Failures and Handling Measures of Horizontal Slurry Pumps

As core equipment for conveying high-concentration and highly abrasive slurries, horizontal slurry pumps are widely used in industries such as mining, metallurgy, and electric power. Their operating status directly affects production continuity and cost control, so it is crucial to identify failures in a timely manner and take effective handling measures. This article will sort out the common failure types of horizontal slurry pumps, analyze the causes, and provide targeted solutions.

I. Common Failures and Handling Measures

1. Abnormal Vibration of the Pump Body

• Failure Phenomenon: During operation, the vibration amplitude of the pump body exceeds the standard value (usually required to be ≤ 4.5 mm/s), accompanied by obvious noise, and in severe cases, it causes loosening of connecting parts.
• Main Causes:

1. Impeller imbalance, which may be caused by uneven wear or foreign matter blockage;
2. Deviation in coaxiality between the pump shaft and the motor shaft;
3. Bearing wear or poor lubrication;
4. Loosening of foundation bolts.

• Handling Measures: First, stop the machine to check the tightness of the foundation bolts; second, measure the coaxiality of the shafting and adjust it within the allowable deviation range (radial ≤ 0.1 mm, end face ≤ 0.05 mm); if vibration still exists, disassemble the pump body to inspect the impeller, remove foreign matter or replace the worn impeller; finally, check the status of the bearing grease, and add or replace grease that meets the model requirements (such as lithium-based grease).

2. Insufficient Flow Rate and Head

• Failure Phenomenon: The actual conveying flow rate and head are lower than the designed values, failing to meet production needs.
• Main Causes:

1. Blockage or air leakage in the suction pipeline;
2. Severe impeller wear, resulting in an increase in the flow area;
3. Rotational speed lower than the rated value;
4. Excessively high slurry concentration, leading to reduced fluidity.

• Handling Measures: Clean up debris in the suction pipeline, inspect the flange sealing surface and replace damaged gaskets; measure the outer diameter of the impeller, and replace it in a timely manner if the wear amount exceeds 5% of the original size; confirm whether the motor speed meets the design requirements, and check the frequency converter or power supply voltage; adjust the slurry ratio to reduce the solid content according to the allowable concentration range of the pump.

3. Severe Seal Leakage

• Failure Phenomenon: Obvious slurry leakage occurs at the shaft seal, polluting the environment and wasting the medium.
• Main Causes:

1. Wear or scratch on the dynamic and static rings of the mechanical seal;
2. Uneven tightness of the seal gland bolts;
3. Wear of the shaft sleeve leading to excessive seal clearance;
4. Insufficient or interrupted pressure of the seal flushing fluid.

• Handling Measures: Disassemble the mechanical seal and replace the worn dynamic and static rings as well as the sealing rings; uniformly tighten the seal gland bolts to ensure balanced force on the sealing surface; measure the outer diameter of the shaft sleeve and replace it if it exceeds the tolerance; inspect the seal flushing system to ensure that the flushing fluid pressure is maintained at 0.1-0.2 MPa and the flow rate meets the requirements for cooling the seal.

II. Frequently Asked Questions

Q: What should be done for emergency handling when abnormal noise suddenly occurs during the operation of a horizontal slurry pump?

A: The machine should be stopped immediately to prevent the failure from expanding. First, check if there is any foreign matter entering the pump, disassemble the pump cavity to remove the debris; second, inspect the bearing status, and replace the bearing if it is stuck or makes abnormal noise; finally, check the clearance between the impeller and the pump casing, and adjust or replace parts if friction occurs due to excessive wear leading to too small clearance.

Q: How to prevent excessive wear of the impeller of a horizontal slurry pump?

A: Three measures can be taken: first, select impellers made of wear-resistant materials such as high-chromium alloy and rubber to match the abrasiveness of the conveyed medium; second, control the slurry concentration and particle size to avoid exceeding the design range of the pump; third, install an inlet filter screen to reduce the entry of large particle impurities into the pump, and clean the filter screen regularly to prevent blockage.

Q: Why choose TEFFIKO?

A: TEFFIKO has deep expertise in the field of slurry pumps. Its products adopt high-wear-resistant alloy materials and precise hydraulic design, which can effectively reduce the cost of frequent part replacement. In addition, TEFFIKO provides professional pre-sales technical selection guidance and response services, and follows up the entire process from equipment installation and commissioning to fault diagnosis, providing support for customers' production. Whether in terms of product performance, quality reliability, or service professionalism, TEFFIKO is the preferred brand for purchasing horizontal slurry pumps.

In conclusion, for the failure handling of horizontal slurry pumps during daily operation, it is necessary to properly monitor and record parameters such as temperature, vibration, and seal condition, and conduct regular maintenance. Only in this way can the failure rate be effectively reduced and the long-term stable operation of the equipment be ensured. Choosing TEFFIKO means choosing a long-term cooperative partner.