1100 Startup and Troubleshooting

Abstract
This section contains a pump startup checklist and troubleshooting guides. Informa-
tion on troubleshooting mechanical seal problems is included in Section 800.
Although some references are made to vibration problems, the reader is referred to
the CUSA IMI Candidate's Manual or to the “Other References” section in this
manual for more information on troubleshooting those problems.

Contents Page

1110 Startup Checklist 1100-2

1120 Introduction to Troubleshooting 1100-9
1130 Troubleshooting Insufficient Flow/Pressure from Centrifugal
Pumps 1100-12
1140 Procedure for Performance Monitoring Centrifugal Pumps
(“Curving the Pump”) 1100-13
1150 Centrifugal Pump Troubleshooting Checklist 1100-20
1160 Vertical Turbine Pump Troubleshooting Checklist 1100-22
1170 Metering Pump Troubleshooting Checklist 1100-24
1180 Reciprocating Pump Troubleshooting Checklist 1100-27
1190 Rotary Pump Troubleshooting Checklist 1100-30

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1110 Startup Checklist

Startup Items for All Pumps
Initials Date
Piping
1. Inspect check valves for correct flow direction. ________ ________
2. Verify that all process and auxiliary piping is free of cold spring at the pump flanges. ________ ________
3. Flush and, where appropriate, chemically clean all process and auxiliary piping
which has been opened or repaired. Verify cleanliness with filters or flange screens. ________ ________
4. Perform thorough leak checks of all welds, flanges, and fittings during any
hydrotests. Do not permit hydrotests against pump mechanical seals unless they
have been rated for the higher pressures. Test with a fluid compatible with the
process whenever possible. Otherwise, thoroughly drain and flush the test fluid. ________ ________
5. Verify that all operational personnel are familiar with the suction and discharge
piping systems as well as control valves. Do the same with all auxiliary piping and
turbine driver steam piping. Personnel should also be familiar with suction-to-
discharge bypass systems and their purposes for startup, low flow, or high pressure
control. ________ ________
6. Prepare a list of piping blinds to be removed prior to startup. Include a signoff
column where operating personnel can certify and document the status of the blinds. ________ ________
7. Open seal flush valve (if equipped). ________ ________
8. Ensure that all drain valves are properly plugged. ________ ________
9. Verify that all auxiliary piping for sealing and flushing is connected to the right ports
at the pump gland. ________ ________
10. Verify all safety tags are removed from system valves and switchgear. ________ ________
11. Inspect suction screen shortly after startup. ________ ________
12. Prime the pump by filling suction line and pump with process fluid and bleeding air to
atmosphere or relief as appropriate. ________ ________
13. Inspect for static (pre-startup) leaks. ________ ________

Instrumentation
1. Verify operating personnel are familiar with all associated processes and auxiliary
instrument systems. Ensure the systems have been sufficiently calibrated, loop
checked, and functionally tested. ________ ________
2. Prepare a list of instrument systems which must be tested on-line. Ensure that test
provisions do not impair personnel safety or machinery reliability. ________ ________
3. Verify that all systems pressure safety relief valves have been tested and set per local
policy. Ensure that relief block valves have been locked open with a locally
accepted method. ________ ________
4. Check vibration systems for proper installation, calibration, and alarm/shutdown
settings. ________ ________
5. Verify Automatic Pump Start (APS) systems are installed and operationally tested. ________ ________

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Initials Date
Shaft Mechanical Seals
1. Review seal-flush plan, function, and operation. ________ ________
2. Leak test the mechanical seal(s) in place at a pressure corresponding to the
maximum design stuffing box pressure. Repair leaks before starting. ________ ________
3. Verify that all auxiliary flushing, quenching, and cooling systems provide flow at the
design pressures, temperatures, and rates. When critical to operational reliability or
safety, insure these auxiliary systems are alarmed and/or have redundant features. ________ ________
4. Bleed and fill the stuffing box with flush fluid prior to starting. (This is particularly
important for vertical pumps and high fluid vapor pressure pumps.) ________ ________
5. Check the following for any external seal-flush cooler: ________ ________
– Open cooling water valves to flush cooler. ________ ________
– Vent-tube side (flush) of cooler at high point for pumping-ring systems, if
non-hazardous. ________ ________
6. Check the following for double seals with external pressurizer/circulator: ________ ________
– Fill reservoir with proper buffer (barrier) fluid. ________ ________
– Start buffer circulating pump. ________ ________
– Set buffer fluid backpressure to a minimum of 25 psi above impeller-side
pressure at inner seal. ________ ________
– Test buffer fluid low pressure, low flow, and low level alarm settings. ________ ________
7. Check the following for double seals with pumping rings: ________ ________
– Fill buffer fluid reservoir with proper fluid. ________ ________
– Vent all air out of buffer system. ________ ________
– Pressurize buffer system to 25 psi above impeller-side pressure at inner seal. ________ ________
– Inspect all buffer pressure connections for leaks. ________ ________
– Test low pressure, low level alarm, and any other alarms. ________ ________
8. Check the following for tandem seals with pumping rings: ________ ________
– Fill buffer fluid reservoir with proper fluid. ________ ________
– Vent all air out of buffer system. ________ ________
– Test buffer fluid high pressure, high level, and low level alarms. ________ ________
9. Verify that all real vent and drain parts are properly connected and/or plugged. ________ ________
10. During startup, note and document all seal leaks, their location, and whether they
appear to be increasing. Generally, any leak requires a repair. Seals rarely “run in”
and stop leaking. ________ ________
11. When required by local regulations, check the running seal for excessive fugitive
hydrocarbon emissions. ________ ________

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Initials Date
Shaft Packing
1. Verify the flush supply to the lantern ring, if included, is at adequate pressure. ________ ________
2. Verify that the stuffing box cooling jacket water, if supplied, is flowing. ________ ________
3. Verify that the shaft turns freely to check for over-tightened packing. Once the pump
is running, tighten adjustable packing to a slow drip to ensure adequate lubrication.
Tighten the packing by evenly turning the gland boltnut a quarter turn at a time.
(Avoid initial overtightening of packing materials such as Graphoil. Consult packing
manufacturer recommended tightening procedures for initial run-in.) ________ ________
4. If a pump with self-adjusting packing has a leak greater than a drip, shut down and
replace the packing. ________ ________

Bearings
1. Ensure the bearing housings are clean of grit, sand, metal shavings, or other debris.
Verify that bearing housings and lube oil systems are filled with the proper oil and
filled to the correct level. ________ ________
2. Monitor bearing vibration throughout startup. Do not exceed prescribed danger
levels at any time. Watch for increasing vibration levels as an indicator of deterio-
rating mechanical conditions. ________ ________
3. Observe bearing housing or oil temperatures throughout startup. Do not exceed the
prescribed danger levels any longer than necessary to shut the pump down. On ball
bearing-type pumps, this is best done by measuring the bearing housing tempera-
ture. On pressure lubricated sleeve bearings, use thermocouples to sense the
bearing metal temperature or the exit (outlet) oil temperature. ________ ________
4. Drain an oil sample from the bearing housings to look for signs of dark oil, metallic
debris, or other contamination. Shut down and investigate if contamination is found
after a short period of time. ________ ________
5. Check that oiling rings or slingers provided with ball bearings are rotating and deliv-
ering oil to the bearings. ________ ________
6. Bearing temperature should not exceed 180°F. Do not run water over hot bearings.
Such action is more likely to contaminate the oil with water than it is to cool the
bearing. A hot bearing is a sign of an overload or impending failure. ________ ________

Lubrication Systems
1. Check the following when starting an oil-mist system: ________ ________
– Verify the reservoir is filled with the correct oil and not over filled. ________ ________
– Verify air pressure regulator setting. ________ ________
– Test generator alarm lights. ________ ________
– Test the low pressure, high pressure, low temperature, high temperature, and low
oil level switches. ________ ________
– Verify pressure at the end of the main header is the same as the generator
pressure. ________ ________
– Check for visible signs of mist at the last out-of-service pump on the header. ________ ________

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Initials Date
Lubrication Systems (continued)
2. Check the following when starting equipment with pressure lube systems: ________ ________
– Verify reservoir is filled to the proper level with the correct lube-oil. ________ ________
– Check for installed breather, and plug all reservoir drain valves prior to system
run-in. ________ ________
– Check for presence of flow restriction orifices at individual bearings (if required by
Vendor's design). Check for correct sizes at each location. ________ ________
– Run-in lube system prior to initial main machinery operation. Check for leakage.
Watch filter differential pressure, and check for cleanliness as measured by
debris caught in filters or temporary in-line screens. (Refer to API Standard 614
for guidance on Cleanliner Standards.) ________ ________
– Sample lube-oil prior to on-line operation and change if necessary. Replace filter
elements. ________ ________
– Establish cooling water flow to oil coolers. ________ ________
– Check settings of lube heater pressure regulators and relief valves. ________ ________
– Test alarm and shut down switches. ________ ________
– Verify operation of the auxiliary lube pump during main machinery startup, shut-
down, and on low lube pressure. (Shaft-driven main lube pumps that are situated
above the reservoir are usually primed by the auxiliary pump, which requires the
auxiliary pump to be running prior to starting the equipment.) ________ ________
– Check for a minimum lube-oil temperature of 100-110°F prior to main machinery
startup. ________ ________
– During initial on-line operation, check for oil flow at each of the bearing sight
glasses. ________ ________
– Oil temperature rise through bearings should not exceed 50°F when inlet oil
temperature is at or below 110°F. ________ ________

Motor Drivers
1. Verify that all coupling guards are installed and bolted down. ________ ________
2. Ensure motor heaters, if installed, are working when motor is off. ________ ________
3. “Bump” motor to check for correct rotation. Verify that rotation arrow on pump
matches pump drawing or data sheet. ________ ________
4. Determine how many restarts the motor is permitted in one hour's time and follow
those limits. ________ ________
5. Do not frequently push the “Stop” button before motor has reached full speed, partic-
ularly on larger motors. Do not push the “Start” button until motor has coasted to a
complete stop. Such actions may trip or even damage the electrical equip-ment. ________ ________
6. If motor repeatedly trips on start attempts, check: ________ ________
– Process for excessively high flow or pressure demands. (Some centrifugal pumps
can only be started against a nearly closed discharge valve. Many positive
displacement pumps must be started on a suction-to-discharge bypass.) ________ ________

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Initials Date
Motor Drivers (continued)
– Improper electrical switchgear relay or circuit breaker settings. ________ ________
– Low system voltage during starting. ________ ________
– Higher-than-design fluid viscosity in the pump. ________ ________
– Mechanical problem such as bad motor or pump bearings or internal rubbing. ________ ________

Steam Turbine Drivers

1. Open drains to remove condensate from turbine casing and steam lines. ________ ________
2. Overspeed test the turbine. ________ ________
3. Run-in carbon rings. ________ ________
4. Open the steam exhaust valve slowly. ________ ________
5. Warm the turbine by cracking open the supply steam block valve or by opening its
warmup bypass. ________ ________
6. Close drain valves when condensate has been purged. ________ ________
7. Draw a sample of bearing oil to visually check for water content. Drain and refill oil if
water is found. ________ ________
8. Open cooling water valves to turbine when provided. ________ ________
9. Open the sealing steam lines, when provided, on both the low and high pressure ends. ________ ________
10. Manually begin turbine rotation up to idle speed by further cracking open the main
steam supply valve. ________ ________
11. Check bearings for oiling ring rotation and listen for rubbing sounds. ________ ________
12. Hand trip the overspeed mechanism to check for proper action. Reset to continue
startup. ________ ________
13. Open the steam block valve completely to allow the turbine to accelerate to governor
control. Check that it is controlling to the desired speed. ________ ________

Startup Checklist For Centrifugal Pumps

1. When required for process safety, drain the pump casing. (One example would be a
hot pump which has recently been steamed out.) ________ ________
2. Verify any external mechanical seal flush supply line is open and flowing. Check for
the prescribed flush pressure or flow. Refer to “shaft mechanical seals” checklist,
this section, for checks on other sealflush plans. ________ ________
3. When supplied, check that cooling water is flowing to bearings, stuffingbox, seal
coolers, gearbox coolers (on Sundynes), and pump supports. ________ ________
4. Ensure that steam is open to pump jackets and piping tracing. Verify that all tracing
steam traps are functioning correctly. ________ ________
5. When provided, open pump warm-up lines to allow pump to reach prescribed starting
temperature. Note that some pumps are warmed through a small hole in the
discharge check or block valves. (Warm-up any pump with operating temperatures
above 350°F.) ________ ________

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Initials Date
Startup Checklist For Centrifugal Pumps (continued)
6. Open the pump suction line and vent casing to atmosphere, closed drain system or
relief, as appropriate. ________ ________
7. Verify that the pump minimum flow bypass is open and that any associated control
valves and instrumentation are functioning. (This is particularly important on high
pressure, high horsepower, parallel operation, or high-speed pumps.) When a
minimum flow bypass is not provided, crack open the discharge block valve prior to
starting. ________ ________
8. Vent pump case. ________ ________
9. Start pump with discharge valve cracked, then fully open the discharge valve once
the pump is at speed. ________ ________
10. Do not operate pump more than 15 seconds without discharge pressure. Do not
operate below minimum stable flow. Avoid parallel operation. ________ ________
11. Check for and correct any of the following problems: ________ ________
– High vibration. ________ ________
– Normal discharge pressure and flow. ________ ________
– Cavitation or “pumping marbles” type sounds. (If heard, immediately look for
suction or discharge blockages, excessive flow, low flow, excessively hot fluid, or
low suction vessel level.) ________ ________
– Mechanical seal leaks. Excessive package leakage. ________ ________
– Excessive power required. ________ ________
– Hot bearings. ________ ________
– Grinding or growling type noises typical of metal-to-metal contact. ________ ________
– Lack of oiling or slinger rotation in bearing housings. ________ ________
– Improper lubrication system operation. ________ ________
– Malfunctioning instrumentation. ________ ________
12. High temperature or turbine driven pumps may require hot alignment. If so, pump
should be shut down after a few hours operation to check the alignment and make
adjustments. ________ ________
13. The performance of new, modified, or significantly overhauled pumps should be
checked once the process is stabilized. This will require accurate pressure gages
and flow meters as well as knowledge of the fluid's specific gravity. Motor ammeter
readings are also needed. Refer to Section 1140 of the Pump Manual for test proce-
dures and calculations. ________ ________

Startup Checklist For Vertical Centrifugal Sump Pumps

1. Verify that the sump level float controls are properly set and functional. ________ ________
2. When supplied, check that the bearing flush supply is open and flowing. (Note that
many flush systems are opened with some type of solenoid device when the pump
motor is energized. If so, check for proper operation of the flush controls.) ________ ________
3. When shaft bearings are grease lubricated, inject grease on a prescribed basis
through provided fittings. ________ ________

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Initials Date
Startup Checklist For Vertical Centrifugal Sump Pumps (continued)
4. Start pump and check for high vibration. ________ ________
5. If pump cycles on and off frequently, consider repositioning float switches to optimum
levels. ________ ________
6. Evaluate pump performance by observing discharge pressure and time to pump out
the sump. Compare to Vendor's curve. ________ ________

Startup Checklist For Steam-Driven Reciprocating Pumps

1. Check that all linkages have been recently lubricated. ________ ________
2. Verify that the lubricator reservoir is full of the specified oil. Refer to “Shaft Packing”
checklist in this section of the manual for other packing items to be checked. ________ ________
3. Open drains on the steam casing and piping to purge condensate. ________ ________
4. Crack open steam inlet valve to warm casing, leaving the drains slightly open. ________ ________
5. Open suction and discharge valve on pumped fluid side. ________ ________
6. Slowly open the steam inlet valve to desired pumping rate. If pump is on external
control, open block valve completely. ________ ________
7. If pump stalls or relief valves open, check for blockage in the discharge line. ________ ________
8. If the pump chatters, check for restrictions or loss of fluid in the suction system. ________ ________
9. If piping vibration is excessive, adjust speed slightly to avoid resonance. Brace
piping as needed. ________ ________
10. Verify that the lubricator is functioning properly. ________ ________
11. Readjust packing to obtain a slow drip. ________ ________
Startup Checklist For Motor-driven Reciprocating Pumps
1. Verify that the discharge-to-suction relief valve is unblocked. Check tags that the
valve has been tested and set per local policy. Ensure any block valves are locked
open. ________ ________
2. Check that the crankcase oil level is full. ________ ________
3. Ensure that the discharge-to-suction startup bypass line is open. ________ ________
4. Verify that suction/discharge pulsation bottles are fully operational (N2 filled, steam
dome on, etc.). ________ ________
5. When packing lantern rings are provided, ensure the flushlines are open and pressur-
ized. ________ ________
6. When packing lubricators are provided, check that the supply reservoir is filled with
the prescribed oil. ________ ________
7. If supplied with auxiliary lube-oil pump, verify its proper operation and control
settings. ________ ________
8. If variable speed control is provided, slowly bring the pump up to full speed. ________ ________
9. If belt driven, check for proper belt tension and sheave alignment. ________ ________

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Initials Date
Startup Checklist For Motor-driven Reciprocating Pumps (continued)
10. Check for and correct any of the following problems: ________ ________
– High vibration of the pump. ________ ________
– Loud chattering or pounding noises indicative of insufficient suction pressure.
(This can be very destructive. Stop the pump immediately.) ________ ________
– Low lube-oil supply pressure or high differential pressure at the filter. ________ ________
– Improper conditions of the motor and the speed changers (gearbox, belt, hydraulic
drive, etc.). ________ ________
– Excessive packing leaks. ________ ________
11. Check for excessive piping vibration. If any, verify that any gas-filled dampers are
properly charged. Brace piping as needed. ________ ________
12. Readjust packing to obtain a slow drip. ________ ________

Startup Checklist For Proportioning Pumps

1. Verify that the crankcase is full of the proper oil. For pumps with the hydraulic
section separate from the crankcase, verify the hydraulic section is also full of the
proper oil. ________ ________
2. Bleed air from hydraulic section between double diaphragms when pump is new or
has been repaired. ________ ________
3. Set the flow adjustment to zero. ________ ________
4. Open the suction valve and bleed the line where possible. ________ ________
5. Check that the discharge-to-suction relief valve is not blocked and has been tested
and set per local policy. For pumps with internal relief in the crankcase or hydraulic
section, verify the relief has been set correctly. ________ ________
6. Open the discharge valve. ________ ________
7. Start pump motor and check for unusual vibration or noises. ________ ________
8. Slowly increase flow setting to the desired level. If pump does not immediately take
suction, allow it running time to purge any residual gas in the system. If it continues
not to pump, shut down and check for valve problems or problems in the inlet system. ________ ________
9. If pump has packing, adjust as required to obtain a slow drip. ________ ________
10. Set pump to automatic flow control, where provided. ________ ________

1120 Introduction to Troubleshooting

General Comments
The following comments may be helpful background to the detailed checklists in
this section, plus those in Section 800:
1. Although machinery (pump) problems can be exceptionally complex, practical
solutions are usually quite simple. Look for the simple cause/solution first.
For example, there are many reasons why a bearing will fail prematurely; some

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reasons are quite complicated. Nevertheless, the most likely cause, and the
first you should check, is inadequate lubrication.
2. No machine operates perfectly, or in a perfect environment. Numerous devia-
tions exist in every machine, yet do not surface as operational or maintenance
problems. For example, every machine operates with some imbalance, some
misalignment, some imperfections in construction, etc.
Therefore, when called on to solve a problem that has surfaced, expect to find
several “problems” during the investigation. The job is not to find a deviation
(problem), but to find the deviation, or combination of deviations which are
causing the problem that needs to be corrected. A common error is to stop at
the first deviation from correct operation, assuming it to be the cause. This
leads to wasted time and further efforts in the future.
3. As in any problem-solving effort, one of the most important steps is to define
the problem. For example, problems often surface as “pump won't put out -
repair as necessary.” The pump is overhauled at considerable expense even
though the real problem may simply be a plugged line restricting flow.
4. Many problems with pumps fall into one of the following categories:
a. Broken or worn components in the pump.
b. Broken or worn components in the driver.
c. Control mechanisms out of adjustment.
d. Mechanical components out of adjustment.
e. Problems external to the pump (for example, insufficient flow due to
plugged piping, faulty flow meter, excessive pressure loss, etc.).
Defining the problem in terms of the above categories can often reveal that
there is no problem with the pump at all, or the corrective action will be less
expensive than expected. It's much easier to adjust a turbine governor than to
overhaul a pump. When investigating, look to the less expensive, simpler
causes, first.
5. As implied above, the causes of many pumping problems are often related to
factors outside the pump. This is especially true for the following “problems.”
a. Insufficient flow rate or discharge pressure.
b. Insufficient power or driver “kicking out.”

Problem Solving in General

The following steps are a common problem-solving technique:
1. Define the desired performance.
2. Define the deviation from that performance. This is the real problem.

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3. Analyze the cause of the deviation, based on a combination of practical and

technical knowledge.
4. Take corrective action to eliminate the cause.
5. Monitor performance following corrective action.
6. Document the important points and communicate to those who will benefit
from the knowledge gained. Retain in files.
Although the checklists that follow are generally aimed at helping in Step 3, it is
important to remember all the steps. Repetitive problems are usually caused by
failing to complete one of the steps above.

Problem Solving Checklists

The figures and charts in the following sections help identify the cause of common
pump problems:
1130 Troubleshooting Flow Chart for Insufficient Flow or Pressure from
Centrifugal Pumps.
1140 Procedure for Monitoring the Performance of Centrifugal Pumps
(“Curving” the Pump).
1150 Centrifugal Pump Troubleshooting Checklist.
1160 Vertical Turbine Pump Troubleshooting Checklist.
1170 Metering Pump Troubleshooting Checklist.
1180 Reciprocating Pump Troubleshooting Checklist.
1190 Rotary Pump Troubleshooting Checklist.

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1130 Troubleshooting Insufficient Flow/Pressure from

Centrifugal Pumps
Fig. 1100-1 Troubleshooting Flowchart for Centrifugal Pumps

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1140 Procedure for Performance Monitoring Centrifugal Pumps

(“Curving the Pump”)
Background
This technique determines if pump internals such as wear rings and/or impellers are
worn. This information is useful to: (1) monitor the trend of a pump's performance
over time, or (2) decide if the pump needs to be disassembled and repaired.
Appendix H of this manual is a guideline for testing centrifugal pumps in the
factory. In order to check a pump against its curve, the following fundamentals
should be understood.
1. Density is the weight per unit volume of any liquid. Water weighs 62.4 lbs.
per cubic foot at 60°F. Most petroleum stocks weigh less. A few liquids (e.g.,
caustic) weigh more.
2. Specific Gravity is a comparison of the weight of the liquid to that of water at
60°F. Petroleum has a specific gravity less than one, generally between 0.5 and 0.9.
Another way to express specific gravity is in “Degrees API.” (Water is 10
“Degrees API.”) Note that Degrees API increase while specific gravity
decreases. A conversion formula is shown in the attached “Pump Curve Work-
sheet,” or refer to the specific gravity chart in the Appendix.
3. Effect of Temperature. Calculations use specific gravity at the flow tempera-
ture. Therefore, specific gravity will have to be converted to the value at
pumping temperature. The specific gravity of almost all liquids decreases as
the temperature is raised. For example, a stock with a specific gravity of 0.9 at
60°F may be 0.8 at 340°F. The Appendices include information relating
specific gravities to temperature.
4. Gage and Absolute Pressure. The pressure shown on most pressure gages is
called Gage Pressure, expressed as psig. Gage pressure is the pressure above atmo-
spheric pressure. Absolute pressure is pressure measured above a perfect vacuum.
Atmospheric pressure is 14.7 psi (sea level) above a perfect vacuum, or 14.7 psia.
To convert from psig to psia at sea level, add 14.7 (At other elevations, add the
local atmospheric pressure.)

psia = 14.7 + psig

Pressure below 0 psig is a vacuum. Note that many pumps may have a vacuum
on the suction side.
Figure 1100-2 may help you keep these concepts in mind (assuming standard
atmospheric conditions at sea level).
5. Centrifugal Pump Characteristics. For practical purposes, a centrifugal
pump will put up the same differential head for any liquid. Differential head is
defined as the pressure increase across the pump expressed as feet of liquid

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(sometimes referred to as total head). Consider a pump that puts up 100 differ-
ential feet of water. It will also put up 100 feet of any other liquid.

Fig. 1100-2 Absolute and Gage Pressure

Absolute Pressure Gage Pressure
24.7 psia 10.0 psig
14.7 psia 0.0 psig
0.0 psia -14.7 psig

One can think of this as a column of water 100 feet high at the pump's
discharge (assuming the suction is zero). If we change the liquid to propane
and the suction stays the same, the discharge pressure will be a column of
propane 100 feet high, the same as water.
Because water and propane have different specific gravities (propane is
lighter), the pressure at the bottom of each column will be different. The pres-
sure at the bottom of the water column will be greater than at the bottom of the
propane column. Therefore, the discharge pressure in psig will be different for
water and propane. Figure 1100-3 shows that a pressure gage would read
43 psig for water, and 21.5 for propane.

Fig. 1100-3 Centrifugal Pump Characteristics

In an actual pump, the differential head can be obtained by subtracting the

suction pressure from the discharge pressure. (For example, a discharge pres-
sure of 500 psig and a suction pressure of 100 psig will yield a differential
pressure of 400 psi or, 924 feet of head if the fluid is water with SG=1.0).
6. Flow is volume of liquid going through a pipe per unit of time. It can be
expressed in gallons per minute, barrels per hour, or barrels per day. However,
almost every pump curve expresses it in gallons per minute.
Flow is usually measured on an instrument calibrated to read the flow at 60°F,
even when the actual stock temperature is higher. Thus, the recorded flow
must be corrected to actual flow for the pump curve.

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Actual Flow =
Recorded Flow × Specific Gravity @ 60°F
-------------------------------------------------------------------------------------------------------
Specific Gravity @ Flow Temp.

7. Viscosity is a measure of “thickness” (a fluids resistance to shear), and is

usually measured in SSU or centistokes. The higher the number, the “thicker”
the stock and the more it resists movement. High viscosity stocks require more
pumping horsepower. The flow and head of a pump are less than they would
be at lower viscosities.
Most pump curves are based on the viscosity of cold water. However, the vendor
who supplies the pump usually draws a new curve that represents the proper
viscosity. If not, you may have to adjust the head-capacity curve down and the
horsepower curve up for significant changes in viscosity (see Section 200).

Performance Monitoring Procedure

The following procedure can be used with the performance monitoring worksheet
to determine the condition of a centrifugal pump:
1. Run a field test. Copy the pump suction and discharge pressure. If possible,
use the same pressure gage to eliminate instrument error or use an accurate
differential pressure gage. Suction pressure is very important to check but often
difficult to obtain.
Ideally, the pump should be tested at 4 points:
a. Best efficiency point (BEP)
b. Some point about 10–25% above BEP
c. Some point about 10–25% below BEP
d. At or near shutoff. If possible, momentarily close the discharge pressure
valve, then record suction and discharge pressure at zero flow. This point
is called “shutoff” head. Do not keep the discharge valve closed more
than a few seconds or you may damage a pump component, especially a
mechanical seal.
2. Record the discharge pressure, suction pressure and flow rate at each test
point. Also record the stock temperature if available. Suction pressure is often
difficult to obtain. Do your best to obtain or estimate an accurate number.
3. Use the worksheet to convert to the units on the pump curve (usually pressure to
feet of head and flow to GPM). Record the other information on the worksheet.
4. Plot the worksheet data on the pump's individual performance curve. If it is
within 10% of the curve, the pump is healthy. If the pump is operating more
than 10% below the curve and the conditions from the flow chart in Section
1130 are satisfied, the pump is probably worn internally and needs an over-
haul. Any uncertainty about the accuracy of flow rate should be noted in the
horizontal direction of the chart, and uncertainties about the accuracy of

Chevron Corporation 1100-15 January 1991

1100 Startup and Troubleshooting Pump Manual

specific gravity and pressure measurements should be noted in the vertical

direction (S.G. is proportional to pressure).

Notes
1. It is a good idea to run the “shutoff” head test in addition to the other tests.
Pumps with a plugged suction line or plugged inlet will usually put up the
design shutoff head, but will plot below the curve at increased flow. Doing both
tests could detect a plugged inlet or suction line and avoid a needless repair.
2. If possible, record the amps on motor drivers. Determine if the amps are
greater than normal. This could indicate an unmetered flow, a faulty flow
meter, or internal recirculation.
3. If no suction pressure gage exists, the suction pressure will have to be calcu-
lated. Add the pressure in the suction vessel to the static head (the vertical
distance between the liquid level in the suction vessel and the centerline of the
pump suction flange) and subtract the friction loss in the suction piping.
Suction lines are usually designed with low friction loss.
4. Each pump is designed for one specific application. It has its own individual
performance curve. The most difficult job throughout this entire process may
be to find the correct performance curve. Many pumps are old and their curves
have been lost. To locate the right curve, refer to the Engineering files, or
perhaps the vendor catalog. You may have to request the correct performance
curve from the vendor. Make sure the curve is corrected for viscosity. The
time spent depends, of course, on potential costs involved.
5. Once the correct performance curve is found, make sure the speed and impeller
diameter of the pump are the same as shown on the pump's performance
curve. If not, the curve will have to be adjusted. This can be done from the
old curve once the new speed or new impeller diameter is known. Use the
“Affinity” laws (see Section 200).

Sources of Error
1. An underperforming driver will cause the pump to underperform. While elec-
tric motors normally run at-speed, or not at all, it is not uncommon for a
turbine driver to run at underspeed because of a mechanical problem (in the
turbine or the pump) or because of steam supply problems. A portable tachom-
eter can be used to quickly check driver speed. You should also note motor
rotation, a pump running backward may put up as much as 60% of normal head.
2. An erroneous test or test analysis will produce false conclusions about perfor-
mance. Some common errors are:
a. Mis-estimating suction pressure when no gage is available.
b. Failing to correct the measured flow rate to flow rate at flowing temperature.
c. Using the wrong specific gravity. (If the tester assumed a higher specific
gravity than actual, he would conclude there was a significant performance
problem.)

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Pump Manual 1100 Startup and Troubleshooting

d. A different size impeller from the original one can cause profound varia-
tion from the original curve because pump head capacity varies as the
square of the impeller size. (Check local records to verify the running
impeller size).
e. A highly viscous fluid will impair pump performance and increase power
required. Viscosities of some hydrocarbons change substantially over wide
temperature swings. This is particularly important if viscosity is above
100 centistokes (water @ 70°F has a viscosity of 1 centistoke).
f. Incorrect flow, pressure, and/or temperature readings will result in an inac-
curate curve. Flow meters may not be correctly calibrated, especially if
recent process changes have been made. PI's and TI's should be replaced
if there is any doubt about their accuracy.

Example
Is the following pump (Figure 1100-4) operating on its curve?

Fig. 1100-4 Pump Curve Diagram

The pump curve in Figure 1100-5 shows one operating point obtained from a field
test and calculated on the example worksheet (Figure 1100-6). Calculations show
the pump at 181 GPM flow and 1204 ft differential head. Plotting this on the curve
shows the pump operating on its performance curve. The pump is “healthy.”
(Figure 1100-7 illustrates a blank Pump Curve Worksheet.)

Fig. 1100-5 Field Test Pump Curve

Chevron Corporation 1100-17 January 1991

1100 Startup and Troubleshooting Pump Manual

Fig. 1100-6 Pump Curve Worksheet (Sample)

January 1991 1100-18 Chevron Corporation

Pump Manual 1100 Startup and Troubleshooting

Fig. 1100-7 Pump Curve Worksheet

Chevron Corporation 1100-19 January 1991

1100 Startup and Troubleshooting Pump Manual

1150 Centrifugal Pump Troubleshooting Checklist

Symptoms Possible Causes
(Each number is defined in the list below)
Insufficient capacity delivered 1-2-3-4-5-6-7-8-9-10-11-13-14-17-19-20-21-23-24-25-26-32-33-34
Insufficient pressure developed 5-11-13-14-17-19-21-22-24-32-34
Pump requires excessive power 12-13-14-15-16-17-20-21-24-27-30-31-32-33-34-35-36-39
Pump overheats and/or seizes 2-4-18-19-30-36-37-38-40
Pump vibrates, cavitates, or is noisy 1-2-3-4-5-9-10-18-20-21-27-28-29-30-31-34-37-38-40-41-42-43-44-
45-46
Pump loses prime 3-5-7-8
Excessive package leakage 27-29-35-36-37-38-39-53
Packing life short 27-29-31-35-36-37-38-39-53
Bearings overheat or wear rapidly 27-40-42-43-44-45-46-47-48-49-50-51-52-54
Mechanical seal problems Refer to Section 800

Possible Causes
Suction Causes System Causes

1. Suction manifolded improperly 11. Speed too low

2. Pump or suction pipe not completely filled with 12. Speed too high
liquid
13. Wrong direction of rotation
3. Suction lift too high
14. Total head of system higher than pump design head
4. Insufficient margin between suction pressure and
15. Total head of system lower than pump design head
vapor pressure
16. Specific gravity of liquid different from design
5. Excess air or gas in liquid
6. Air pocket in suction line 17. Viscosity of liquid differs from design
18. Operation at very low capacity
7. Air leaks into suction line
19. Parallel operation of pumps unsuitable for such
8. Air leaks into pump through stuffing boxes
operation
9. Inlet of suction pipe insufficiently submerged
20. Spare pump's check valve stuck open
10. Suction screens/piping plugged
21. Malfunctioning minimum flow by-pass
22. Lower-than-design specific gravity
23. Plugged discharge piping/valves
24. Malfunctioning pressure or flow indication
25. Fouled heat exchanger downstream

January 1991 1100-20 Chevron Corporation

Pump Manual 1100 Startup and Troubleshooting

Mechanical Causes

26. Foreign matter in impeller 42. Lack of lubrication

27. Misalignment 43. Improper installation of antifriction bearings
(damage during assembly, incorrect assembly of
28. Foundations not rigid
stacked bearings, use of unmatched bearings as a
29. Shaft bent pair, etc.)

30. Rotating part rubbing on stationary part 44. Dirt in bearings

31. Bearings worn 45. Rusting of bearings due to water in housing (bearing
seals or improper protection while idle for long
32. Wear rings worn periods)
33. Impeller damaged 46. Excessive cooling of water-cooled bearing resulting
34. Defective casing gasket permitting interstate in moisture condensation in the bearing housing
leakage 47. Incorrect oil level (too high/too low)
35. Packing improperly installed 48. Insufficient bearing cooling
36. Incorrect packing for operating conditions 49. Bearings too tight, or excess preload
37. Shaft running off center because of worn bearing 50. Oil ring not functioning
or misalignment
51. Oil mist problems
38. Rotor out of balance results in vibration
52. Improper lubricant
39. Gland too tight resulting in no flow of liquid to
lubricate packing 53. Stuffing box, neck ring, shaft, or packing sleeve worn

40. Excessive thrust caused by mechanical failure 54. Insufficient oil flow (insufficient pressure, wrong
inside the pump or by failure of the hydraulic orifice size, etc)
balancing device, if any
41. Excessive grease or oil in antifriction bearings
housing or lack of cooling, causing excessive
bearing temperature

Chevron Corporation 1100-21 January 1991

1100 Startup and Troubleshooting Pump Manual

1160 Vertical Turbine Pump Troubleshooting Checklist

Symptoms Possible Causes
(Each number is defined in the list below)
Insufficient Capacity 1-2-8-10-11-13-17-22-23-26
Insufficient Discharge Pressure 1-7-9-11-13-15-22-23-26
Vibration 4-5-6-12-13-14-16-18-19-20-24-25-29-30-31-32
Abnormal Noise 3-6-12-16-19-21-28-30
Power Demand Excessive 11-12-14-16-24-25-27
Mechanical Seal Problems See Section 800

Possible Causes and Solutions

Cause Solution

1. Pump Suction Interrupted (Water Level Below Inlet) Check Sump Level
2. Low Water Level Check Water Level
3. Cavitation Due to Low Submergence Check Submergence
4. Vortex Problem Install Vortex Breaker Shroud
5. Suction or Discharge Recirculation Establish Design Flow
6. Operation Beyond Maximum Capacity Rating Establish Proper Flow Rate
7. Entrained Air Install Separation Chamber
8. Strainer Clogged Inspect and Clean
9. Impeller Plugged Pull Pump and Clean
10. Impeller or Bowl Partially Plugged Pull Pump and Clean
11. Impellers Trimmed Incorrectly Check for Proper Impeller Size
12. Improper Impeller Adjustment Check Installation/Repair Records
13. Impeller Loose Pull Pump and Analyze
14. Impeller Rubbing on Bowl Case Check Lift
15. Wear Rings Worn Inspect During Overhaul
16. Shaft Bent Pull Pump and Analyze
17. Shaft Broken or Unscrewed Pull Pump and Analyze
18. Enclosing Tube Broken Pull Pump and Analyze
19. Bearings Running Dry Provide Lubrication
20. Worn Bearings Pull Pump and Repair
21. Column Bearing Restrainers Broken Pull Pump and Analyze
22. Wrong Rotation Check Rotation
23. Speed Too Slow Check RPM

January 1991 1100-22 Chevron Corporation

Pump Manual 1100 Startup and Troubleshooting

Cause Solution

24. Speed too High Check RPM

25. Misalignment of Pump Assembly Inspect for Excessive Pipe Strain
26. Leaking Joints Inspect
27. Pumping Sand, Silt, or Foreign Material Check Liquid Pumped
28. Motor Noise Check Sound Level
29. Motor Electrical Imbalance Perform Phase Check
30. Motor Bearing Problems Consult Driver Manual
31. Motor Drive Coupling Out of Balance Inspect
32. Resonance: System Natural Frequency Near Pump Perform Vibration Analysis and Modify and Brace
Speed as Needed

Chevron Corporation 1100-23 January 1991

1100 Startup and Troubleshooting Pump Manual

1170 Metering Pump Troubleshooting Checklist

Symptoms Possible Causes
(Each number is defined in the list below)
Pump does not start 1-2-3-4-7-8-13-14-33-34-54
Pump starts, no delivery 9-11-12-13-14-35-36-37-60
Pump does not deliver to capacity 4-5-7-8-15-16-18-19-22-25-26-27-34-38-40-41-42-43-55-56-58-60
Capacity falls off 4-15-18-28-29-30-32-34-40-41-43-53-55-56-57-60
Erratic delivery 4-7-16-27-29-31-32-42-53-56-58-60
Loss of prime 9-10-11-12-13-14-15-18-19-25-26-34-35-36-40-41-43-57-60
Noisy liquid end 21-23-24-25-26-27-32-37-55-56-58-60
Noisy mechanical end 17-19-24-33-39-40-44-46-51-55
Noisy piping 10-23-24-25-26-32
Rapid packing, plunger, or piston wear 14-18-19-20-24-28-37-40-41-43-53-57-58-59
Pitted seals and valves 27-29-32-53
Overheated motor 3-6-8-24-31-39-45-54
Pump mechanism running hot 28-31-38-39-45-46-47-50-51-52-54-56-57-58-59
Pump leaking oil 24-46-47-48-50-52
Contamination in crankcase power source 20-38-46-50-58-59

Possible Causes and Solutions

Cause Solution

Power Source
1. Circuit Breaker Open or Fuse Blown Locate Reason for Overload Before Replacing or
Resetting
2. Broken or Disconnected Wire Repair or Replace
3. Improper Wiring Check Wiring Diagrams
4. Incorrect Signal Check Signal Source
5. Motor Speed Too Slow Check Voltage, Frequency, Wiring, and Specifications
6. Motor is Overloaded Check Job Conditions
7. Insufficient Air Supply Repair Compressor; Clean Filters
8. Low Voltage Check and Correct
9. Supply Vessel Empty Fill With Process Liquid
10. Suction Piping Too Long or Too Small Shorten, Increase Size, or Install Accumulator Near
Suction Point
11. Strainer Clogged Clean or Replace

January 1991 1100-24 Chevron Corporation

Pump Manual 1100 Startup and Troubleshooting

Cause Solution

Supply and Discharge System

12. Suction Pipe Not Submerged Fill Tank or Realign
13. Valves Closed Open Full; Check All Valves in Suction and Discharge
Piping
14. Clogged Piping Clean; Check Product Conditions
15. Insufficient Suction Pressure ‘Raise Supply Tank; Increase Pipe Diameter; Pressurize
Tank
16. Insufficient Discharge Pressure Install a Loop or Back-Pressure Valve
17. Too Much Suction Pressure Lower Supply Tank; Install Back-Pressure Valve
18. Leak in Suction Piping Locate and Repair, If Foot Valve Required, Test for Seal
19. Pump Not Level or Rigid Realign
20. Dirty Environment Clean Immediate Area of Pump; Change Lubricant
21. Extreme Pipe Vibration Shorten Discharge Line; Increase Size; Install Dampener
22. Calibration Incorrect Evaluate Method of Measurement and Measuring Instru-
ments for Possible Error
23. Discharge Line Too Long or Too Small Shorten; Replace; or Install Dampener
24. Discharge Pressure Too High Install Dampener; Remove Restriction; Increase Size of
Piping
25. Surge Chambers or Dampeners Full of liquid Recharge With Gas or Air Liquid
26. Surge Chambers or Dampeners Improperly Charged Check Specifications and Recharge Properly
27. NPSHA Not Sufficient Check and Correct
28. Pump Vapor bound Allow Pump to Operate at Low Pressure Through
Bypass to Eliminate Vapor, or Put in Vent Before Suction
29. Change in Liquid Properties Compare Original Job Conditions to Present Conditions
30. Viscosity Changed or Too High Improve Suction Head; Lower Viscosity; Change
Metering Head and Valve Design
31. Change in Ambient Temperature Relocate Pump; Control Ambient Temperature
32. Process Liquid Vaporizing Check NPSHA; Change Head, Location, Piping,
Temperature as Necessary

Pump Mechanism – Mechanical

33. Coupling Loose or Disconnected Tighten or Replace
34. Check Valve Dirty or Worn Clean or Replace
35. Check Valves Lodged Open by Solids Clean; Inspect; Add Strainer or Slurry Valves
36. Check Valves Stuck Open by Corrosion Clean Guides; Inspect for Wear
37. Prime Lost Check and Reprime
38. Seals Leaking Inspect Seals and Seal Surfaces; Replace Defective Seals
39. Pressure-Relief Valve Set Too High Adjust to Required Pressure Within Pump Design Limits
40. Plunger Loose or Scored Tighten; Repack; If Cylinder Worn, Also Change

Chevron Corporation 1100-25 January 1991

1100 Startup and Troubleshooting Pump Manual

Cause Solution

Pump Mechanism – Mechanical (continued)

41. Packing Worn or Hardened Adjust or Change
42. Pressure-Relief Valve Set Too Low Adjust to Required Pressure Within Pump Design Limits
43. Piston Seals Worn or Hardened Change
44. Loose Bearings Adjust or Replace
45. Tight Bearings Adjust or Replace
46. Worn Cams, Rods, or Gears Inspect; Check for Overload; Inspect Bearings
47. Pump Overfilled with Lubricant Check and Adjust Level
48. Defective Seals Replace
49. Plugged Breather or Vent Inspect and Clean
50. Low Lubricant Level Inspect for Leaks and Refill
51. Lubricant Contaminated Inspect for Cause and Change
52. Erosion/Corrosion Check for Dirty Product; Incompatible Materials;
Replace
53. Mechanism Frozen Up Check for Corrosion on Moving Parts

Pump Mechanism – Hydraulic

54. Hydraulic System Underprimed Check for Cause and Reprime
55. Hydraulic Relief and Make-up Valves Functioning Check for Restricted Supply or Discharge, Broken
Diaphragm, Worn Packing, Defective Valves. Do Not
Tighten Beyond Limits of Pump
56. Hydraulic Fluid Level Low Fill to Correct Level
57. Hydraulic Fluid Breaking Down Check Temperature, Pump Load, Restricted Supply
58. Hydraulic Fluid Contaminated Check Filters, Breathers, Seals, Diaphragm
59. Hydraulic System Vapor Locked Check Bleeder, Make-Up Valve, Restricted Supply, and
NPSHA

January 1991 1100-26 Chevron Corporation

Pump Manual 1100 Startup and Troubleshooting

1180 Reciprocating Pump Troubleshooting Checklist

Symptoms Possible Causes
(Each number is defined in the list below)
Failure to deliver rated capacity 1-2-3-4-5-6-7-8-9-10-11-12-13-14-15-16-17-18-19-20-21
Liquid not delivered 22-23-24-25-26-27-28
Cavitation 29-30-31-32-33
Leak at cylinder head or valve cover 34-35-36
Water in crankcase 37-38-39-40-41
Oil leak from crankcase 42-43-44-45
Excessive heat in power end 46-47-48-49-50-51-52-53-54-55-56-57-58
Pump overloads driver 59-60-61-62-63-64-65-66-67
Stuffing box leakage 68-69-70-71-72
Stud failure 73-74-75
Excessive valve noise 76-77-78-79
Inlet or discharge line vibration 80-81-82-83-84-85-86-87-88-89
Noisy operation or knocks 90-91-92-93-94-95-96-97-98-99-100-101-102-103-104-
105-106-107-108
Broken shafts, bent, stripped threads, and catastrophic 109-110-111-112-113-114-115-116-117
failures
Packing failure 118-119-120-121-122-123-124-125
Valve failure 126-127-128-129-130-131
Plunger failure 132-133-134-135-136-137-138-139

Causes
1. Air or vapor pocket in inlet line 12. Worn valves and seats
2. Capacity of charge pump less than capacity of power 13. Safety relief valve partially open, or not holding
pump pressure
3. Air or vapor trapped in or above inlet manifold 14. Worn liners, piston rings or plungers
4. Air leak in liquid supply piping system 15. Bypass valve open, or not holding pressure
5. Loose bolts in pump inlet manifold 16. Blown liner gasket
6. Air or gases entrained in liquid 17. NPSHA not sufficient
7. Foreign object holding pump inlet or discharge 18. Liquid bypassing internally
valve(s) open 19. Foreign object blocking liquid passage
8. Incorrect drive ratio 20. Vortex in supply tank
9. Loose belts 21. Insufficient power delivered by motor
10. Incorrect motor or engine speed 22. Pump not primed
11. Loose valve covers or cylinder heads 23. Air or vapor pocket in inlet line

Chevron Corporation 1100-27 January 1991

1100 Startup and Troubleshooting Pump Manual

Causes

24. Clogged inlet line 60. Low voltage or other electrical trouble
25. All inlet valves stuck open 61. Trouble with engine, turbine, gear or other related
26. All discharge valves stuck open equipment

27. Loose bolts in pump inlet manifold 62. Excessive discharge line pressure

28. Valve velocities too high 63. Clogged discharge line

29. NPSHA too low 64. Closed or throttled valve in discharge line

30. Liquid not delivered to pump inlet connection 65. Incorrect liner size for application

31. Excessive stuffing box leakage 66. Improper bypass conditions

32. NPSHR too high 67. Overtightened stuffing box glands on adjustable
packing
33. Acceleration head too high
68. Worn packing
34. Operating over recommended pressure
69. Worn rods or plunger
35. Loose cylinder head, valve cover
70. Worn stuffing boxes
36. Damaged gasket.
71. Wrong size or type packing
37. Water condensation
72. Worn O-ring seal (replaceable boxes)
38. Worn seals
73. Excessive discharge pressure
39. Clogged air breather(s)
74. Improper torquing of nuts
40. Worn crankcase packing
75. Shock overload caused by pump pulsations
41. Loose covers
76. Broken or weak valve spring
42. Oil level too high
77. Pump cavitation
43. Work seals
78. Air leak in inlet piping or loose bolts in pump inlet
44. Worn crankcase packing manifold
45. Loose crankcase cover 79. Air trapped above inlet valve
46. Pump operating backward at too low a speed 80. Piping inadequately supported
47. Insufficient oil in power end 81. Inlet line too long or too small in diameter
48. Excessive oil in power end 82. Too many bends in inlet line
49. Incorrect oil viscosity 83. Multiple pump installations operating in parallel
50. Operating in excess of recommended pressure 84. Obstruction under valve(s)
51. Main bearings too tight 85. Packing worn
52. Drive misaligned 86. Operating in excess of recommended pressure or
53. Belts too tight speed
54. Discharge valve of one or more cylinders stuck open 87. Low NPSHA
55. Insufficient cooling 88. Surge chambers or dampers need recharging
56. Pump speed too low 89. Surge chambers or dampers missing
57. Inadequate ventilation 90. Piston or plunger loose
58. Liquid end packing adjusted too tight (adjustable 91. Valve noise amplified
packing only) 92. Pump cavitation
59. Pump speed too high 93. Liquid knock

January 1991 1100-28 Chevron Corporation

Pump Manual 1100 Startup and Troubleshooting

Causes

94. Air leak in inlet piping 114. Disintegration of worn valves

95. Loose bolts in pump inlet manifold 115. Frozen liquid in liquid end
96. Hydraulic noise in liquid end 116. Air leak in liquid supply system
97. Loose or worn crosshead pins and bushings 117. Loose bolts in pump inlet manifold
98. Loose connecting rod cap bolt(s) 118. Normal wear
99. Worn connecting rod bearings 119. Improper material, wrong packing
100. Worn crosshead 120. Improper lubrication
101. Main bearing end play excessive 121. Adjustable packing - gland too tight
102. Worn gears or chains 122. Dirty liquid
103. Gears or chains out of line 123. Plunger or piston rod misalignment
104. Pump running backward 124. Dirty environment
105. Partial loss of prime 125. Damaged rod or rod coating
106. Pulsations in piping system 126. Normal wear
107. Water in power end crankcase 127. Pump cavitation
108. Poorly supported piping, abrupt turns in piping, 128. Abrasives of foreign matter in fluid
piping misaligned, pipe size too small 129. Incompatibility of valve components to corrosive
109. Startup against closed valve in discharge line. If liquid
valve seats are discovered driven too deeply after 130. Galvanic corrosion
operation of the pump, look for the following pattern
of driven seats, indicative of startup or run against a 131. Incorrect installation – driving on the valve stem,
closed discharge line valve: improper torque on jam nut, valve seat and valve
deck not thoroughly clean and dry when seat
Triple single acting plunger pump: installed
2 inlet and 1 discharge valve seat, or 132. Packing too tight
1 inlet and 2 discharge valve seats 133. Thermal shock (cold water hitting hot ceramic
Quintuplex single acting plunger pump: plunger)
3 inlet and 2 discharge valve seats, or 134. Inlet valve becomes disassembled while pump is
2 inlet and 3 discharge valve seats operating

Duplex double acting piston pump: 135. Stuffing box gland rubbing on plunger due to
improper tightening procedure
2 inlet and 2 discharge valve seats
136. Dirty liquid
110. Low oil level
137. Dirty environment
111. Contaminated oil
138. Wrong packing/packing material
112. Main bearing failure
139. Inadequate flush to lantern ring
113. Piston or plunger striking cylinder head

Chevron Corporation 1100-29 January 1991

1100 Startup and Troubleshooting Pump Manual

1190 Rotary Pump Troubleshooting Checklist

Symptoms Possible Causes
(Each number is defined in the list below)
No Liquid Delivered 1-2-4-15
Insufficient Capacity 1-3-5-6-9-13-1417
Starts, but Loses Prime 3-4-5-6
Excessive Wear 2-3-7-9-10-11-12-18
Excessive Heat 2-10-11-12
Vibration and Noise 1-2-3-5-6-9-10-11-12-16-19
Excessive Power Demand 8-9-10-11-12-19

Possible Causes and Solutions

Cause Solution

1. Suction Filter or Strainer Clogged Clean Strainer or Filter

2. Pump Running Dry Reprime
3. Insufficient Liquid Supply Look for Suction Restriction or Low Suction Level
4. Suction Piping Not Immersed in Liquid Lengthen Suction Pipe or Raise Liquid Level
5. Liquid Vaporizing in Suction Line Check NPSH.
Check for Restriction in Suction Line
6. Air Leakage Into Suction Piping or Shaft Seal Tighten and Seal all Joints;
Adjust Packing or Repair Mechanical Seal
7. Solids or Dirt in the Liquid Clean System
Install Filtration
8. Liquid More Viscous than Designed For Reduce Pumped Medium Viscosity;
Reduce Pump Speed;
Increase Drive HP
9. Excessive Discharge Pressure Check Relief Valve or By-pass Setting;
Check for Obstruction in Discharge Line
10. Pipe Strain on Pump Casing Disconnect Piping and Check Flange Alignment
11. Coupling, Belt Drive, Chain Drive Out of Alignment Realign
12. Rotating Elements Binding Disassemble and Inspect
13. Internal Parts Wear Inspect and Relace Worn Parts
14. Speed Too Low Check Driver Speed
15. Wrong Direction of Rotation Check and Reverse if Required
16. Coupling Out of Balance Balance
17. Relief Valve Improperly Seated Check and Repair
18. Packing too Tight Readjust or Replace
19. Bent Drive Shaft Repair or Replace

January 1991 1100-30 Chevron Corporation