What Are Common Faults and Solutions for Mud Pump Machine

Mud pump machine can be widely used in mining, electric power, metallurgy, coal, environmental protection and other industries to transport slurry containing solid particles. Some failures often occur because mud pump machine is used in this special environment.

OCEAN Pump is the leading sand pump manufacturer and supplier with 20+ years of industrial experiences, we wholesale complete line of sand suction pump, slurry pump, sand dredger and solutions for sand pumping industry. In this article, let’s explore right method to use and maintain dredging sand suction pump that ensure correct usage and maintenance of sand suction pump in terms of capacity, efficiency, durability, and cost effectiveness from the sand pump manufacturer’s view.

What should I do if the mud pump cannot start? What should I do if the supporting power motor overheats? Followed are the common faults and solutions for mud pump machine explained by OCEAN PUMP.

1. Mud pump machine can not be started

1.1 Cause:

1. When troubleshooting a pump issue, it is important to start by checking the power supply. Ensure that the joint connections are secure and the switch contacts are tight. Verify if any fuses are blown and inspect for any loss of phase in the three-phase power supply. If there are open circuits, poor contacts, blown fuses, or a lack of phase, identify the underlying causes and repair them promptly. Addressing power supply issues is crucial to ensure proper functioning of the pump. Regular maintenance and inspection of the power supply system can help prevent potential disruptions and optimize the performance of the pump.
2. When assessing a mud pump machine for mechanical failures, it’s important to consider common causes such as worn or damaged components like seals, bearings, or impellers. Misalignment of shafts or couplings can also lead to issues. Excessive vibrations caused by imbalanced rotating parts, blockages or clogging in the pump’s volute or suction pipe, and overheating due to insufficient lubrication or cooling should also be examined. By identifying these mechanical failures, appropriate steps can be taken to address them and ensure the smooth functioning of the mud pump machine. Regular maintenance and inspections are key to preventing such failures.

• If the packing in the pump is too tight or if debris blocks the gap between the impeller and the pump body, it can cause issues. The excessive tightness of the packing may result in increased friction and wear, while debris blockage can hinder the flow and reduce pump efficiency. Regular maintenance and inspection are necessary to ensure proper packing adjustment and clear any obstructions, allowing the pump to operate smoothly and efficiently.
• If the pump shaft, bearing, or leakage reducing ring are rusted, it can lead to problems. Rust can cause increased friction, wear, and potential failures. Regular inspection and maintenance are essential to prevent rust formation. Applying appropriate protective coatings, lubrication, and addressing any moisture-related issues can help prevent rust and ensure the smooth operation of the pump components.
• If the shaft of the mud pump machine is severely bent, it can cause significant issues. A bent shaft can lead to vibrations, misalignment, and increased stress on the pump components. It can result in reduced efficiency, increased wear, and potential failures. In such cases, it is necessary to replace or repair the bent shaft promptly to restore the proper functioning of the mud pump machine and prevent further damage. Regular maintenance and inspections can help identify and address shaft misalignment or bending issues early on.

1.2 Solution:

• To address issues related to packing, it is necessary to loosen the packing to ensure proper adjustment. Additionally, if gutters are clogged, they should be unclogged to maintain smooth flow and prevent any potential disruptions in the pump system.
• To remove debris and rust from the mud pump machine body, it is necessary to disassemble it. Carefully disassemble the components, clean out any debris or rust, and ensure thorough cleaning. This helps prevent blockages, maintain optimal performance, and extend the lifespan of the machine. After cleaning, reassemble the mud pump machine with proper care and attention to ensure its smooth operation. Regular maintenance and cleaning are essential to keep the machine in good working condition.
• If the pump shaft requires calibration or is damaged beyond repair, it is necessary to remove it from the mud pump machine. Calibrating the shaft involves precise measurements and adjustments to ensure proper alignment and functioning. Alternatively, if the shaft is irreparably damaged, it should be replaced with a new one. Proper installation and alignment of the pump shaft are crucial to maintain the integrity and efficiency of the mud pump machine. Regular inspections and proactive replacements help prevent unexpected failures and optimize the performance of the pump system.

2. Overheating of supporting power motor

2.1 Cause:

2.1.1 Power supply.

The voltage of the mud pump machine is too high or too low, under a specific load, if the voltage fluctuation range is outside +10% to -5% of the rated value, it will cause the motor to overheat; The three-phase voltage of the power supply is asymmetric, if the phase-to-phase unbalance of the three-phase voltage of the power supply exceeds 5%, it will cause the winding to overheat; Running with lack of phase, experience shows that more than 85% of agricultural motors are burned due to running with lack of phase, and a lack of phase protection device should be installed on the motor.

2.1.2 Water pump.

The selection of power is not matched, the motor is overloaded for a long time, these cause the temperature of the motor is too high; Start too frequently, the motor which was rated for short-term or intermittent duty work continuously. The times of starting should be limited, the thermal protection should be selected correctly, and the motor should be used according to the rated value marked on the motor.

1. It’s the motor itself. The connection method is wrong, and the △ shape is mistakenly connected to a Y shape, so that the temperature of the motor rises rapidly; The stator winding has phase-to-phase short-circuit, inter-turn short-circuit or local grounding. In light cases, the motor is partially overheated, and in serious cases, the insulation is burned out; The squirrel cage rotor is broken or defective, the motor runs for 1 to 2 hours, and the temperature of the iron core rises rapidly; If the ventilation system fails, check whether the fan is damaged, whether the rotation direction is correct, and whether the ventilation holes of the mud pump machine are blocked; Bearing wear and eccentric sweeping of the rotor make the iron core of the stator and rotor rub against each other and produce a metal impact sound. The temperature of the iron core rises rapidly. In severe cases, the motor emits smoke, and even the coil is burned.
2. The work environment. The motor winding is damp or dust, oil, etc. adhere to the winding, resulting in reduced insulation. The insulation resistance of the motor should be measured, cleaned and dried; The ambient temperature is too high. When the ambient temperature exceeds 35°C, the inlet air temperature will be too high, which will make the temperature of the motor too high. Try to improve the working environment, such as setting up a shed for sunshade, etc.

Note: If there is a failure due to electrical reasons, an electrician who has obtained a professional qualification certificate should be invited to repair it. People with little knowledge should not repair it blindly to prevent the occurrence of personal injury accidents.

3.Mud pump machine heats up

3.1 Cause:

• Bearing damage.
• The clearance of the mud pump machine rolling bearing or bracket cover is too small.
• The mud pump machine shaft is bent or the two shafts are not concentric.
• The tape is too tight; Lack of oil or poor oil quality.
• The balance hole on the impeller is blocked, the impeller is out of balance, and the thrust to one side is increased.

3.2 Solution:

• Replace bearings.
• Remove the rear cover and install a spacer between the bracket and the bearing seat.
• Check the mud pump machine shaft or adjust the concentricity of the two shafts.
• Properly adjust the tightness of the tape.
• Inject clean butter, the butter accounts for about 60% of the clearance in the bearing; Clear the blockage in the balance hole.

4. Mud pump machine flow is insufficient.

4.1 Cause:

• The power speed of the mud pump is not matched or the belt slips, which makes the speed low.
• Axial flow pump vane installation angle is too small.
• Insufficient lift, too long pipeline or right-angle bend of pipeline.
• High suction lift.
• Partial blockage of bottom valve, pipeline and impeller or impeller defect.
• Serious water leakage of discharge pipeline.

4.2 Solution:

• Restore the rated speed, remove the belt grease, and adjust the belt tightness.
• Adjust the blade angle, lower the installation position of the water pump, shorten the pipeline or change the curvature of the pipeline.
• Seal the leak of the water pump and press the packing.
• Clear blockage, replace impeller.
• Replace the leak-reducing ring and block the leak.

4.3 Cause:

• There is air in the mud pump machine body or air in the water inlet pipe, or the bottom valve is not closed tightly which causes the irrigation water is not full filled, and the vacuum pump packing leaks air seriously, The gate valve or flapping door is not closed tightly.

4.4 Solution:

• Press the water up, then fill the mud pump machine body with water, and start the mud pump machine.
• Check whether the check valve is tight, and whether there is air leakage in the pipeline and joint. If air leakage is found, apply lubricating oil or blending paint to the joint after disassembly, and tighten the screws.
• Check the oil seal ring of the water pump shaft, if the wear is serious, replace it with a new one; If the nut does not be tightened during installation, the pipeline may leak water or air. If the leakage is not serious, apply cement or cement slurry mixed with asphalt oil in the place where the air or water leaks. Damp mud or soft soap can be applied for temporary repairs. Tighten the nut with a wrench if water leaks at the joint. The cracked pipe must be disassembled and replaced if the water leakage is serious.
• Lower the lift and press the pipe inlet of the water pump under the water for 0.5m.
• The mud pump machine vibrates violently.

4.5 Cause:

• Electric rotor unbalances.
• Poor coupling.
• Bearing wears and bends.
• The rotating parts are loose or be broken.
• Pipe support is not strong.

4.6 Solution:

• Adjustment, repair, reinforcement, straightening, replacement and other methods can be adopted respectively.
• These are the common causes of mud pump machine failure, not all of them. Please analyze actually, follow the principle of first outside and then inside, do not operate blindly in practice.

Conclusion

During the use of mud pumps, some common faults are often encountered. The following is a summary of common mud pump failures and corresponding solutions:
(1) The mud pump cannot be started: It may be caused by power failure, motor damage, circuit connection problems, etc. Solutions include checking the power supply, troubleshooting the motor, checking whether the circuit connection is normal, etc.
(2) Excessive vibration of the mud pump: Excessive vibration may be caused by unbalanced pump, loose pump foot bolts, damaged bearings, etc. Solutions include rebalancing the pump, tightening pump foot bolts, replacing damaged bearings, etc.
(3) Mud pump body leakage: Pump body leakage may be caused by aging seals, wear or damage to the pump body, etc. Solutions include replacing seals, repairing or replacing damaged pump components, etc.
(4) Mud pump flow rate decreases: The flow rate decrease may be caused by internal blockage of the pump, impeller wear, insufficient opening of the inlet valve, etc. Solutions include clearing blockages inside the pump, replacing worn impellers, ensuring the inlet valve is fully open, etc.
(5) Excessive working noise of the mud pump: Excessive working noise may be caused by looseness of the pump body, unbalanced impeller, damaged bearings, etc. Solutions include tightening pump components, balancing impellers, replacing damaged bearings, etc.
(6) Mud pump motor overheating: Motor overheating may be caused by excessive load, motor winding failure, poor ventilation, etc. Solutions include reducing loads, repairing motor windings, improving ventilation conditions, etc.

When dealing with these common faults, appropriate solutions should be taken in a timely manner. In addition, regular mud pump maintenance, correct operation, and reasonable selection of pump models and materials can also help prevent failures. If you encounter a problem that cannot be solved, it is recommended to consult a professional or seek relevant technical support.

Follow the steps and suggestions provided by OECEAN Pump above, you can operate your mud pump correctly, ensure it works efficiently, extend its life, and improve work efficiency and safety. We not only provide pump customization, but also provide guidance on pump use and maintenance. Any questions or inquiries, please contact us.

Tai’an Ocean Pump Co., Ltd. (referred to as OCEAN PUMP) is a manufacturer and exporter of sand pumps, wear-resistant gravel pumps, slurry pumps, mud pumps, sediment pumps, sewage pumps, dredging pumps, sand dredgers and other sand pump machine. OCEAN PUMP integrates independent research and development, equipment manufacturing, pre-sales and after-sales service, the business covers sand suction and dredging projects. The products cover 20 series and more than 500 specifications. The products are exported to 36 countries and regions. OCEAN PUMP has won the praise and trust of users with its more than 20 years industry experience, professional technology and excellent service.