Interpreting a pump failure

That which remains after a failure explains much to a discerning observer

By Ed Nelson

Taken From Pumping Technology (July 1999)

A poorly performing pump frequently exhibits both hydraulic and mechanical

problems and one must distinguish between the two. Examining even these smallest of
details is the key to establishing and effective long-term solution. In my last two columns
in this magazine, I discussed the importance of a structurally sound impeller design and
the proper radial and axial dimensional positioning of the pump rotor in the casing. Now,
it is appropriate to discuss interpreting some of the signs or clues a pump failure leaves
behind.

Component failures
A failure of the impeller shrouds or the
casing volute (diffuser) tongues, such as
those shown in Figures 1 and 2, might
suggest a need for a search for a new
alloy for the casing. In reality, this is not
the case. Because the origin of both of
these failure is hydraulic in nature,
metallurgical changes to the impeller or
casing will offer only minimal
improvements. These failures are caused
by interactions between the rotating
impellers, the stationary casing and the moving fluid. Liquid flow in the internal channels
of a centrifugal pump impeller and casing is a complex phenomenon, especially at off-
design conditions. Flow disturbances related to suction recirculation, discharge
recirculation and cavitation are always present in both diffuser- and volute- type pumps.
The internal flow is unstable and unsteady, with violent pressure changes sometimes
occurring from one liquid channel to the next liquid channel of the impeller as shown in
Figure 3. The outer tip of an
impeller blade experiences
severe pressure pulsation as it
passes loaded vanes of volute
tongues or diffuser tips.
These pressure
pulsations may represent as
much as 20 percent of the total
head at a frequency of between
1 and 10 Hz-frequencies below
6 Hz are the most common. The outside of the impeller does not feel the same
instantaneous pressures, which can lead to shroud bulging or fatigue breakage. Low
frequency hydraulic pulsations may cause fracture-type failure of the shrouds or covers of
the impeller. An impeller failure may occur after
only a few hours of operation at lower flows or it
can take several months for the fatigue mechanism
to take place. The pulsations caused the failures
shown in Figures 1 and 2.

Pressure pulsations
Flow disturbances related to suction recirculation,
discharge recirculation and cavitation are always
present in both diffuser and volute type pumps. The
liquid recirculates within the impeller and the
casing hydraulic channels, which offers suspended
particles in the fluid an opportunity to strike the
cane surfaces a number of times before finally
being discharged. This turbulent flow results in
development of stall, a lower pressure pocket that
promotes volute- or diffuser-tip fatigue breakage (see Figure 4). This highly disturbed
flow is much more common than previously thought.
This pump is trying to tell us something. Inadequate radial clearance (see Figure5)
between the outside diameter of the
impeller vane and volute tongue is the
cause of the broken volute tongue. The
first reaction of many pump repair
facilities would be to weld the broken
volute section. The best repair, however,
is to cut back and equal distance and
keep the tips 180 degrees apart.
If the impeller has been trimmed,
the flow distribution across the exit width
of the impeller becomes even more
unstable. Trimming greatly increases the
tendency for the high-pressure liquid to
return to the low-pressure side of the vane and create tip recirculation. Frequently, the
impeller will also be cracked at the outer diameter near the point that the non-pushing
side of a blade joins the shroud plates. This is an area of lower fluid velocity and pressure
as compared with the pushing side of a blade.

Corrections for pressure pulsations

Careful machining of the colure or diffuser tips to increase the gap between the impeller
vane tip and the volute tongue or diffuser vane-while maintaining gap “A”-had been used
for a number of years to reduce greatly the vane-passing frequency vibration. The
pulsating hydraulic forces acting on the impeller can be reduced 80 to 85 percent by
increasing the radial impeller-volute gap from one to six percent. There is no loss of
overall pump efficiency when the diffuser or volute inlet tips are recessed. In fact, a slight
efficiency improvement results from the reduction of various energy-consuming
phenomena: the high noise level, shock, vibration caused by vane-passing frequency and
the stall generated at the diffuser inlet.
If attention is not paid to certain
details during the initial design and
installation, then overall reliability of the
pumping system will be reduced. Analysis
and correction of the basic problems can be
difficult after installation. Careful evaluation
of any signs of basic causes of failures
during repairs becomes vital.