S.A. de C.V.

Problem Solving
Rotary Lobe Pumps

2008
Contents
Page

Section 1.0: Introduction

Introduction to problem solving Positive Displacement pumps 2

Section 2.0: Positive Displacement Pump Problems

Overview of pump problems typically found on Positive Displacement pumps 3
2.1.1 Inspect the entire seal 5
2.1.2 Examine the wear track 6
2.1.3 Examine the faces 7
2.1.4 Signs of heat 10
2.1.5 Inspect the seal drive 10
2.1.6 Check the springs 11
2.1.7 Check the elastomer 12
2.1.8 Check for accidental rubbing 13
2.1.9 External symptoms of seal failure 14

Section 3.0: Typical Problems and their effect on Rotary Lobe Pumps
Detailed look at the most common problems advising causes and solutions 15
3.1.1No Flow 15
3.1.2 Shaft Rotation 15
3.1.3 Excessive Discharge Pressure and/or Change in Fluid Viscosity 15
3.1.4 Inability to Prime 17
3.1.5 Cavitation 18
3.1.6 Gas Content 20
3.2.1 Excessive Discharge Pressure 21
3.3.1 Excessive Temperature and/or Rapid Temperature Change 23
3.4.1 Excessive Noise or Vibration 24
3.5.1Pump Head Contact Summary 25
26
Section 4.0: How correct System Design and Installation can avoid potential
problems
Advises guidelines relating to correct pump installation, system design and pipework 27
layout.
4.1 Pipework 27
4.2 Protection 28
4.3 Operation 28
4.4 Baseplate Foundations 29
4.5 Coupling Alignment 30
4.6 Pre-start up Checks 30

1
1.0 Introduction

Introduction to problem solving Positive Displacement pumps

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 trouble free 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 Positive Displacement pumps are shown herein with
particular effects on our range of rotary lobe pumps.

2
2.0 Positive Displacement Pump Problems

Overview of pumps problems typically found on Positive Displacement Pumps

Typical pump problems include:

• No flow
• Excessive discharge pressure
• Excessive temperature and/or rapid temperature change
• Excessive noise or vibration
• Seal leakage

Typical causes are as follows:

No flow:
• Pump is not primed.
• The drive unit 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).
• A by-pass valve is open.
• Air leak in the suction pipe.
• Air ingress through (Packed) Gland.
• Pumping element is severely worn.
• Failure in drive train.
• No power to the pump.
• Pump speed too high.
• Pumped media viscosity is higher than expected.

Excessive discharge pressure:

• Valves are closed or there is an obstruction in the discharge pipework.
• A strainer of filter is clogged.
• Pumped media viscosity is higher than expected.
• Discharge pressure is higher than calculated.

3
Excessive temperature:
• Too high process temperature.
• Increase in ambient temperature.

Excessive noise or vibration:

• Pump and driver are misaligned.
• Pipework is not properly supported.
• Pumped media viscosity is too high.
• Pump is cavitating.
• Relief valve oscillating.
• Foundation or anchor bolts have become loose.
• Pumphead contact.
• Pump speed too high.
• Gas entrainment.
• Loss of shaft support (bearing failure).
• Pumped media contains unexpected abrasive particles.
• Poor pipework / system design.

Seal leakage (see section 2.1 for further detail):

• 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.

Effect on Positive Displacement Lobe Pumps

Dry Running None, providing gland area is flushed.
Excessive Temperature Pumphead contact
Excessive Discharge Pressure Pumphead seizure
Cavitation Reduced flow, pumphead contact or even erosion
Unexpected Hard Solids Pumphead contact and Jamming

4
2.1 Seal Leakage

Mechanical seals are precision designed and manufactured products, yet one of the most common
causes of failure in Positive Displacement pump types is due to the malfunction of its mechanical seal. 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. under sleeve, behind gasket, along shaft etc.
• 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

2.1.1 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.

5
2.1.2 Examine the wear track

Normal wear pattern

Cause: If leakage is present it is probably due to problems with elastomer
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 and seals. Check shaft is correctly aligned, and check
system pressures and alleviate any pipe strain.

Off center 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.

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.

6
2.1.3 Examine the faces

Cracked ceramic face

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

Thermal shock
Cause: Thermal stress is a common cause of fracture and usually occurs when
the seal face is subjected to rapid temperature change i.e. after pumping hot
media the pump/seal is cleaned with a cold cleaning fluid.
Solution: Replace seals and investigate process and CIP temperature regimes
and change accordingly.

Example of crack in
seal insert caused
by thermal shock

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.

Coating removal
Cause: This is due to incompatibility of the plating or base material with the
pumped media causing chemical attack to part the different materials.
Solution: Replace seals with different seal face material that is compatible with
pumped media from seal manufacturer’s recommendations.

7
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 3.1.4).

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).

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 be
compatible with the pumped media from seal manufacturer’s
recommendations.

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
vaporize 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
and/or an improved carbon grade. Corrosive attack of carbon can be
eliminated by selecting carbons which are relatively binder free upon seal
manufacturer’s advice.

8
 Example of pitting corrosion Example of crevice corrosion on
on stainless steel a stainless steel face

Worn spot in the stationary ring

Cause: This usually occurs on soft face materials such as carbon or stainless steel but can arise in other
materials under severe conditions. The usual cause of failure is a flush line being directed at the static
face causing erosion. If the flush media contains abrasive particles and/or flow rate is excessive, the
effect will be increased.
Solution: Ensure flush is directed tangentially to the seal faces, reduce flush flow rate, eliminate any
abrasive particles from the flush media and change to hard face combination such as silicon carbide.
Fitting a flushed mechanical seal arrangement will alleviate this problem.

An example of seal faces being An example of mechanical seal failure whereby

subject to chemical attack the pumped media has been allowed to solidify
on the seal faces causing leakage.

9
2.1.4 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.

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

An example of a mechanical seal where the seal faces have been allowed to run dry

2.1.5 Inspect the seal drive

Mechanical seal designs all use some method to transmit torque from the shaft to the rotary seal face and
mostly this is achieved by pins or grub screws. Seals are usually loose in torsion, that is, outside the
pump you can twist them slightly before they engage. The pins or grub screws should be inspected for
any signs of wear.

Worn drive dogs or slots

Cause: This can be caused by ‘slip stick’, where the two seal faces will stick together causing excessive
stress on the drive pins. This ‘stress’ is then transferred back to the seal face causing it to accelerate and
then stick again. Instead of a smooth rotary motion, the seal face is being beaten around in its circular

10
path. Slip stick is caused by a lack of face lubrication. The wear can also be the result from vibrations
within the pump and could also be the result from a static face not being fitted squarely to the shaft
causing axial movement of the rotary face.
Solution: Ensure the seal is properly installed as per seal manufacturers fitting instructions. Ensure the
pump operates at specified pressure and/or speed. A single seal with flush or a double seal with a barrier
fluid should be considered ensuring proper lubrication of the seal. Ensure any vibrations are eliminated.

Worn inner diameter of spring retainer

Cause: This can be caused by the grub screws not being properly tightened during installation of seal.
Also extreme shear stress between the seal faces due to pumped media properties has overcome the grip
of the grub screws. The grub screws will show signs of severe wear. This failure is very often combined
with longer periods of non-operation for the pump and poor cleaning cycles.
Solution: Ensure the seal is properly installed as per seal manufacturers fitting instructions. For media
having tacky properties, a single seal with flush or a double seal with a barrier fluid should be considered
ensuring proper lubrication of the seal. Ensure proper cleaning cycle is applied within the process.

2.1.6 Check the springs

Cause: Springs fail usually because of a combination of chemical attack and high stresses. Stress
corrosion can occur for stainless steel springs used in certain pumped media containing either chlorine,
bromine, iodine, fluorine ions or compounds of these elements. The free ions will attack the protecting
chrome oxide layer of the stainless steel and while the oxide layer is being attacked the flaw will open up
small cracks. If the oxide particles wedge into these cracks a sudden failure can occur. Other causes of
failure can be: within single seal configurations where a very small leakage can be detrimental for the
spring as local concentrations will be high. Fatigue, which is the result from repeated load changes
generated by repeated compression/decompression of the spring. This could be the result from a static
face not being fitted squarely to the shaft.
Solution: Ensure the concentration of corrosive elements on the spring is minimised by using either a
single flush or a double seal arrangement. Change spring material to a more corrosion resistant material,
such as Hastelloy. Ensure vibrations within the pump are minimised. Ensure axial movement is within
specification. Ensure the seal is properly installed as per seal manufacturers fitting instructions.

11
2.1.7 Check the elastomers

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
manufacturer’s recommendations.

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 manufacturer’s 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 manufacturer’s 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.

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.

12
2.1.8 Check for accidental rubbing
In a troubleshooting approach it is important to carefully inspect the shaft, seal and seal chamber if
possible, looking for signs of rubbing. For pumps handling high temperature pumped media the rubbing of
parts may only take place when the pump is hot. When cooled, the worn marks may become covered
over and not be as noticeable.
Some causes for accidental rubbing are:

• Flush or barrier fluid pipework entering the seal housing and extending into the seal area itself.
• Housings which do not pilot, slip down and hit the seal.
• Gaskets slip into the seal cavity.
• Rotary or stationary rings which do not pilot and come into contact with the shaft.
• Build up of scale in the seal area.
• Seal area not concentric with the shaft.
• Excessive shaft deflection caused by throttling the discharge or otherwise operating the pump
at its wrong capacity or pressure.

Solution: Ensure the shaft and seal area is per specification by checking with pump/seal manufacturers.
Ensure the seal is properly installed as per seal manufacturers fitting instructions. Ensure operating
conditions as those for which the pump/seal was selected i.e. pressure, speed, temperature and product
details.

Fretting on pump shaft/shaft sleeve

Cause: Fretting corrosion is the result from a constant back and forth movement of the secondary seal
over shaft/shaft sleeve causing permanent damage, appearing pitted or shiny bright. Fretting corrosion is
most common for PTFE (Teflon) secondary seals. This will be the result from axial vibrations or pressure
pulsations.
Solution: Eliminate axial movement of the shaft. Eliminate pressure pulsations. Ensure hardness of
shaft/shaft sleeve is per specification by checking with pump manufacturer. Consider hardening of the
shaft/shaft sleeve for severe applications referring to pump manufacturer.

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2.1.9 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 vaporizing/flashing between the faces.

Seal spits and sputters (popping). Liquid film vaporizing/flashing between the faces.

Seal drips steadily (heavy leakage is Primary:

normally from the faces rather than the Faces not flat.
o- rings). 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.

Seal Hardware:
Spring failure.
Erosion damage.
Seal drips steadily (heavy leakage is normally from the
faces rather than the o-rings)
Corrosion of drive mechanism.

Pump/Shaft Vibration. Shaft misalignment.

Cavitation.
Pump/Shaft Vibration.
Bearing failure.

14
3.0 Typical Problems and their effect on Rotary Lobe Pumps

3.1.1 No Flow
The cause of this problem is normally due any of the following:

• Incorrect direction of shaft rotation.

• Excessive discharge pressure and/or change in fluid viscosity.
• Inability to prime
• Cavitation.
• Gas content.

3.1.2 Shaft Rotation

This although obvious is often overlooked. The direction of flow is dictated by the direction of drive shaft
rotation. Reversing the direction of rotation will reverse the flow direction.

Inlet Outlet

Outlet Inlet Outlet

Outlet Inlet

3.1.3 Excessive Discharge Pressure and/or Change in Fluid Viscosity

Rotary lobe pump performance on low viscosity fluids is greatly affected by excessive discharge pressure
and/or changes in fluid viscosity. This is due to ‘Slip’, defined as the fluid lost by leakage through the
pump clearances. The direction of slip will be from the high pressure to the low pressure side of the pump
i.e. from pump outlet to pump inlet. The amount of slip is dependent upon several factors.

Low pressure High pressure

Inlet Outlet

15
 Clearance Effect
Increased clearances will result in greater slip. The size and shape of the rotor will be a factor in
determining the amount of slip.

Pressure Effect
The amount of slip will increase as pressure increases which is shown below. For a given pump speed
the amount of slip can be seen as the capacity at ‘zero’ bar less the capacity at ‘X’ bar. To overcome this
amount of slip it will be necessary to increase the pump speed to maintain the capacity required.

0.0 bar “x” bar

Capacity 0.0 bar
Required capacity

Slip
Capacity at

Capacity
0.0 bar

“x” bar
Speed
increase to
Actual capacity maintain capacity
At “x” bar
Speed rev/min
Speed rev/min

Viscosity Effect
The amount of slip will decrease as fluid viscosity increases. The effect of viscosity on slip is shown
below. The pressure lines will continue to move towards the ‘zero’ pressure line as the viscosity
increases.

0.0 bar “x” bar 0.0 bar “x” bar 0.0 bar “x” bar
Viscosity = 1 cP Viscosity = 10 cP Viscosity = 50 cP

Req. Req. Req.

Capacity

Capacity Capacity
Capacity

Capacity

Capacity

Speed rev/min Speed rev/min Speed rev/min

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.

16
 Newtonian Fluid Behavior
Typical Newtonian fluids are:

• Water
Viscosity

• Beer
• Hydrocarbons
• Milk
• Mineral Oils
• Resins
Shear rate • Syrups

However, there are many fluids which do not follow this linear law, these fluids are named Non-Newtonian
fluids. Of these, Pseudoplastic fluids can have an affect on pump performance if not taken into
consideration upon initial pump sizing. With Pseudoplastic 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.

Pseudoplastic Fluid Behavior

Typical Pseudoplastic fluids are:

• Blood
Viscosity

• Emulsions
• Gums
• Lotions
• Soap
• Toothpaste
Shear rate • Yeast

Sizing a pump and drive unit on the assumption that a fluid’s ‘at rest’ viscosity is the same as that under
pumping conditions can result in an incorrectly sized pump and drive unit being applied, such that
performance will not be as desired.

For example, a liquid soap can have an ‘at rest’ viscosity of 12000 cP but at the applied shear in a pump
the applicable viscosity can be as low as 50 cP. If the pump was sized based upon the ‘at rest’ viscosity
of 12000 cP, the pump speed would be relatively slow. As the applicable viscosity in the pump is 50 cP,
the result would be the pump not producing the expected design flow rate. Therefore to achieve the flow
rate required it will be necessary to increase the pump speed thereby changing drive unit, or even
replacing pump and drive unit with a larger model.

3.1.4 Inability to Prime

Rotary lobe pumps may be classed as ‘self priming’. This means that within limits, they 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 pump’s priming capability.

17
3.1.5 Cavitation
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 if the fluid
may evaporate generating small vapor bubbles known as ‘vacuoles’. These vacuoles are carried along by
the fluid and implode instantly when they get into areas of higher pressure.

Examples of
small vapor
bubbles

Tri-lobe Rotor Pump Circumferential Piston Pump

For all 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.

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 and drive train. The surface of these components are typically perforated and
pitted as material is eroded by implosive forces.

18
Typical cavitation effect on pump rotor Typical cavitation effect on pump
case cover. rotor case.

Severe cavitation will be evident even after Cavitation can cause damage within the
a short operating period. Blemishes will rotor case as a consequence of shock
appear on the rotor case cover on the loading the shafts. In extreme cases this
discharge side of the pump where can result in the rotor tips making contact
vacuoles implode in the high pressure with the casing as well as material
region. erosion from imploding.
Ultimately this will erode the stainless steel
cover as with the rotor.

Cavitation effect on pump rotor may result in

rotor to rotor contact.

Rotor flank showing effect of typical cavitation

damage where minute particles of the rotor
material are eroded by implosions of vacuoles.

19
Ensuring Sufficient Net Positive Suction Head (NPSH)
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:

How to calculate the NPSHa:

Pressure action on
± Static suction head – Pressure drop – Vapor pressure
surface of liquid

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.

3.1.6 Gas Content

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.

20
3.2.1 Excessive Discharge Pressure
The design concept of the rotary lobe pump is to have no contacting parts in the Pumphead. This requires
having the shaft support bearings to be mounted outside of the Pumphead, which results in an overhung
load, caused by the rotors fitted to the shafts as shown below.

Force due to pressure

Outlet

Rotor
Support bearings

Shaft

Inlet
Overhang
length

The effect of pressure on the rotors will cause shaft deflection, which could result in contact between
rotors, rotor case and rotor case cover. To allow for this pressure effect, clearances are built into the
Pumphead between surfaces that may contact. For the pump ranges there is two rating.

Should the pressure rating be exceeded it is likely that as product wetted parts of the pump ranges are
predominantly manufactured from stainless steel any contact between rotating and stationary parts would
cause ‘galling’ and possible pump seizure.

Due to the positive action of the rotary lobe pump any restriction on the outlet side of the pump, either
partial or total, may result in excessive pressure developing in the Pumphead. To protect pump, drive unit
and also limit pressure build up within associated process equipment it is advisable to install overload
protection such as:

• Fitting an external spring-loaded pressure relief valve to the outlet side of the pump which will
open under high pressure and allow fluid to return to the inlet side of the pump via a by-pass
loop.
• Fit the pump with an integral pressure relief valve.
• Use proprietary electronic devices.

21
Outlet Inlet Outlet

Rotor tip contact will be initially visible on Rotor tip contact will be initially visible on
the discharge side of the rotor case cover the suction side of the rotor case rear
internal face. face.
If overload continues pump is likely to be If overload continues pump is likely to be
damaged beyond repair. damaged beyond repair.

If damaged areas on the rotor case cover, rotors

and rotor case have been polished to attempt
repair, one area is usually forgotten, the inside
diameter of the gland bushing.

Example of rotor galling

22
3.3.1 Excessive Temperature and/or Rapid Temperature Change
Changes in temperature will cause expansion upon heating or contraction upon cooling, to the pump rotor
case and gear case components. The most significant result is the movement between shaft and
gear case / rotor case allowing the rotors to move forward or backward in the rotor case. With the rotors
being allowed to move forward there will be a reduction to the front clearance. To compensate for this, the
pump ranges have increased clearances as shown below.

Rotor case
Rotor
Thermal
Shaft expansion

Standard Increased
clearance clearance
Standard Decreased
rotor width rotor width

Pumps are designed for two rotor temperature ratings, below 120°C (248°F) and over 120°C (248°F). For
the pump range, the design of the mechanical seal eliminates any contact between the fluid being
pumped and the shaft. This results in the shaft not being subjected to the full temperature variation and
therefore only one rotor temperature rating of 120°C (248°F) is necessary. It is imperative during any CIP
operation that pumps are not subjected to rapid temperature changes i.e. hot to cold, as pump seizure
can result from thermal shock.

Here the shafts have contracted at a faster Rear rotor face with signs of rotor case
rate than the rotor case, thereby causing contact, indicative of rapidly decreasing
contact with rear casing face. temperature i.e. thermal shock - hot to cold.

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3.4.1 Excessive Noise or Vibration
Excessive noise and/or vibration can be a symptom of many things such as:

• Cavitation.
• Mechanical damage to pump assembly.
• Misalignment of drive.
• Harmonics with other elements of the system.

Cavitation, as previously described in 3.1.4, is especially true if the discharge pressure is fluctuating or
pulsating.

Mechanical causes of noise and vibration can include:

• Shaft misalignment.
• Loose couplings.
• Loose pump and/or driver mountings.
• Loose pump and/or driver guards.
• Worn or damaged pump driver.
• Worn pump bearings.
• Valve noise seemingly coming from the pump.

Valves, especially on the discharge side of the pump can sometimes go into a hydraulic vibration mode
caused by operating pressure, flow rate and the valve design. Resetting or a change in an internal valve
component is usually sufficient to solve the problem.

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3.5.1 Pump Head Contact Summary
For successful pump operation, rotary lobe pumps should operate without any contact of pump head
components. Should contact occur, consideration should be given as to the position the rotor has had to
move with respect to the rotor case, rotor case cover and/or other rotor to create the mark pattern as
shown below. Also noted should be the factors that could have induced this relative movement i.e.
pressure, temperature, shaft movement, casing movement, etc.

Rotor case

Suction Discharge

Rotor

Examples of ‘galling’ caused by initial hard solid passing through pump

Example of corrosion on Example of corrosion on Example of corrosion on

pump rotor. pump rotor case port. pump rotor case cover.

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Contact Marks Possible Cause Possible Cause

Rotor and rotor case cover (full face). High temperature and/or rapid temperature
increase.
Loss of axial shaft retention.
Loss of rotor retention.
Insufficient front clearance.

Rotor and bottom of rotor case (full face). Rapid temperature decrease.
Loss of axial shaft retention.
Insufficient back clearance.

Rotor case cover (discharge side), rotor case (inlet side High pressure.
on back face and bore) and rotor (tips tapering front to
back and front and back face outer diameter).

Rotor (all lobes on same flank). Loss of timing.

Rotor (all lobes on both flanks and some tips) and rotor Cavitation.
case (corresponding with rotor tip marks).

Rotor case (bore and back face, more severe at outer Abrasive pumped media.
diameter) and rotor (tips and front and back face).

Rotor (indentation in profile, in or near mesh). Large hard solid.

Rotor case (indentation in bore). Large or hard solid.

All product wetted surfaces (deterioration of surface). Corrosion.

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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. Other factors such as base plate mounting, coupling alignment and pre-start up checks should
also be noted.

4.1.1 Pipework
• Have short straight inlet pipework. 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. This will minimize pressure losses and/or turbulence in the pipework.
• Keep pipework horizontal where applicable. 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 3.1.4). This is crucial for ensuring the smooth operation of the pump and preventing
cavitation.
• Avoid suction lifts and manifold/common suction lines for two rotary lobe pumps running in parallel. This
will prevent vibration or cavitation.
• Include eccentric reducers on suction lines. This will minimize pressure losses and/or turbulence in the
pipework.
• Avoid the use of blind tees. This will avoid pressure pulsing and thereby noise and possible pump
damage.
• Include for seal flushing pipework and/or Plane “Z”

media for heating/cooling jackets and saddles. Plane “X”

This will ensure satisfactory seal operation
and/or maintain pumped media temperature in
Pumphead.
• All pipework must be supported. The pump
must not be allowed to support any of the
pipework weight and the moments and forces
Plane “Y”
attributed to each particular pump should be
taken into consideration.

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 Example of a poor pump installation, not adhering too many of the considerations advised

4.2.1 Protection
• Protect the pump against blockage from hard solid objects e.g. nuts, bolts, welding slag etc. This will
prevent possibility of Pumphead seizure.
• Protect the pump from accidental operation against a closed valve by using relief valves, pressure
switches or current limiting devices. This will prevent over pressurization.
• Ensure any automated valve systems do not permit directional switching valves to close or partially
close. This will avoid ‘dead heading’ the pump on discharge.
• Fit valves, if two pumps are to be used on manifold/common discharge lines. This will prevent over
pressurization.
• Fit suction and discharge monitoring devices. This will assist in any diagnostics.
• Include for monitoring equipment in ATEX defined hazardous areas if applicable. This will ensure safety
with monitoring of seal temperature, pressure and flow.

4.3.1 Operation
• Do not subject rotary lobe pumps to rapid temperature changes. This will prevent thermal shock and
possible Pumphead seizure.
• Ensure pumped media is maintained at the correct temperature. This will avoid dramatic increase in
viscosity leading to possible over pressurization and/or cavitation.
• Try to allow at least 1 m for pump access. This will ease maintenance all round the pump.
• Ensure fluid flow velocity is sufficient. This will avoid pumped media settling out, thereby restricting flow
and increasing pressure.

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 Example of a poor installation showing
a short radius bend fitted directly on to
the pump discharge connection.

Good engineering practice would

dictate to position the bend at least 10
pipe diameters away from the pump
discharge connection.

4.4.1 Baseplate Foundations

Pumps when supplied with a drive unit are normally mounted on a base plate which have pre-drilled fixing
holes to accept base retaining bolts. To provide a permanent rigid support for securing the pump unit, a
foundation is required which will also absorb vibration, strain or shock on the pumping unit. Methods of
anchoring the base plate to the foundation are varied, they can be studs embedded in the concrete either
at the pouring stage as shown below, or by use of epoxy type grouts. Alternatively mechanical fixings can
be used.

Waste put around bolt Foundation surface The foundation should be

Before pouring concrete left rough to
anchor grout approximately 150 mm longer and
wider than the base plate. The depth
of the foundation should be
proportional to the size of the complete
10 D pump unit. For example, a large pump
One D
min. Sleeve unit foundation depth should be at
3D
least 20 times the diameter of the
Lug
1/2 D welded
foundation bolts.
min. To bolt head
4D

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The drawing above shows two typical methods for foundation bolt retaining. The sleeve allows for ‘slight’
lateral movement of the bolts after the foundation is poured. Rag or waste paper can be used to prevent
the concrete from entering the sleeve while the foundation is poured. A minimum of 14 days is normally
required to allow the curing of the concrete prior to pump unit installation.

4.5.1 Coupling Alignment

Before the pump unit is installed it is important to ensure that the mounting surface is flat to avoid
distortion of the base plate, which may cause pump/motor shaft misalignment and pump/motor unit
damage.

Parallel misalignment
Once the base plate has been secured, the pump shaft to motor shaft
coupling alignment should be checked and adjusted as necessary.
This is achieved by checking the maximum angular and parallel
Angular misalignment
allowable misalignments for the couplings as stated by the coupling
manufacturer.

4.6 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 pump and drive lubrication levels are correct.
• Check that seal flushing is connected if applicable.
• Check that all valves in the system are open.
• Check that all safety guards are in place.
• Check that pumped media is flowing in correct direction by starting and stopping pump.

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