viscosity below rated figure
Fluid temperature above rated figure
Fluid temperature below rated figure

Unexpected solids in fluid

Discharge pressure above rated figure

Seal flushing inadequate
Pump casing strained by pipework
Metal to metal contact of pumping
element
Worn pumping element
Suction lift too high
Fluid pumped not compatible with
materials used
Pump allowed to run dry
Faulty motor
Too large clearance between impeller
and back plate/casing
Too small impeller diameter
Pumping element missing i.e. after
service

37

Solutions

Reverse motor
Expel gas from suction line and pumping chamber and
introduce fluid
Increase suction line diameter.
Increase suction head.
Simplify suction line configuration and reduce length.
Decrease fluid temperature - check effect of increased viscosity?
Increase suction line diameter.
Increase suction head or pressure on fluid surface,
Simplify suction line configuration and reduce length.
Decrease fluid temperature - check effect of increased viscosity?
Remake pipework joints
Service fittings
Increase fluid temperature.
Increase motor speed.
Check seal face viscosity limitations.
Decrease fluid temperature
Cool the pump casing.
Reduce fluid temperature .
Check seal face and elastomer temperature limitations.
Heat the pump casing.
Increase fluid temperature.
Clean the system.
Fit strainer to suction line.
If solids cannot be eliminated, consider fitting double mechanical
seals.
Check for obstructions i.e. closed valve.
Service system and change to prevent problem recurring.
Simplify discharge line to decrease pressure.
Increase flush flow rate.
Check that flush fluid flows freely into seal area.
Check alignment of pipes.
Fit flexible pipes or expansion fittings.
Support pipework.
Check rated and duty pressures.
Refer to pump maker.
Fit new components
Lower pump or raise liquid level
Use optional materials
Ensure system operation prevents this.
Fit single or double flushed mechanical seals.
Check and replace motor bearings
Reduce clearance between impeller and back plate/casing
Fit larger size impeller - check motor size
Fit pumping element

Alfa Laval Kolding A/S

P O Box 802
DK-6000 Kolding
Denmark
Tel: +45 79 32 22 00
Fax: +45 79 32 25 80
www.alfalaval.com

Aug 2010