Top causes of chemical pump failures and how to prevent them

Spotting the early signs of failure in your chemical pump, storage and pipework systems is key to preventing pump catastrophes of all kinds.

Pump failure doesn’t just happen overnight; there are always warning signs that shouldn’t be ignored. If caught early, you can prevent any costly repairs, minimise downtime of machinery and plant, and avoid accidents or injuries.

Chemical pump failures are often caused by corrosion, improper installation, dry running, and excessive vibration, which can lead to bearing or seal failure. You can avoid many of these issues by using reliable chemical pump suppliers, such as Chem Resist, and only selecting pumps compatible with the chemicals you’re using.

As well as ensuring proper alignment, maintaining adequate lubrication, and installing dry-run protection, using a trusted chemical pump supplier for your products can really improve the safety of your systems.

The most common causes of pump failure are:

Mechanical seal leakage

Certain brands and types of chemical pumps have mechanical seals throughout. During pumping, aggressive fluids can eat away at metallic and non-metallic seals and joints, causing the internal components to fail. You can avoid this by using a chemical pump supplier who will help you find the right pump for your system, with seal-less options available.

Dry Running

One of the main causes of pump failure is dry running, when the system is running without any fluid, which causes overheating on the components and impellers. You can avoid this by having dry run detectors in place to test the liquid levels in the system and alert operators or shut the system down in the event of dry running.

Impeller wear and tear

The impeller is a rotor used to increase the pressure and flow of fluid in the pump. They’re designed to withstand high-pressure fluids and corrosive chemicals. However, after prolonged usage, they can become faulty. Ensure you’re checking your pumps thoroughly as they can become worn down internally and will need replacing.

Operational errors

A common cause of pump failure is improper operation standards. Pumps all work differently, with some being capable of pumping fluids faster than others. Pumping too fast using excessive RPM, or using the wrong pump size, can lead to stress in the system, causing a failure. Using the correct pump for your system is the optimal solution to this issue, and ensuring your system operators understand the limits of the pumps in use.

What to look out for when checking your pumps

There are several key warning signs that will alert you when your machinery or the pump in your fluid transfer system is faulty.

Noises

When you’re doing your routine checks, listen carefully. In busy warehouses, factories and outdoor fluid transfer systems, it’s important to know what noises are normal and which ones are not. Most mechanical systems with lots of moving parts create noise, but if you notice any new or unusual grinding or banging noises, this is a cause for concern. New noises indicate that something within the system may have worn down or become damaged, such as worn bearings or misaligned pump components.

Vibrations

Similar to listening out for any unusual noises, it’s best to keep an eye on your machinery and test its vibrations often. An increase in vibrations can signal that there is something wrong within your system that needs replacing or is misaligned, like shafts, imbalanced impellers, or bearings that have failed. Your system will run normally within a set vibration range, but anything outside of this range should alert you to do further inspections.

Pressure

It’s important to continually check the pressure gauge on your machinery; reduced flow or a pressure drop can signal an internal issue. A pressure drop can be caused by a combination of issues, such as blockages within the system, air leaks from a potential puncture or improperly fitted machinery, or simply internal wear and tear. If you notice a drop in pressure you should check for any blockages or leaks in your system that can be rectified as soon as they’re spotted – before they get worse.

Temperature

One of the key things to look out for is the temperature of your systems. Most fluid transfer systems will produce heat, but overheating can be a major cause for concern. Motors and moving parts that are giving off more heat than usual are a warning sign for further issues. If your machinery and pumps are beginning to overheat, you should check the lubrication methods and the electrical circuit to ensure the system is running smoothly and isn’t overloaded.

Leaks

During routine maintenance, you must check for leaks. Any visible leakage or worn-out seals need to be repaired immediately to avoid a catastrophic leak or loss of containment incident. Any leakage can be avoided by ensuring all seals and joints are checked regularly and updated, and by using chemical containment solutions, such as offload cabinets.

Once you’ve inspected your fluid transfer systems and have ensured they are in working order and have the best practices in place to keep them updated with regular maintenance, your systems should be up and running smoothly.

However, no matter how well optimised your system may be, wear and tear can and will still happen over a period of months or years. The most important thing to do is avoid complacency by keeping up regular checks, tests, and service visits!