Neglecting the diagnosis and rectification of critical issues affecting pumps can have disastrous consequences. In various industries, ranging from paper mills to water treatment facilities, the failure of a single pump can result in the complete shutdown of production processes.

It’s crucial to keep pumps healthy, but to do that you need to answer one important question: why do pumps fail? These 5 things account for over 60% of pump failures

1. Mechanical seal leakage

The typical occurrence of leakages often transpires at the interface between the two seal faces, although there are instances when leakages can emanate from the secondary sealing area. The reasons behind mechanical seal leakage are diverse and encompass factors like dry running, thermal distortion, and misalignment of seal rings, among others.

2. Process issues

Instances of such failures arise from the usage of inadequately chosen pumps concerning the particular process, industrial application, or operational parameters. Therefore, the utmost importance lies in selecting the appropriate pump tailored precisely to suit your specific application requirements.

3. Bearing issues

The predominant cause behind bearing failures is improper lubrication, accounting for approximately 80% of such incidents, leading to overheating. Furthermore, other contributing factors encompass improper bearing selection, overloading, fatigue, and a myriad of additional factors.

4. Impeller wear and tear

Similar to other failures, impeller wear and tear can be attributed to various reasons. Foremost among them is erosion, although inadequate pump sizing also plays a significant role, potentially leading to pressure imbalances.

5. Coupling-related issues

The most prevalent occurrences of coupling failures stem from the following factors: misalignment, overloading, unusual environmental influences, torsional vibration, and improper lubrication.

6. Electrical Issues:

Electrical problems such as voltage surges or power outages can damage a pump and cause it to fail. Many protective devices can safeguard the pumps from this, but sudden surges can still cause the pump failure.

7. Cavitation:

Cavitation is a condition where air pockets are formed in the liquid being pumped. This can damage the pump and eventually lead to failure.

7. Vibration:

Excessive vibration can damage the internal parts and lead to pump failure. These vibrations are caused generally due to alignment issues, inherent installation issues or even overuse of pumps.

What Are The Major Symptoms Of Pump Failure?

Instantaneous pump failures are easy to detect. However, pumps start showing particular symptoms over time, leading to pump failure. You must know these symptoms to act on time to save the pump.

The pump doesn’t seem to be working as efficiently as it used to.
You notice an increase in the energy required to operate the pump.
The pump makes strange noises that you haven’t heard before.
You see water or other fluids leaking from the pump.
The pump isn’t generating enough pressure to correctly move fluids through your system.
The pump is running hot, even when there’s no load on it.
The motor seems to be struggling or straining when the pump is running.
You notice vibrations or excessive movement coming from the pump.
The pump just stops working altogether.
You see smoke or fire coming from the pump.

How To Mitigate Pump Failure?

No engineer would want an operational pump to fail. It will only lead to process disruption and possible loss in revenue. Hence you must try and avoid pump failure as much as possible. Following are the ten ways to mitigate pump failure:

Use a reputable pump manufacturer with a good track record.
Select the right pump for the application – one that is appropriately sized and has the required flow and pressure capabilities. Your pump manufacturer can guide you in this process.
Ensure that the pump is installed by qualified personnel and meets all installation requirements as provided by the pump manufacturer.
Follow the manufacturer’s operating and maintenance instructions to keep the pump running smoothly and efficiently.
Inspect the pump regularly and perform routine maintenance according to the schedule recommended by the manufacturer.
Keep an eye out for early warning signs of pump failure, such as increased vibration or noise, leaks, or erratic performance, and take action to address them promptly.
Use high-quality pump parts and fluids, and make sure they are compatible with each other.
Be aware of the conditions that can lead to pump failure, such as cavitation, overheating, and dry running, and take steps to avoid them.
Use a monitoring system to track the pump’s performance and identify potential problems early on.
Have a plan in place for dealing with pump failure, including having spare parts on hand and knowing how to troubleshoot and repair the problem.