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Some problems arise with greater frequency than others. By understanding how and why, preventative measures can
be applied to reduce productivity loss, maintenance costs and operator frustration.
The ability of hydraulic diaphragm metering pumps to inject precise, controlled amounts of chemicals under
pressure makes them particularly well-suited to a wide variety of process control applications. Keeping these pumps
up and running efficiently demands careful attention to proper installation and maintenance procedures.
LOCATION LOGIC:
One of the first decisions faced by pump users is where to locate the pump. This may seem like a very simple
matter, but all too often its where many pump problems begin. An ill-considered placement, where the pump
is exposed to extreme temperature conditions, or too far from the supply vessel, can be the source of
considerable trouble down the road.
System discharge pressure greater than pump internal relief valve setting
Starved suction
Pumps properly installed with piping fully supported prevents stress on component connections. The installation of
unions will help simplify pump servicing to the supply vessel as practical, to help minimize friction loss in the
suction piping.
Clean or replace (suction line was not flushed prior to making connection to pump, permitting solids or
debris such as pipe sealant, tape, etc. to enter and block check valves)
Insufficient NPSH. Shorten suction piping, increase suction piping size or suction head.
Probable Cause
Remedies
Solution: The service technician discovered that the installation contractor had removed the pumps! actuators from
factory-supplied baseplates, resulting in serious misalignment problems.
SUCTION PIPING
Nearly 85% of all metering pump operating problems can be directly attributed to suction difficulties, either because
of undersized suction piping or due to blockage and/or restrictions in the suction line.
Probable Cause
Remedies
Clean strainer
Repair piping
Probable Cause
Open circuit in limit switches, timers or other control devices in pump motor starter circuit
Motor damage
Remedies
Reset after correcting cause of overload. If malfunction recurs, check heater size
Determine cause and correct
Reset
Probable Cause
Remedies
Clean or replace
Clean line
Open valve
Probable Cause
Starved suction
Internal or external relief valve set too low for system conditions and is relieving
Remedies
Internal Failures
Internal fault can be generally identified by the working pressure and temperature monitoring. Seeing many of the
mechanical failures can be diagnosed by voice and touch, and without the need for any special equipment.
Electrical Faults
Refrigerant causing a malfunction in the cooling plants use the system in question is the three effects.
There is insufficient level of refrigerant in the system. (Less loading)
If you have excessive amounts of refrigerant in the system (overload)
Refrigerant; oil contaminated with moisture in the air and other gases.
Condenser high temperature, the amount of not less Congestion occurring in the water system is
cleaned.
Calcification of the condenser pipe, deterioration of water Pipes are cleaned, repaired water
distributing system distributing system.
The collection of condensed refrigerant in the condenser Learn more liquid collected in the
condenser.
Lack of compressor outlet valve fully open Said valve is fully opened.
2. Low oil level. Check oil level. Replace your oil if necessary
Excessive noise in 1. Loose pulley, flywheel, belt, belt Tighten any loose ends.
operation. guard, cooler, clamps or
accessories.
3. Piston hitting the valve plate. Remove the compressor cylinder head and inspect for
foreign matter on top of the piston. Add a new gasket
and reassemble the head.
4. Compressor floor mounting Tighten the bolts on the air compressor. It may also be
loose. a good idea to replace your vibration pads
Milky oil in oil 1. Water entering oil reservoir due a. Pipe air intake to less humid air source.
reservoir. to compressor operating in high
humidity environment.
4. Wrong oil viscosity. Drain oil, refill with oil of proper viscosity.
5. Compressor tilted too much. Level compressor. Vibration pads may help with this