TL;DR
High power draw is usually excess flow (system resistance dropped), higher liquid density than design, or internal binding. Measure amps and head to locate the cause.
What you might see
- motor amps above nameplate FLA
- overload relay tripping
- driver running hotter than normal
- higher energy bill with no increased output
Likely causes
System resistance decreased (e.g., bypass valve opened), shifting the operating point far right of BEP and increasing required BHP
Process liquid specific gravity or viscosity higher than the original design basis
Internal binding from contact between the impeller and wear rings due to seal collapse or debris
Motor or drive efficiency loss from worn bearings or damaged windings
Required tools
- Clamp ammeter (true-RMS)
- Pressure gauges (suction and discharge)
- Tachometer
- IR thermometer
- LOTO kit
Safety first
- Lock out the driver before opening the casing or rotating the shaft by hand.
- All current measurements on energized equipment require appropriate arc-flash PPE.
Procedure
- 1
Lock out the pump driver.
- 2
Record current suction pressure, discharge pressure, and motor amps. Calculate differential head and compare to the Goulds rated curve to confirm the operating point.[1]
- 3
Verify the process fluid specific gravity and viscosity have not changed from the original design values. A 10% SG increase raises BHP by 10%.
- 4
Check all system valves. A partially open bypass sends flow back to suction, appearing as high amps with low net delivery.
- 5
Rotate the pump shaft by hand with power locked out. Binding or rough spots indicate impeller-to-casing contact or debris.
- 6
Open the casing and inspect for debris lodged between the impeller and casing walls.[1]
- 7
Measure bearing temperatures after a short run. Hot bearings can increase load amps by 3-5% and will worsen over time.
- 8
If the operating point is confirmed far right of BEP, throttle the discharge valve or trim the impeller diameter to match the new system curve.
Sources
Goulds 3196 i-FRAME Process Pump Installation, Operation & Maintenance Manual, Goulds Pumps (ITT)
Goulds 3196 i-FRAME IOM, power consumption and operating point procedures (general)
View source
More guides for Goulds Pumps 3196
How to stop cavitation noise on a Goulds 3196 centrifugal pump
Cavitation is almost always low NPSH. Check the suction line for restrictions or air ingress, lower the pump speed, or raise the liquid level in the suction vessel.
How to fix a leaking mechanical seal on a Goulds 3196 pump
Seal leaks are most often caused by dry running or shaft misalignment. Confirm the seal flush is active before start and measure shaft runout before fitting a new seal.
How to diagnose low flow rate and pressure fluctuation on a Goulds 3196 pump
Low flow with reduced head points to a worn or trimmed impeller or internal recirculation. Measure differential head and compare to the rated curve to confirm.
How to fix a Goulds 3196 pump overheating at low or shutoff flow
Running below minimum continuous stable flow converts pump work into heat. Install or open a minimum-flow recirculation bypass to protect the pump.
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