Common Pump Issues & Troubleshooting
Whether they are running fluid via pipelines, providing water in a facility or residential building, or moving chemicals in a manufacturing plant, pumps are at the core of many industrial, commercial and domestic applications. When pumps run smoothly, everything flows; but when they fail, the entire process might grind to a halt. Pump failures can create significant downtime, resulting in production delays, dissatisfied residents, costly repairs, and even safety hazards.
We’ll go over some of the most frequent pump difficulties, how to diagnose them, and how to keep your pump running efficiently. Furthermore, emphasising crucial preventative steps can help reduce the likelihood of pump failure and minimise downtime.
Disclaimer:
The information provided in this blog is intended for general knowledge and troubleshooting purposes. Pumps should be serviced and maintained by a qualified professional or someone with proper training and expertise. Attempting to repair or maintain pumps without the necessary knowledge can result in further damage, void warranties, create safety risks, or lead to equipment failure. Always follow manufacturer guidelines and always consult a professional, such as a Trebles engineer, for major repairs or technical issues. Trebles are not liable for any damages resulting from improper maintenance or repairs.
Common Pump Issues & How to Troubleshoot Them
Understanding common pump faults can help spot early warning signs and enable speedy troubleshooting before a failure causes lengthy downtime or costly repairs.
Low Pressure
Low pressure in pump systems indicates that the pump is not producing enough force to efficiently move the fluid, resulting in reduced flow rates. This can occur for a variety of reasons, including blockages, air leaks, and suction line issues.
Symptoms:
- Reduced fluid flow rate.
- Inconsistent or fluctuating pressure readings.
- Struggling pump performance.
Troubleshooting:
- Check for obstructions in the suction line: A blockage in the suction line can restrict fluid flow, causing low pressure. Inspect the line for debris, clogs, or any other impediments.
- Inspect for air leaks: Air in the system can disrupt suction and lower pressure. Check the suction-side components for leaks and ensure all connections are airtight.
- Ensure the pump is primed: If the pump isn’t fully primed, air can enter and cause low pressure. Reprime the pump to ensure smooth operation.
- Verify suction lift: The pump’s suction lift (the height difference between the fluid source and the pump) may be too high, making it difficult for the pump to maintain adequate pressure.
Prevention Tips:
- Regularly inspect and clean the suction line to prevent blockages.
- Ensure that the system is properly primed before operation.
- Use suction strainers or filters to catch debris before it enters the pump.
High Pressure
High pressure in a pump system can arise when the pump is operated under conditions that exceed its design capability. This can result in overloading the system, increased wear on components, or even catastrophic failure. Causes include blockages on the discharge side, incorrect valve settings, or improper pump sizing.
Symptoms:
- Excessive system pressure beyond recommended levels.
- Frequent trips or shutdowns triggered by pressure relief devices.
- Loud noises or vibrations due to excessive stress on components.
Troubleshooting:
- Inspect discharge lines for blockages: A clogged or obstructed discharge line can cause pressure to build up. Check for debris or valve malfunctions that could be restricting flow.
- Check pressure relief valves: Faulty or improperly set pressure relief valves can lead to high pressure. Ensure they are working correctly and set to the appropriate levels.
- Verify system demand vs. pump capacity: If the pump is too powerful for the system, it can generate more pressure than necessary. Reassess the pump sizing to ensure it matches system requirements.
Prevention Tips:
- Regularly inspect discharge lines and pressure relief valves to ensure proper functioning.
- Install pressure gauges to monitor real-time pressure and catch problems early.
- Use a pump that matches the system’s requirements to avoid overpressurising.
Cavitation
Cavitation happens when vapour bubbles form in the pump and then collapse, generating shockwaves that can damage the impeller and other internal components. It is frequently caused by low pressure in the pump’s suction line, high fluid temperatures, or excessive fluid velocity.
Symptoms:
- Unusual noises, often described as a “gravel” sound or like marbles rattling inside the pump.
- Reduced pump efficiency and flow rates.
- Damage to impellers and other internal components upon inspection.
Troubleshooting:
- Check the suction pressure: Ensure that the pump is operating within the required pressure range. If the suction pressure is too low, increase the pressure or check for obstructions in the suction line.
- Lower the pump speed: High speeds can cause cavitation. Reducing the pump’s RPMs can alleviate this issue.
- Decrease fluid temperature: Higher fluid temperatures reduce the pressure at which cavitation can occur. Cool down the fluid if possible.
Prevention Tips:
- Install suction strainers or filters to prevent blockages.
- Ensure proper system design with adequate net positive suction head (NPSH).
- Regularly monitor suction pressure and fluid temperature.
Seal Leakage
Seal leakage is a typical problem that can cause fluid loss, contamination, and even damage to the pump and surrounding equipment. Seals may fail owing to wear, faulty installation, or chemical corrosion.
Symptoms:
- Visible fluid leakage around the shaft or seal.
- A drop in system pressure.
- Increased maintenance on seals or frequent replacements.
Troubleshooting:
- Inspect the seal for wear or damage: If the seal is visibly damaged, it needs to be replaced.
- Check for misalignment: Shaft misalignment can cause excessive stress on seals, leading to premature failure.
- Ensure correct installation: Improperly installed seals are more likely to fail. Double-check the installation guidelines.
Prevention Tips:
- Use high-quality seals that are compatible with the fluid being pumped.
- Implement regular maintenance checks for early signs of wear.
- Keep the pump shaft aligned to reduce unnecessary wear on seals.
Pump Overheating
Overheating happens when a pump’s components temperature grows excessively, resulting in thermal expansion, material degradation, or even full pump failure. This issue is frequently caused by insufficient lubrication, friction from worn parts, or operating beyond the pump’s capability.
Symptoms:
- Increased temperature readings on the pump housing or motor.
- Strange smells from burning lubricant or heated components.
- Unusual noises due to parts expanding or rubbing together.
Troubleshooting:
- Check the lubrication system: Insufficient lubrication of bearings or other moving parts can lead to overheating. Refill or replace lubricant as necessary.
- Inspect for worn parts: Bearings, impellers, or seals that are worn can generate excessive heat due to friction.
- Verify that the pump is operating within design parameters: Ensure the pump is not running under conditions that exceed its specified capacity.
Prevention Tips:
- Perform regular maintenance on lubrication systems and ensure they are filled correctly.
- Avoid overloading the pump by operating it within its designed parameters.
- Install temperature sensors and automatic shutdown systems to prevent damage if overheating occurs.
Preventative Maintenance: Reducing Pump Downtime
Preventive maintenance is one of the most effective methods for reducing pump failures and unnecessary downtime. Here are some important maintenance suggestions for keeping your pumps functioning smoothly:
Regular Inspections
Conduct routine visual inspections of your pump system to catch early warning signs of failure. Check for leaks, unusual noises, excessive vibration, and any visible wear on components.
Monitor Performance
Track key performance indicators (KPIs) such as flow rate, pressure, and temperature. A sudden drop in any of these metrics could signal a problem. Using condition monitoring systems that track these KPIs in real-time can alert operators to issues before they escalate.
Lubrication Maintenance
Ensure that all moving parts, such as bearings and seals, are properly lubricated. Lack of lubrication is a common cause of overheating and mechanical failure.
Cleaning and Flushing
Regularly clean and flush the pump system to remove contaminants and buildup that can lead to blockages, corrosion, or wear. This is particularly important in environments where the pumped fluid contains solids or corrosive chemicals.
Alignment and Calibration
Misalignment of the pump shaft or other components can cause excessive wear and lead to failure. Regularly check and adjust alignment as necessary. Similarly, ensure that the pump is calibrated correctly and running within the recommended parameters for pressure, temperature, and speed.
Conclusion
While pump failures are inevitable over time, understanding common problems and applying effective troubleshooting methods can significantly reduce downtime. By implementing preventive maintenance practices, including regular inspections, performance monitoring, and proper lubrication, you can enhance pump reliability and longevity. Keeping pumps in optimal condition will not only prevent costly breakdowns but also ensure that your operations run smoothly and efficiently.
Unsure about your pump’s current situation? For servicing or repairs, email us at service@gmtreble.co.uk or download our Service, Maintenance, and Repair brochure here for more information.
