INVESTIGATION REPORT: ADV/CNN/12

Sep. 15th, 2013

INVESTIGATION REPORT

1. INCIDENCE Requested By

: Pump casing damage : Area incharge & Head-Mechanical

Dept.

: Mechanical

Date Location 2. INVESTIGATED BY: Manojkumar.M

: 15/09/2013 : Chennai

3. INTRODUCTION: Cavitation: Cavitation is the localized formation and subsequent collapse of cavities, bubbles, in a liquid. The formation of cavities (or bubbles) is induced by flow separation, or non-uniform flow velocities, inside a pump casing that result in localized low pressure points.(This is analogous to the effect of air flowing against the leading edge of an airplane wing where flow separation and difference in air velocities reduce the pressure at the top of the wing causing the plane to be air-lifted.) Cavitation in a centrifugal pump has a significant effect on pump performance. Cavitation degrades the performance of a pump, resulting in a fluctuating flow rate and discharge pressure. Cavitation can also be destructive to pumps internal components. When a pump cavitates, vapor bubbles form in the low pressure region directly behind the rotating impeller vanes. These vapor bubbles then move toward the oncoming impeller vane, where they collapse and cause a physical shock to the leading edge of the impeller vane. This physical shock creates small pits on the leading edge of the impeller vane. Each individual pit is microscopic in size, but the cumulative effect of millions of these pits formed over a period of hours or days can literally destroy a pump impeller and casing. Cavitation can also cause excessive pump vibration, which could damage pump, bearings, wearing rings, and seals.

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Design SpecificationsPUMP: Design flow 18.5 M3/hr Head - 21.6 m NPSH 2.2 m Rpm 2900 Make -VBB

Tank: Size - 1500 dia 2000 mm ht

4. OBSERVATIONS: It was found that there is a leakage from the casing of pump

It was observed that the pump runs continuously, though there is no liquid in the tank

5. REASONS OF INCIDENCE: Input Flow coming to the tank is very less(Approx-7m3/hr) than the pump discharge-8m3/hr.So pump running most of the time with bottom level of liquid.This causes cavitation to occur and leads the pump casing to damage There is no level switch for the tank to control the pump based upon the liquid level present in the tank No VFD to control the pump rpm NPSHR>NPSHA- Pump NPHR is 2.2 Metre but the total height of the tank is only 2 Metre Suction pipe choking due to foreign materials

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6. RECOMMENDATIONS: S. No. Recommendation Level switch to be fixed in the cloth wash tank to control the pump based upon the level Tank height to be increased by another 2 metre to have the total tank height of 4 metre Foreign materials(mostly polythene) deposition to be avoided and regular cleaning to be done Process Mech Action By Instru

Enclosed Photos 1. Damaged pump casing

2.

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Pits on casing

3.Cavitation effects on impeller

4.

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Damaged vanes

5. Tank

Pump

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