Home / Knowledge Base / 10 Ways To Murder Your Pump

10 Ways To Murder Your Pump

Article ID: KBA-1

Date: October, 2021

Your Pump is Critical. Is Yours Installed and Maintained Correctly?

Pump maintenance plays a critical role in the smooth operation of businesses and households, ensuring the efficient movement of liquids and maintaining systems’ functionality. However, the longevity and reliability of this equipment can be severely compromised by various factors. In our analysis, we’ve compiled the top 10 ways that can inadvertently lead to the demise of pumping systems.

From neglecting regular maintenance to using the wrong type of fluids, these common pitfalls can result in costly repairs and downtime. Understanding these risks is crucial for anyone relying on pumping solutions to sustain daily operations.

1. Overwork Your Pump Unit

Perform regular checks

To ensure pumping equipment is suitable for the application and operating duty of the system, it is essential to perform regular checks of operating conditions and monitor equipment such as flowmeters, pressure gauges, amp/voltmeters, pump glands, and pipework for unusual noise levels.

Schedule maintenance

Proper maintenance must be scheduled, and adequate time must be allocated to address any issues. A standby unit should be provided for pumping systems requiring 24-hour operation to maintain continuous function. Additionally, when altering duty cycles or applications, it is crucial to review the equipment’s design criteria, including head capabilities, operating speeds, impeller diameters, and pipe system details, to confirm compatibility and maintain optimal performance.

Preventive maintenance

A key focus of preventative maintenance is detecting leaks in vital components such as mechanical seals, packing glands, bearings, and O-rings. It’s important to inspect pipe systems and corrosion-prone areas to prevent operational failures. Regular inspections identify issues early, reducing unexpected breakdowns and safety risks.
Regular checks of drive assemblies, including couplings, belts, and gearboxes, are crucial. Monitor for proper alignment, vibrations, unusual noise, and wear signs, as these can affect efficiency and cause strain. Also, operating temperatures should be observed to ensure they stay within safe limits.

Structured maintenance plan

Understanding operational nuances is essential for proper equipment maintenance. Packed glands allow a small amount of fluid leakage for cooling, while mechanical seals are designed to operate without leakage. Following these guidelines helps prevent damage. Implementing a structured maintenance plan extends equipment life and promotes safer operations.

Photos of Pump Servicing

2. Break Its Limbs

Pump mounting

Properly mounting pumping equipment on level surfaces is essential to maintain its integrity and performance. Using shims, packing, or machined surfaces prevents the warping of housings, which can compromise functionality. Additionally, heavy suction and discharge piping and fittings must be adequately supported and designed with flexibility to handle stress or vibration effectively. These measures help protect the pumping equipment and ensure reliable, long-term operation.

Pump Skid Mounting Systems

3. Poison It

Check product datasheet

When providing details about the product to be handled by the pumping equipment, it is essential to review the manufacturer’s product datasheet to confirm the suitability of the materials. Any changes to the equipment’s application should not be made without conducting the necessary checks, as components such as mechanical seals, packing, and construction materials may not be compatible with the new requirements. This thorough evaluation ensures that the equipment operates reliably and maintains its intended performance.

4. Stab It

Use a suction strainer

Selecting a pump that fits your application, whether for clean water, sewage, or dirty and gritty liquids like slurry, is critical for optimal performance. Always use a suction strainer, ensuring its inlet holes match the pump’s handling capacity; for example, a pump designed for 10mm solids requires a strainer with holes no larger than 10mm.
Pay attention to whether the strainer uses slots or drilled holes, as this can affect performance. Regularly check and clean suction strainers to prevent clogs that could restrict the pump’s intake and compromise efficiency.

Example Suction Strainers

5. Fry It

Operate within the specified temperature range

Operating a pump within the manufacturer’s specified temperature and range is vital to ensure its performance and longevity. Restricted suction, clogged delivery, or recirculating valves can lead to serious issues, such as a rise in liquid temperature that damages centrifugal pumps or causes overheating in submersible pump motors due to inadequate cooling. These problems not only compromise the pump’s efficiency but can also result in costly repairs or replacements.

Ensure regular maintenance is performed

To avoid such risks, always ensure proper maintenance and system checks. Venting air from pipe systems is essential to maintain smooth operation and prevent unnecessary strain on the pump. Taking these precautions helps preserve the pump’s functionality and ensures it operates reliably within its designed parameters.

6. Neglect Medical Check-Ups

Regular service and maintenance

Regular service maintenance is a vital practice for ensuring the reliability and longevity of equipment. Preventative maintenance, when compared to crisis or no maintenance, is far more cost-effective. By addressing issues before they escalate into significant problems, you can avoid expensive repairs, minimise downtime, and maximise the efficiency of your equipment. Investing in regular maintenance pays off in the long run by extending the overall lifespan of your systems and preventing unexpected breakdowns that can disrupt operations.

Leak detection

One critical aspect of maintenance is detecting leaks in key components. Mechanical seals, packing glands, bearings, O-rings, and pipe systems can all suffer from wear and tear, leading to potential leaks. These leaks, if not identified and addressed promptly, can compromise equipment performance and even lead to catastrophic failures. Corrosion in pipe systems is another concern, especially in environments where equipment is exposed to moisture or other corrosive elements. Regular inspections can help detect early signs of wear or damage, allowing for timely repairs and replacements.

Drive assemblies

Drive assemblies, including couplings, belts, and gearboxes, also require thorough attention. Proper alignments and adjustments are essential to ensure smooth operation and prevent strain on the system. Vibrations, unusual noises, or visible wear on components are warning signs that should not be ignored. Such issues can indicate underlying problems that need immediate resolution to avoid further damage. Regularly checking and maintaining these components is critical to keep the entire system running efficiently.

Operating temperatures

Monitoring operating temperatures is another essential practice during maintenance. Excessive heat can indicate friction or inefficiencies within the system, leading to potential component failure. Bearing temperatures, gearbox temperatures, and other critical areas should be routinely assessed to ensure they fall within safe operating ranges. Early detection of overheating can help prevent serious issues and keep the equipment functioning reliably.

Operational requirements

It is also important to consider the unique operational requirements of different equipment components during maintenance. Packed glands, for instance, are designed to allow a small amount of fluid leakage to provide cooling. This leakage is essential to prevent overheating and to lubricate the packing effectively. On the other hand, mechanical seals should remain entirely leak-free to prevent any loss of fluid or intrusion of air into the system. Understanding and respecting these operational nuances ensures that the equipment performs as intended.

By prioritising regular service maintenance and addressing these key areas, you can uphold the performance, efficiency, and safety of your equipment. A proactive approach to maintenance not only reduces long-term costs but also ensures that your systems operate smoothly and without interruption.

7. Shake It To Pieces

Sturdy foundations

Sturdy, level foundations are essential for successful equipment installation and long-term performance. Equipment should be mounted on even bases or foundations, ensuring gaps are adequately packed using shims or grout. Avoid pulling down on foundation bolts to close gaps, leading to uneven pressure and instability. Proper groundwork avoids unnecessary strain on the equipment and provides a secure base for reliable operation.

Accurate drive alignment

Accurate drive alignments are equally critical in ensuring the equipment functions optimally. All alignments should be completed carefully during installation and checked thoroughly for precision. After any repairs or transportation back to the site, it’s essential to re-check these alignments to account for possible shifts or changes. Precise alignment helps reduce wear on components and ensures smooth, efficient operation.

Check for cavitation

Monitoring the pump unit for cavitation noise is another key aspect of maintenance. A rattling sound in the pump can indicate cavitation, which occurs when vapour bubbles form and collapse within the pump, potentially causing damage. Common causes of cavitation include using suction pipes that are too long or too small, excessive suction lifts exceeding the pump’s design limits, or changes to the pump duty without referencing performance specifications or consulting the manufacturer. Incorrect shaft speeds can also contribute to cavitation. Addressing these issues promptly minimises the risk of damage and ensures the pump operates efficiently.

Imbalanced or blocked impellers

Another critical step is inspecting radial and axial thrust loading on bearings and impellers. Imbalanced or blocked impellers and improper thrust loading can cause undue stress on these components, leading to premature wear or failure. Additionally, ensure that all mounting and foundation bolts are secure, as loose bolts can compromise the stability of the equipment and increase vibration, further impacting performance.

Precision Motor & Pump Alignment

8. Drown It

Installing a sump or external drainage

Installing equipment in positions or plant rooms without a sump or external drainage poses significant risks to the equipment and the surrounding space. Without proper drainage, the area is highly susceptible to flooding from water leakage in pipe systems, valves, or other sources. Accumulated water can quickly compromise the equipment’s functionality and lead to costly damage, impacting performance and overall operational efficiency.

Check water leaks

One primary concern in such settings is gland or seal water leakage. If not effectively managed, this type of leakage can cause severe issues like pump or motor bearing failure. Bearings rely on a controlled and dry environment to operate smoothly, and water leakage introduces conditions that can lead to premature wear or complete breakdown. Over time, repeated exposure to leakage also accelerates corrosion on equipment surfaces, further degrading its structural integrity and shortening its lifespan.

Mitigate risk

To mitigate these risks, it is crucial to ensure all gland drain provisions and external liquid drains are adequately maintained and blockage-free. When drains are obstructed, water has nowhere to go, creating pools and increasing the likelihood of damage. A proactive approach to checking and clearing drains before problems arise can protect the equipment and the surrounding environment. Keeping these drainage systems fully functional is key to preventing floods, leaks, and their costly consequences.

9. Inadequate Service

Proper maintenance and attention to equipment are essential to ensure its performance and prevent costly failures.

Lubrication

One common issue is insufficient lubrication for bearings, resulting in excessive friction and wear. Using the wrong lubrication or over-lubrication can also lead to complications, such as grease buildup or bearing failure. Regular checks and the correct application of grease or oil help extend the lifespan of these crucial components.

Gland packing and mechanical seals

Neglecting gland packing or mechanical seals can have serious consequences. When these components are not properly maintained, air can intrude into the system. This air intrusion can cause the pump to lose its prime, disrupting its ability to operate effectively. Careful attention to these parts is necessary to prevent pump malfunctions and reduce the risk of unplanned downtime.
Over-tightening gland packing can create its own set of problems. Excessive pressure on the packing generates heat from the shaft, which can negatively affect the grease applied to the bearings. The breakdown of bearing grease reduces its lubricating properties, eventually leading to bearing damage. Striking the right balance in tightening ensures that the packing performs its sealing function without introducing additional strain on the system.

Ventilation and cooling

Ventilation and cooling are critical factors in maintaining equipment performance. Enclosures that are too confined and lack proper ventilation can overheat motors or engines, particularly those of the TEFC (Totally Enclosed Fan-Cooled) or combustion types. Overheating can reduce efficiency and shorten the equipment’s lifespan. Similarly, submersible motors, such as those used in sewage or borehole pumps, require adequate cooling water flow to perform efficiently. Insufficient cooling water flow can cause the motor to overheat, leading to potential damage or complete failure.

Pump Servicing Options

10. Choke It

Inaequate liquid supply

An adequate liquid supply is crucial for adequately operating any equipment that relies on fluid transfer. A falling or lowered liquid level increases the suction lift required for the pump, which can strain the system and affect its efficiency. Similarly, modifications to suction pipework, such as increased length or diameter changes, can affect performance and result in insufficient fluid flow to the pump. Ensuring suction pipework remains within the recommended specifications helps maintain consistent operation.

Closed vales or clogged strainers

Closed valves on the suction intake can block the liquid supply entirely, preventing the pump from functioning as intended. This can lead to severe damage, especially if the pump continues to operate without fluid. Clogged suction strainers, pipework, or impellers can also restrict the liquid flow, further straining the system. These components are regularly cleaned and maintained to ensure a steady, unobstructed flow.

Material supply

Issues such as an empty storage reservoir or a stopped supply can render the system inoperable. When the liquid source runs dry, the pump may lose its prime or operate in a “dry” state, which can cause irreparable damage. A functioning boost pump, when used, plays a critical role in maintaining steady liquid flow. Maintaining these systems is vital to prevent failures caused by supply interruptions.

Leaks and fittings

Leaking or broken suction lines and faulty fittings are other factors that contribute to inadequate liquid supply. These leaks reduce overall system efficiency and can lead to operational breakdowns. Problems with components like the gate valve gland can also compromise suction integrity. Inspecting and repairing these components periodically reduces the likelihood of disruptions.

Application and operating parameters

Changes in application or duty outside the equipment’s operating parameters can pose significant risks. When equipment operates under conditions it was not designed for, such as incompatible liquid flow rates or pressures, it becomes more susceptible to losses in efficiency or failure. Pumps running dry due to improper adjustments may lose their prime, making it impossible for the system to function until corrective measures are taken.

Final Thoughts

Pump maintenance doesn’t have to be complicated but requires consistency and attention to detail. By following the tips and avoiding common mistakes outlined in this guide, you’ll not only extend the life of your pump but also improve its efficiency and reliability.

If you’re unsure about your maintenance strategy or need expert advice, don’t hesitate to contact a professional. A little effort today can save you significant time and money tomorrow—your pump will thank you for it!

Contact Dowdens

Featured Products

Dowdens Pumping & Water Treatment offers a wide range of pumping solutions. This extensive selection allows us to provide customised solutions for any project, supported by our industry-trained engineers, draftsmen, project managers, salespeople, and tradespeople who can design tailored solutions for various purposes.

Our experienced team is ready to assist you in selecting the right products to meet your needs. Whether you require an immediate solution or are planning for the long term, we can help you source the products necessary for a successful installation.

SKU: 5170YE

Davey 5170YE Diesel Engine Driven Firefighter Pump

SKU: XJ90P

Davey XJ90P Dynajet Pump with Pressure Switch

SKU: JMP110

Onga JMP110 Pressure Pump

SKU: IMH2200K

Onga IMH2200K Intellimaster Pressure Pump

SKU: RS4E-ESYBOX

DAB Rainsaver MK4E Change Over Device & DAB E.SYBOX

SKU: DAB-NOVA600A

DAB NOVA 600A Submersible Drainage Pump

SKU: SCALA2 3-45

Grundfos Scala2 3-45 Pressure Booster Pump

SKU: JP 5-48 PM1

Grundfos Jet 5-48PM Pump

Featured Capabilities

Dowdens Pumping & Water Treatment provides comprehensive services across various industries, including tailored Asset Management, a user-friendly Document Library, and Engineering, Procurement, and Construction (EPC) services for large projects.

Our Knowledge Base aids in troubleshooting pumping and water treatment challenges, while branches in Mackay, Rockhampton, Brisbane, and Proserpine offer convenient access to workshop and field services.

Additionally, the Photo Library showcases completed projects, a skilled Solutions Engineering team for design and system servicing, and a Video Library with informative content.

Asset Management

Document Library

EPC

Solutions Engineering

Documents

At Dowdens, we are committed to providing our customers with the resources they need to make informed decisions and achieve their goals. That’s why we maintain a comprehensive Document Library brimming with valuable insights about our latest product offerings, industry expertise, and real-world applications.

BFL-71

Pressure Pump Sizing Guide

BFL-14

Dowdens P&WT Group Capability Statement

WDL-85

Dowdens Solar Pumping Capabilities

DAVEY-DDCPP

Davey DynaDrive Constant Pressure Pumps

DAVEY-DWJPD

Davey Deep Well Jet Pumps Datasheet

GRUNDFOS-PSMIN

Grundfos Pump Solutions for Mining

GRUNDFOS-BPR

Grundfos Submersible Pump Systems

GRUNDFOS-SPSV1DP

Grundfos Solar Pumping Solutions Version 1

ONGA-FMP

Onga Farmmaster Pumps

ONGA-HIFLO14TP

Onga HI-FLO 14 Series Water Transfer Pumps

DAB-JETCOM

DAB JETCOM Self Priming Centrifugal Pumps Technical Catalogue

DAB-CENTRIFUGAL

DAB Centrifugal Pumps Technical Catalogue

Featured Videos

Dowdens has a large video library that we hope will provide insights and help you better understand how our products work and can be used. You can view our entire library by clicking on the link below.

Dowdens

Borehole Camera Inspection and Maintenance

Dowdens

Dowdens Diesel Fire Pump Skid Testing

Dowdens

Dowdens 50 Years of Solutions

Dowdens

Dowdens Quality and Service is Second to None

Featured Case Studies

Looking for more information, our Case Studies provide detailed insights into various projects that Dowdens Pumping & Water Treatment has effectively managed and completed.

CS-05 – August 2017

Unique Floating Solar Pump

CS-41 – December 2012

Town Water Pump Station Upgrade

CS-63 – July 2017

Mine Site Diesel Fire Booster Pump System Upgrade

CS-128 – April 2019

Remote Control Truck Fill Pump Stations

Are you Interested in Pump Maintenance Options?

The Dowdens Team are ready to help. Contact us today for more information and to start the conversation.

Our Locations

Dowdens has four convenient locations throughout Queensland. We have branches in Mackay and Proserpine in the north, servicing the Sugar and Coal industries, a centrally located branch in Rockhampton, specialising in the Agricultural and Coal industries, and a branch in Brisbane, servicing multiple industries in southeast Queensland.

Dowdens Mackay

Dowdens Brisbane

Dowdens Rockhampton

Dowdens Proserpine

Contact Us

"*" indicates required fields

Facebook

This field is for validation purposes and should be left unchanged.

Name*

Business Name

Phone*

Email*

Location*

Subscripe to our Newsletter

When you subscribe you will receive our monthly newsletter and other promotion emails. You can unsubscribe at any time.

Comments*

10 Ways To Murder Your Pump

Your Pump is Critical. Is Yours Installed and Maintained Correctly?

1. Overwork Your Pump Unit

Perform regular checks

Schedule maintenance

Preventive maintenance

Structured maintenance plan

Photos of Pump Servicing

2. Break Its Limbs

Pump mounting

Pump Skid Mounting Systems

Fire Pump System Munted to Skid

Underground Mining Booster Pump Skid

Diesel Skid Fire Pump Skid

Skid Based Diesel Pump System

3. Poison It

Check product datasheet

4. Stab It

Use a suction strainer

Example Suction Strainers

Stainless Steel Suction Strainer

Galvanised Steel Suction Strainer

Poly Hose Tail Suction Strainers

PVC Foot Valve with Strainer

5. Fry It

Operate within the specified temperature range

Ensure regular maintenance is performed

6. Neglect Medical Check-Ups

Regular service and maintenance

Leak detection

Drive assemblies

Operating temperatures

Operational requirements

7. Shake It To Pieces

Sturdy foundations

Accurate drive alignment

Check for cavitation

Imbalanced or blocked impellers

Precision Motor & Pump Alignment

WEG Motor - Stalker Pump Precision Alignment

WEG Motor - Stalker Pump Precision Alignment

WEG Motor - Stalker Pump Precision Alignment

WEG Motor - Stalker Pump Precision Alignment

8. Drown It

Installing a sump or external drainage

Check water leaks

Mitigate risk

9. Inadequate Service

Lubrication

Gland packing and mechanical seals

Ventilation and cooling

Pump Servicing Options

Workshop Painting Services

Domestic Pump Servicing

Industrial Pump Servicing

Servicing of Cold Water Extraction Pump

10. Choke It

Inaequate liquid supply

Closed vales or clogged strainers

Material supply

Leaks and fittings

Application and operating parameters

Final Thoughts

Featured Products

Davey 5170YE Diesel Engine Driven Firefighter Pump

Davey XJ90P Dynajet Pump with Pressure Switch

Onga JMP110 Pressure Pump

Onga IMH2200K Intellimaster Pressure Pump

DAB Rainsaver MK4E Change Over Device & DAB E.SYBOX

DAB NOVA 600A Submersible Drainage Pump

Grundfos Scala2 3-45 Pressure Booster Pump

Grundfos Jet 5-48PM Pump

Featured Capabilities

Asset Management

Case Studies

Document Library

EPC

Knowledge Base

Photo Library

Solutions Engineering