If you use a follower pump, you likely have encountered some of these problems at some point. Fortunately, they can be easily fixed with some simple maintenance.
When feeding high viscosity grease or other fluids from drums, it is important to utilize a follower plate. This plate closes tight to the barrel wall by a soft sealing lip and lowers slowly.
1. Leakage
Leakage problems are generally caused by faulty packing. It is recommended that you always remove the old packing from your pump unit, and never add a new layer of material.
Some leakage problems are caused by poor lubrication, which is why you should always check the lubrication system before you start any repair process. This will help you determine whether the problem is due to packing or a problem with the seals.
A good lubrication system will prevent friction between the gland and shaft. This will reduce the amount of heat created, which helps maintain the correct leakage rate.
However, if you are not sure of the lubrication system, you should contact the manufacturer of your equipment for more information. This will help you to determine what the cause of your pump’s leakage is.
Packing failure can also result in other issues such as smoke inside the stuffing box, protrusions from the packing and even brittle packing. If the packing is brittle, it will not be tight against the follower, which can lead to further trouble with the gland.
Mechanical seals are another option, but they can be costly and labor-intensive to change out. Their fragile nature makes them less desirable than compression packing.
If the pumped medium has too much abrasive content or harsh chemicals, it can wear down a seal faster than it should. A pump seal will also not perform as well if it is exposed to too much mechanical stress, such as if you frequently need to take your pump apart for cleaning or if the pressure or temperature around the seal is changing.
The most common solution to this issue is to replace the packing in your pump. Using the proper packing will help to prevent leakages and keep your pump running smoothly for years to come.
2. Noise
The good news is that most pump noise problems can be solved without too much fuss. In fact, many of them can even be avoided with proper maintenance.
The best way to tackle noisy pumps is by first identifying the cause of the problem. For example, if the problem is excessive noise in the suction line of your pump, reducing the flow to the impeller from the main pumping line could reduce the vibration that produces that sound.
If the problem is in the discharge line, resetting a valve or replacing the part that enables a high-speed reversal of a flow can also be effective noise-reducing measures. If the problem is in the pump itself, an ultrasonic listening device or a mechanic’s stethoscope can help you discover the source of the noise.
In most cases, the hum worm is more likely to be caused by overheating. A good thermostat will prevent the pump from overheating and causing damage to its components.
If you aren’t sure what the aforementioned hum worm might be, ask your pump dealer for a free pump inspection. This will allow you to determine the root of the problem so you can get back to the business of operating your process system efficiently. Then you can start addressing the other problems mentioned above to keep your facility running smoothly. Remember, the most important thing is to do it right the first time so you can save money in the long run. Hopefully, these troubleshooting tips will make you a pro at solving the most common pump problems.
3. Overheating
Overheating is a serious issue that can cause a pump to malfunction and result in costly repairs or replacements. To prevent ปั้มไลค์ from happening, it is important to understand the warning signs of overheating and act quickly.
The best way to determine if your pump is overheating is to check its thermostat. If it is set too high, you may need to reset it.
Also, check for any leaks in the cooling system. If you have a leaking coolant tank, you should drain the tank as soon as possible and replace it with fresh coolant.
Another potential culprit is a clogged filter. This can lead to a build-up of dirt which can also cause overheating.
Aside from the usual filter cleaning and replacement, you can also use a multimeter to test the actual voltage of your power source. If the reading on your meter is higher than you think it should be, it may be time to upgrade your wiring.
Finally, consider checking your pump’s bearings to see if they are overheating or not. If the bearings are overheating, they can wear down and result in a failure.
The most common causes of overheating include lack of lubrication, poor bearing design and debris in the oil. Keeping the bearings clean will help to prevent this from occurring.
Using a proper oil pump can significantly reduce the chances of overheating your pumps. This can save you money on your water bill and keep your pool looking its best. It is also important to have your pump serviced on a regular basis to make sure that it is running at peak performance. If you are not comfortable doing the maintenance yourself, it is always best to hire a professional.
4. Damaged Shaft
When pump shafts are damaged, they can cause problems in the rotating equipment that they power. This can be caused by a variety of factors, including vibration, abrasion and corrosion. In the mining industry, gland packing and bushing damage can also be a factor.
When the shaft becomes worn, it can result in problems such as overheating or overpressure. These problems can also lead to leakage or damage to the pump’s bearings.
To solve the problem, you must first identify what is causing the shaft to wear prematurely. This will allow you to replace the damaged parts and re-pack the system.
You can do this by inspecting the old rings and checking the stuffing box, shaft sleeve and throat bushing for wear or damage. If there is raggedness or shredding on the inside surface of the rings, you probably have improper alignment of the shaft and a bad rod or plunger.
If you see evidence of extrusion between the rod or shaft and the gland follower, you may have too much gland bolt pressure used to seal the gland box. You can remedy this by installing a bull ring or anti-extrusion ring to reduce clearance between the rod or shaft and the follower.
If you notice any of the above clues, you need to take action. If you don’t address these problems, the dredge will continue to experience DPPGA and your repair costs and production losses will continue to increase.
5. Damaged Bearings
A pump’s bearings are essential machinery components, protecting the moving shaft from wear and damage. They also need to be lubricated in order to prevent friction. In some cases, however, a lack of lubrication can lead to premature failures.
When replacing a bearing, it’s important to be sure to use the correct type and size for the application. For example, a roller-ball bearing that’s dimensionally the same as a deep groove bearing may not fit properly and will quickly fail.
Other factors that can contribute to damage include vibration, overloading and electrical current. Vibration can lead to a buildup of false brinelling on the bearing races, which will eventually cause bearing failure.
To solve this issue, you can either use a vibration absorber or shim the shaft so any contact is spread across the bearing surface. Alternatively, you can use a radially locking ring to lock the non-drive end of the shaft.
Plastic bushings are a common off-the-shelf option for reducing vibration in pumps and other equipment, but they can actually crack under heavy loads. This can lead to part damage and increase the friction between mating parts, which can also reduce the life of the bushing.
Both oil/grease lubricated and self-lubricating plastic bushings can fail in extreme situations. For instance, grease/oil lubricated bushings can carbonize at high temperatures and expand rapidly, causing the shaft to seize or necessitate large clearances. Meanwhile, plastic bushings can also melt or deform at high temperatures, increasing the risk of fire. In addition, if a plastic bushing misaligns during assembly, it can increase the friction between the bearing and the mating parts. These factors can lead to premature bearing failure and costly repairs.