Pump failure is not an option.
You know that. We know that. But do you know how to catch the subtle symptoms of impending pump system failure?
Increased vibration or heat levels, changes in sound, uneven flow readings, and leaks signify emerging issues. Catching these early warnings allows maintenance teams to diagnose and correct problems through proactive maintenance before catastrophic breakdowns occur. Proactively identifying these issues prevent the safety risks and costs of unplanned pump failures. Technicians who regularly monitor parameters such as vibration, noise, and temperature can reliably forecast maintenance needs and head off unexpected outages.
Let’s break down the top five symptoms that can help you identify impending pump failure.
1. Vibration
Positive displacement pumps naturally vibrate during normal operation as fluid flow accelerates and decelerates through the pump’s chambers. Excessive vibration, however, can escalate to dangerous levels that threaten the pump and system.
Excessive vibration is often caused by pulsations within the pump and pipes. These pressure spikes fatigue components and loosen pipe supports. Left unaddressed, excessive vibration can lead to failures of pipes, valves, gaskets, and other parts.
Warning signs of problematic vibration include:
- Shaking, swaying, or rattling of pipes
- Loud, undiagnosed banging or noise from pipes
- Loosening of pipe supports and fittings
Addressing excessive vibration will minimize system risks. This may involve installing surge suppressors, pulsation dampeners, or modifying system design.
By correcting excessive vibration issues proactively, costly component damage, leaks, and unplanned downtime can be avoided.
2. Unexpected Pump Noises
Industrial pumps emit noise during normal operation, but experienced technicians know to listen to abnormal sound. New or unusual noises often indicate emerging problems.
For example, high-pitched whining can signal cavitation - when inadequate inlet flow starves the pump. Knocking or banging noises may result from obstructed flow or component damage. Without correction, these issues accelerate wear and risk sudden failure.
By tuning your ear to the characteristic sounds of your pumps, odd noises act as an early alert. Diagnosing and addressing the root cause can prevent unexpected failures and downtime. Whether it's cavitation, blocked flow, or loose parts, abnormal pump noises should prompt further investigation.
Listening to your pumps gives advanced notice to head off catastrophic breakdowns. Taking the time to decode noises and respond to their warnings keeps operations humming.
3. Uneven Flow
Even without obvious vibration, pressure pulsations, or water hammer, within pump systems inflict damage.
Excessive pulsation manifests through:
- Inaccurate flow rate readings
- Irregular pressure and flow
- Fluctuating pressure displays
These symptoms reveal harmful underlying pressure variations. Though not as apparent as vibration, pulsation still sabotages components, accuracy, and control.
4. Component Fatigue
Premature component failures reveal underlying issues. The results can be significant:
- Damaged valves, gauges, and regulators from harsh hydraulic forces.
- Ruptured piping, seals, and gaskets fatigued by spikes.
- Worn pump diaphragms weakened by repeated flexing.
- While replacing individual parts is straightforward, recurrence signals a deeper problem.
Addressing the underlying sources is essential to preventing component fatigue and failure cascades.
Don't just replace worn components, diagnose what is wearing them out. Correcting pulsation results in lasting reliability.
5. Process Fluid Splashing, Foaming, or Spillage
Foaming or splashing of pumped fluids indicates an issue exists within the pump or piping system. Depending on the application, agitation degrades process quality and risks equipment damage.
For example, splashing ruins uniform coatings, while foaming introduces problematic air into systems. Expanding batch tanks only temporarily masks these symptoms.
The root causes of fluid agitation include:
- Cavitation from inadequate inlet pressure
- Surging from uncontrolled acceleration
- Pulsation from system design flaws
Correcting these underlying issues, rather than just expanding tanks, resolves splashing and foaming at their source. This restores smooth, quiet fluid flow and high-quality outcomes.
Don't ignore agitated fluids - they reveal deficiencies requiring attention to restore proper operation.
What's Causing These Symptoms?
If you’re regularly seeing the above symptoms, you are most likely experiencing pulsation, surge, cavitation, and possibly water hammer in your pump system.
These symptoms can be caused by a range of issues including:
- Positive displacement pumps with high amplitude/low-frequency pulses
- Rapid acceleration or deceleration of fluid
- Acceleration head loss at the pump inlet
- Rapid pump startup or shutdown
- Quick closing valves
- Fast-acting, worn, or improperly used valves
- Pump ramp-up speed and power
These are all common issues for positive displacement pumps, but you can correct them. Instead of leaving the resulting pressure spikes unchecked, work with Blacoh to minimize the damage and chance of failure.
How Blacoh Can Help You Minimize Pump System Damage
Blacoh knows pump failure is not an option.
Which is why we offer a simple but effective solution for positive displacement pump flow and pressure issues: pulsation dampeners.
These vessels act as shock absorbers for your pump system, accumulating and releasing process fluid as needed to reduce the rate of fluid velocity change. When you install a dampener, you can expect:
- Smooth and consistent fluid flow
- Pumps, piping, valves, fittings, and components protected from damaging vibrations and fatigue
- Improved accuracy and longevity of flow meters, pressure gauges, and other inline instrumentation
- Uniform and continuous flow in spraying and coating processes
- Minimized acceleration head loss
- Reduced risk of cavitation
- Protection from destructive water hammer caused by quick-closing valves or pump startup/shutdown
- Improved pump performance, efficiency, and lifespan
This means less downtime, fewer failures, and improved safety for your team and community.
Interested to hear more about the physics behind water hammer and how Blacoh’s fluid control solutions can reduce its effects?
Click here to watch our Surge Vessels webinar.
Click here to watch our Demystifying Water Hammer webinar.
Click here to watch our Transient Monitoring webinar.