When a pump fails, the impact is immediate: production halts, maintenance costs rise, and safety risks increase. Understanding the causes of pump failure is essential for preventing unplanned downtime and keeping systems running efficiently. This blog explores the most common reasons pumps break down, along with preventative strategies to minimise risk.
One of the most common causes of pump failure is improper installation and misalignment. When a pump and motor are not correctly aligned, excessive stress is placed on the shaft, seals, and bearings. This stress leads to premature wear, increased vibration, and eventually failure.
Even small alignment errors during installation can create major problems once the pump is in service. For example, shaft misalignment can cause seals to leak, bearings to overheat, and couplings to fail. In mining and heavy industrial plants, where pumps run continuously under high loads, these failures can result in costly downtime and unplanned maintenance.
Pumps rely on correct lubrication to keep bearings and moving parts operating smoothly. In mining and industrial settings—where pumps often run for long hours under heavy loads—poor lubrication is one of the leading causes of overheating and premature wear.
Too little lubrication can cause metal-to-metal contact, generating excessive heat and rapidly damaging bearings. On the other hand, over-lubrication can increase friction and lead to seal failures. Using the wrong type of lubricant for the application is another common mistake that shortens component life.
Neglecting routine maintenance—such as checking oil levels, replacing contaminated lubricants, and inspecting bearing condition—further compounds the issue. Over time, these oversights result in reduced efficiency, unplanned shutdowns, and higher operating costs.
Cavitation occurs when the pressure at the pump inlet drops below the liquid’s vapour pressure, causing vapour bubbles to form. As these bubbles collapse violently within the pump, they create shock waves that pit and erode the impeller and casing.
Beyond physical damage, cavitation generates excessive vibration, noise, and heat, all of which reduce efficiency and shorten the lifespan of the pump. Left unchecked, it can quickly escalate into complete pump failure.
The root causes are often linked to improper suction design, clogged strainers, undersized piping, or operating the pump outside its duty point. Preventing cavitation requires ensuring correct Net Positive Suction Head (NPSH) conditions, maintaining proper fluid levels, and designing suction systems to handle the specific demands of the application.
For more details, read our blog: What is Pump Cavitation and How to Avoid It
Mining and industrial processes often involve pumping fluids that are far from clean water. Abrasive slurries, corrosive chemicals, and high-solid-content fluids put enormous stress on pump components. Over time, these harsh operating conditions wear down impellers, casings, and liners, leading to reduced efficiency and eventual failure.
Abrasive particles in slurries can erode metal surfaces, thinning walls and changing flow paths inside the pump. Corrosive fluids, on the other hand, chemically attack materials, weakening them and accelerating deterioration. The combination of abrasion and corrosion is especially damaging, as it not only shortens service life but can also cause sudden failures that are difficult to predict.
Selecting the right materials for construction—such as hardened alloys, rubber linings, or corrosion-resistant composites—is critical in these environments. Regular inspections and timely replacement of worn parts further help manage the inevitable wear and tear.
Seals and bearings are critical to pump reliability, and when they fail, they’re often a warning sign of bigger system problems. Where pumps operate under heavy loads and harsh conditions, seal leaks or bearing noise can quickly escalate into full-scale breakdowns if ignored.
Seal failures are commonly caused by misalignment, vibration, improper lubrication, or running pumps dry. Once a seal is compromised, leaks can damage surrounding components and create safety hazards. Bearings, meanwhile, are highly sensitive to poor lubrication, contamination, and excessive heat. When they begin to wear, operators may notice unusual vibration or noise—key indicators that the pump is under stress.
Because seals and bearings often fail before other major components, they act as an “early warning system” for maintenance teams. Regular monitoring, proper installation, and timely replacement are essential to prevent minor issues from spiralling into costly downtime.
Every pump is designed to operate within a specific performance range, known as its duty point. When a pump is forced to run outside of this range—whether due to system changes, poor sizing, or fluctuating demand—the consequences can be severe.
Operating off-duty point creates hydraulic imbalances that lead to excessive vibration, noise, and mechanical stress. This not only reduces efficiency, driving up energy costs, but also accelerates wear on bearings, seals, and impellers. In extreme cases, it can cause cavitation or overheating, resulting in complete pump failure.
Running pumps outside their intended design range often shortens service life and increases unplanned maintenance. Preventing this requires careful pump selection during design, regular performance checks, and system adjustments to ensure pumps consistently operate within their optimal duty point.
Regular inspections & predictive maintenance: Routine checks help identify early warning signs—such as unusual vibration, leaks, or rising temperatures—before they escalate into major failures. Predictive maintenance strategies, including scheduled servicing and component replacement, ensure pumps remain in peak condition.
Condition monitoring technologies: Tools like vibration analysis, temperature sensors, and flow monitoring allow operators to track pump performance in real time, detect anomalies, and take corrective action before breakdowns occur. At Allied Pumps, we even provide remote monitoring through our NODEM system.
Selecting the right pump: Harsh mining slurries, corrosive fluids, and fluctuating loads all require pumps engineered with the right materials and duty points to handle those demands. Investing in fit-for-purpose equipment reduces the risk of premature wear and failure.
Partnering with experts: during installation, commissioning, and ongoing lifecycle support ensures systems are set up correctly and maintained to the highest standard. A trusted partner can provide tailored solutions, technical support, and rapid service response to keep operations running smoothly.
At Allied Pumps, we understand the high stakes involved in keeping mining and industrial operations running reliably. That’s why we deliver end-to-end solutions—from design and installation, to commissioning and ongoing service. By managing the full lifecycle of your pumping systems, we ensure every stage is handled with precision and expertise.
Browse our range of mining and industrial pumps and feel free to contact our team for any questions regarding our products or repair/maintenance services.
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