Detection and effects of pump low-flow operation

Operating experience and previous studies have shown that a significant cause of pump problems and failures can result from low- flow operation. Operation at low-flow rates can create unstable flows within the pump impeller and casing. This condition can result in an increased radial and axial thrust on the rotor, which in turn causes higher shaft stresses, increased shaft deflection, and potential bearing and mechanical seal problems. Two of the more serious results of low-flow pump operation are cavitation and recirculation. Cavitation is the formation and subsequent collapse of vapor bubbles in any flow that is at an ambient pressure less than the vapor pressure of the liquid medium. It is the collapse of these vapor bubbles against the metal surfaces of the impeller or casing that causes surface pitting, erosion, and deterioration. Pump recirculation more damaging than cavitation. If located at the impeller eye, recirculation damages the inlet areas of the casing. At the impeller tips, recirculation alters the outside diameter of the impeller. If recirculation occurs around impeller shrouds, it damages thrust bearings. Recirculation also erodes impellers, diffusers, and volutes and causes failure of mechanical seals and bearings. This paper reports on a utility pump failure caused bymore » low-flow induced phenomena. ORNL is investigating the results of low-flow pump operations by evaluating the types of measurements and diagnostic techniques that are currently used by licensees to detect pump degradation. A new, enhanced application of motor current and power data analysis has been developed that uses a signal comparison methodology to produce an instability ratio indicative of normal or unstable flow conditions. Examples of this type of low-flow detection technique are presented in this paper along with a brief discussion of the various types of technologies currently being used by licensees to evaluate pump operation and determine possible degradation.« less