How to Prevent Shaft Breakage in Axial Split Case Pumps: A Practical Guide for Reliable Operation
Axial split case pumps are widely used in industrial and municipal applications due to their high flow capacity, reliable performance, and convenient maintenance features. However, one of the most common and costly failures in these pumps is shaft breakage, which can result in unexpected downtime, production losses, and expensive repairs.
This article explores the main causes of shaft breakage in axial split case pumps and outlines effective prevention strategies. By implementing proper maintenance practices, ensuring correct installation, using quality materials, and adopting real-time monitoring technologies, facilities can significantly reduce the risk of pump shaft failure and maintain long-term operational stability.
Why Do Shaft Breakages Occur in Axial Split Case Pumps?
Understanding the root causes of shaft failure is essential for effective prevention. The most common reasons include:
| No. | Cause | Description |
| 1 | Overload Operation | Operating beyond the pump’s rated flow or head places excessive stress on the shaft and bearings, leading to fatigue and eventual shaft breakage. |
| 2 | Bearing Damage | Worn, damaged, or misaligned bearings increase internal clearance and shaft vibration, creating uneven forces that accelerate fatigue failure. |
| 3 | Material Deficiencies | Inferior or improperly selected shaft materials with defects such as inclusions or porosity may be unable to withstand mechanical stresses, increasing failure risk. |
| 4 | Improper Installation | Shaft or coupling misalignment during installation causes uneven load distribution, resulting in bending stress and progressive cracking. |
| 5 | Sudden Impact Loads | Rapid pressure changes during startup or shutdown can generate hydraulic shock loads, imposing high instantaneous forces on the shaft. |
| 6 | Corrosion and Fatigue | Prolonged exposure to corrosive or aggressive fluids leads to surface degradation, microcrack formation, and reduced shaft strength over time. |
| 7 | Inadequate Lubrication | Insufficient or poor-quality lubrication increases friction and operating temperatures, accelerating shaft wear and fatigue. |
How to Prevent Shaft Breakage in Axial Split Case Pumps
To reduce the risk of shaft failures, it is critical to adopt a proactive maintenance and operational strategy. The following practices are recommended:
| Category | Recommended Measures |
| Regular Maintenance and Inspection | • Conduct routine inspections of bearings, seals, and lubrication systems • Monitor shaft alignment and correct deviations promptly • Replace worn or damaged components before failure occurs |
| Reasonable Pump Selection | • Select an axial split case pump that matches actual flow rate and head requirements • Avoid excessive oversizing or marginal safety margins that can cause inefficiency and mechanical stress |
| Control of Operating Conditions | • Implement soft start and soft stop procedures to reduce hydraulic shock loads • Operate the pump strictly within its rated operating range |
| Strengthen Lubrication Management | • Use high-quality lubricants suitable for the operating environment • Regularly check lubricant condition and replace it according to manufacturer recommendations |
| Use High-Performance Shaft Materials | • Choose corrosion-resistant and fatigue-resistant materials such as duplex stainless steel or high-strength carbon steel • Work with reputable manufacturers that enforce strict quality control during shaft production |
| Train Operators for Proper Use | • Provide systematic training on pump startup, shutdown, and daily operation • Encourage early reporting of abnormal noise, vibration, or performance decline |
| Install Monitoring and Diagnostic Systems | • Use vibration and temperature sensors to continuously monitor pump condition • Early detection of abnormalities enables corrective actions before major damage occurs |
Conclusion: Ensuring Long-Term Reliability of Axial Split Case Pumps
While shaft breakage is a potential risk in the operation of axial split case pumps, it can be effectively mitigated through proper equipment selection, preventive maintenance, and skilled operation. By understanding the underlying causes and implementing targeted strategies—such as improving lubrication, ensuring precise alignment, using durable materials, and investing in real-time monitoring—enterprises can significantly enhance the reliability of their pumping systems.
Ultimately, reducing shaft failure not only safeguards equipment and minimizes downtime but also contributes to the overall efficiency and profitability of the operation. With continuous improvement in management practices and technical implementation, facilities can create a safer and more stable production environment.
