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What You Need to Know About Pump Repair

A pump is a mechanical device used to move fluids (such as liquids, gases, or slurries) from one place to another by mechanical action. Pumps can be classified based on their method of displacement into positive displacement pumps, impulse pumps, velocity pumps, gravity pumps, steam pumps, and valveless pumps.

Pumps serve various purposes in the residential, commercial, and industrial settings. For example, they are used to pump water from the basement of a building to each apartment or hotel room bathroom. They are used to circulate coolant in cars and water in HVAC systems.Pumps are also used to drain flood areas or to pump chemical and oil in plants.

Pumps, along with electric motors, comprise two of the most widely used industrial components; and failure of either can bring operations to a halt. With pumps having a direct impact not only in the industrial world, but also in our homes and offices, it's easy to understand why maintenance is essential.

So, what causes pump failure? A lot of factors. Let’s take a look.

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Types of Pump Failure  

Pump failures can occur for various reasons. Here are some of the common causes:

  1. Cavitation: This occurs when the liquid being pumped begins to vaporize due to a drop in pressure. The vapor bubbles collapse when they reach areas of higher pressure, which can lead to intense shock waves that can damage the pump's impellers and casing.

  2. Wear and Tear: Normal wear and tear can lead to reduced pump efficiency. This is particularly common in pumps that handle abrasive materials.

  3. Corrosion: Pumps that handle corrosive liquids can experience premature wear and damage if they are not adequately protected.

  4. Improper Operation: Running the pump dry, operating outside the recommended flow range, or frequent starting and stopping can lead to premature failure.

  5. Electrical Failures: Issues like phase imbalance, under/over voltage conditions, or incorrect electrical connections can cause motor failures.

  6. Mechanical Seal Failure: Mechanical seals prevent liquid from leaking out of the pump. If they fail, this can lead to leaks and pump failure.

  7. Bearing Failures: Bearings support the rotating components of the pump. Improper lubrication, misalignment, or contaminated lubricant can cause these to fail.

  8. Misalignment: If the pump and motor are not aligned correctly, it can cause excessive vibration and wear, leading to pump failure.

  9. Blocked or Restricted Suction: If the pump's suction line is blocked or restricted, the pump can become starved of liquid, leading to cavitation and potential damage.

  10. Temperature Extremes: Operating a pump beyond its specified temperature range can damage components and reduce efficiency.

  11. Improper Installation: This can lead to a range of problems, including vibration, misalignment, and reduced efficiency.

  12. Impeller Damage: The impeller is a crucial component that drives the liquid. Damage or wear to this component can reduce efficiency and potentially cause the pump to fail.

  13. Operational Errors: Filling the pump with the wrong fluid, operating at the wrong speed, or not following maintenance schedules can all lead to pump failures.

  14. Design Flaws: If the pump is not designed appropriately for its application, it might not perform efficiently and could fail prematurely.

  15. Lack of Maintenance: Regular maintenance, including inspection, cleaning, and part replacements, is crucial to extend the life of the pump. Neglect can result in reduced performance and eventual failure.

Addressing these issues promptly and ensuring regular maintenance checks can extend the life of a pump and prevent unnecessary downtime.

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Signs That a Pump Needs Repair

Ensuring a pump operates efficiently and recognizing signs that it may need service is crucial for system reliability and longevity.

Here are signs that a pump may require service: 

  • Decreased Flow Rate: A significant drop in the pump's flow rate might be due to impeller damage, a clogged filter or strainer, or other obstructions.

  • Increased Power Consumption: If the pump is consuming more power without a corresponding increase in load, it could be a sign of inefficiencies or potential faults.

  • Unusual Noises: Grinding, rattling, knocking, or squealing sounds can be indicators of cavitation, bearing problems, misalignment, or other mechanical issues.

  • Excessive Vibration: Increased vibration can result from misalignment, cavitation, worn bearings, or an imbalance in the rotating parts.

  • Overheating: Overheating in the pump or its motor can be due to friction from misalignment, a failing bearing, inadequate cooling, or insufficient lubrication.

  • Visible Leaks: Leaks, especially around seals and gaskets, signify that the pump needs attention. Seal failures are a common source of leaks.

  • Erratic Pressure Readings: Fluctuating or inconsistent pressure readings might indicate cavitation, issues with the pump's control system, or air entrainment.

  • Operational Irregularities: If the pump trips often, fails to start, or exhibits other irregular behaviors, there might be electrical or mechanical problems to address.

  • Visible Damage: Any evident damage like cracks, wear, or corrosion on the pump housing or impeller needs attention.

  • Increased Maintenance Frequency: If the pump requires frequent minor repairs or replacements, it might have a more significant underlying issue.

  • Age of the Pump: Older pumps might require more frequent servicing or may not operate as efficiently as newer models.

  • Air in the System: If there's evidence of air bubbles or air locks, it may indicate issues with the pump's suction or sealing.

  • Dirty or Contaminated Fluid: If the fluid appears unclean, has an odd smell, or there's evidence of contamination, it might suggest that the pump isn't filtering effectively or there's an upstream issue.

  • Sudden Changes in System Demand: Significant changes in the demand on the pump system (like adding new equipment) could mean the pump needs adjustment or servicing to meet the new requirements.

  • Regular Maintenance Schedule: Even if no immediate problems are evident, regular maintenance checks are vital to ensure optimal performance and prolong the pump's lifespan.

If you observe any of these signs, it's advisable to consult Square One technicians to determine the specific issue and get recommendations for corrective measures.

Preventative Pump Maintenance is Your Safe Bet

Preventative maintenance is essential for ensuring the prolonged operational life, efficiency, and reliability of pumps. By adhering to a regular maintenance schedule, potential issues can be identified and addressed before they lead to major failures or expensive repairs.

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Here are ways to perform preventative pump maintenance:

  • Routine Inspection: Regularly check the pump and its components for signs of wear, damage, leaks, or corrosion.

  • Check Lubrication: Ensure that bearings are adequately lubricated. Replace old or contaminated lubricant and use the recommended type and quantity.

  • Monitor Temperature: Most pumps have an optimal operating temperature range. Continuously monitor the pump's temperature and investigate any unexpected changes.

  • Monitor Vibration: Excessive vibration can indicate problems like misalignment, imbalance, or wear. Regularly check the pump's vibration levels using appropriate equipment.

  • Seal Inspection: Inspect mechanical seals and packing for wear and damage. Replace them when necessary to prevent leaks.

  • Impeller Adjustment: Ensure the impeller is correctly positioned within the casing for optimal performance.

  • Check Alignment: Regularly check and correct the alignment between the pump and its drive motor. Misalignment can lead to premature wear and inefficiencies.

  • Clean Strainers and Filters: Strainers and filters prevent large debris from entering the pump. Regularly clean and replace them to ensure free flow and protect the pump from damage.

  • Inspect Electrical Components: Check starters, motors, and other electrical components for signs of wear, damage, or corrosion. Ensure that electrical connections are tight.

  • Calibrate Instruments: Ensure that instruments like pressure gauges, flow meters, and temperature sensors are calibrated and functioning correctly.

  • Inspect Belts and Couplings: Check for wear, cracks, or stretching, and adjust or replace as necessary.

  • Bolt and Fastener Inspection: Check all bolts and fasteners to ensure they're tight and in good condition. Loose or damaged fasteners can lead to leaks or misalignment.

  • Maintain System Records: Maintain a log of all maintenance activities, including replacements, adjustments, and any issues observed. This helps in predicting potential problems and planning for parts replacement.

  • Flush and Clean: Depending on the type of fluid being pumped and the specific pump, it may be necessary to periodically flush and clean the pump internals to remove debris, scaling, or chemical buildup.

  • Test Safety Systems: Regularly test safety systems like pressure relief valves and thermal overload protection to ensure they function correctly.

  • Operational Parameters: Regularly record and monitor parameters like flow rate, discharge pressure, and power consumption. Any significant deviations from expected values can be a sign of developing problems.

  • Training: Ensure that operators and maintenance personnel are adequately trained and familiar with the pump's operation, maintenance procedures, and potential issues.

  • Regularly Review Manufacturer Recommendations: Always consult the pump's user manual or manufacturer's recommendations regarding maintenance intervals and procedures.

By investing time and effort into a comprehensive preventative maintenance program, the lifespan of pumps can be significantly extended, and costly unplanned downtimes can be minimized.

Square One Electric Motors & Pumps can perform your pump maintenance either on-call or with routinely scheduled PM. Contact Us for a Quote.

Square One Electric Motor & Pump Repair Shop

Whether your end goal is pump repair or maintenance, you need professionals that you can rely on. At Square One Electric Motors and Pumps, we inspect your pump for any damages and identify underlying causes to provide you with the best solution possible.  

From preventative maintenance to repair, our highly experienced team of technicians can take care of it all, starting with a diagnosis of the issue and ending with getting your pump system up and running again. Click here for more tips to keep your pumps running smoothly and efficiently.  

We work with all the makes and models of industrial and commercial pumps, pump motors from small electric motors to single phase motors and three phase motors and pump controls (VFDs). We specialize in working with brands like Peerless, Flygt, ITT, Xylem, Goulds, US, Bell & Gosset, Barnes, Paco, Sta-Rite, Grundfos, Wilo, and others. 

For every consultation, you will get a quote for repair versus replacement so you can make an informed decision.  Our repair shop is open 24/7 for emergency breakdowns. When you think of Square One, think reliability, quality, and fast turnaround time!

You can choose from the following selection of Pump Repair Services: 

  • Equipment Monitoring and Vibration Analysis
  • Field Service 
  • Laser Shaft Alignment 
  • Impeller Balancing  
  • Emergency Breakdowns 
  • Removal, Installation, and Start-up 
  • Troubleshooting 
  • VFD Services 
  • Machining: impeller trim; rebowling; volute repair; coupling boring and key slotting; surface grinding  
  • Fabrication: brass bushings; spacers; shafts; sleeves; wear/case rings 

Our Team is qualified to perform repairs on the following types of pumps:  

  • Submersible Electric Motors
  • Centrifugal
  • Wastewater / Sewage
  • Split Case
  • Industrial / Manufacturing Processes
  • Carbonator
  • Grinder
  • Vertical
  • Booster
  • Chemical Feed
  • Fire
  • Hot Water Circulators
  • Dewatering Sump Pumps
  • Pool Pump Motor and Spa Motor

We also undertake regular pump maintenance services and offer routine pump maintenance plans that you can choose from. No matter what the issue with your pumps, turn to Square One Electric for guaranteed solutions. Call Us Today at (302) 678-0400

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