Seven common water pump failures and how to prevent them

Inefficient or damaged pumps also waste energy, driving up costs and undermining sustainability efforts. However, most pump failures are preventable, says Evan West

Water pumps are the quiet workhorses of manufacturing plants, as they support everything from cooling and boiler feed systems to handling wastewater and chemical processing. When water pumps run reliably, operations stay on schedule. However, when they fail, disruptions can quickly spread across an entire facility. The true cost of pump failure extends far beyond replacement parts; unplanned downtime can stop production lines, delay shipments, and cause product loss. Leaks, overheating, and pressure issues can also create serious safety risks. 

They typically stem from poor system design, improper installation, or inadequate maintenance that worsens over time. Here are seven common causes of water pump failures and how to address them proactively.

2.Cavitation

Cavitation is one of the most destructive and misunderstood pump problems in industrial settings. It occurs when low pressure at the pump inlet causes liquid to vaporise, forming bubbles that collapse violently as pressure increases. This implosion damages internal components and creates noise, vibration, and efficiency loss. Common causes of cavitation include poor suction conditions, clogged or undersized intake piping, excessive pump speed, and selecting an improper pump for the application. Cavitation often develops gradually, making it easy to overlook until significant damage has occurred.

To prevent cavitation, it is critical to ensure proper Net Positive Suction Head (NPSH). This means maintaining adequate pressure at the pump inlet and minimizing restrictions in suction piping. Regularly cleaning intake lines, strainers, and filters helps prevent blockages that reduce suction pressure. Equally important is selecting the correct pump for the application; choose one that matches system flow, pressure, and fluid characteristics. Addressing cavitation early prevents impeller erosion and costly internal repairs.

2. Seal and gasket leaks

Mechanical seals and gaskets are designed to prevent fluid from escaping the pump housing, but they are also among the most vulnerable components. When they fail, leaks can contaminate surrounding equipment, damage bearings, and pose safety or environmental risks. Common causes of seal and gasket leaks include normal wear over time, chemical incompatibility between seal materials and the pumped fluid, improper installation, or operating conditions that exceed design limits.

To prevent these leaks, seal selection is critical. Materials must be compatible with the fluid’s temperature, pressure, and chemical composition. Installation procedures should follow manufacturer specifications exactly, as even small errors can shorten seal life. Routine inspections allow maintenance teams to identify early signs of wear, such as minor leaks or residue buildup, and replace seals before they fail catastrophically.

3. Bearing failure

Bearings support the rotating shaft and allow the pump to operate smoothly. When bearings fail, vibration increases, noise levels rise, and the pump can eventually seize or suffer extensive internal damage. Common causes of bearing failure include inadequate or improper lubrication, shaft misalignment, contamination from leaked fluids, or excessive vibration from other system issues.

To prevent bearing failure, it is essential to have a consistent lubrication schedule using the correct lubricant. However, over-lubrication can be just as damaging as under-lubrication, so precision matters. Monitoring vibration and temperature provides early warning signs of bearing wear. Proper shaft alignment during installation and after maintenance work will also reduce stress on bearings and extend their service life.

4. Impeller damage or wear

The impeller is responsible for moving fluid through the pump, making it central to performance. Damage or wear to the impeller leads to reduced flow, pressure loss, and declining efficiency. Common causes of impeller damage include abrasive particles in the fluid, corrosion from aggressive chemicals, cavitation damage, and debris buildup from inadequate filtration.

To prevent damage, selecting impellers made from wear-resistant or corrosion-resistant materials is a smart long-term investment (especially in demanding applications). Installing strainers or filters will also prevent debris from entering the pump. Routine inspections during scheduled maintenance also allow teams to detect erosion or imbalance before performance suffers significantly.

5. Motor overheating

Pump motors are designed to operate within specific temperature and load ranges. When they overheat, insulation breaks down, efficiency drops, and motors can fail suddenly. Common causes of motor overheating include overloading due to improper pump sizing, voltage fluctuations, poor electrical connections, and inadequate ventilation or cooling.

To prevent overheating, choose the proper sizing of both the pump and motor to ensure the system operates within its design limits. Adequate airflow around motors is also essential, particularly in hot or enclosed environments. Regular monitoring of electrical supply, amperage, and load conditions will also help identify issues before overheating leads to motor burnout.

6. Misalignment and improper installation

Even high-quality pumps can fail prematurely if they are installed incorrectly. Misalignment places unnecessary stress on bearings, seals, and shafts, leading to vibration and accelerated wear. Common causes of misalignment and improper installation include poor foundation design, inaccurate alignment during installation, and settling or shifting over time.

To prevent misalignment, use laser alignment tools to improve accuracy compared to traditional methods. Pumps should be mounted on solid, level foundations designed to minimize vibration. Alignment should be checked not only during installation, but also after startup and following any maintenance work that could affect positioning.

7. Operating the pump outside its design range

Pumps are engineered to operate efficiently within a specific range of flow and pressure. Operating too far outside this range reduces efficiency and accelerates wear. Common causes of this failure include changes in production processes, selecting an incorrect original pump, or excessive throttling to control flow.

To prevent this issue, it is essential to match pump curves to actual system demands. Variable frequency drives (VFDs) can also adjust pump speed to meet changing conditions more efficiently than throttling valves. When manufacturing processes change, pump selection should also be reassessed to ensure the equipment still meets operational needs.

The value of preventive maintenance and monitoring

Preventive maintenance and condition monitoring transform pump management from reactive to proactive. Sensors that track vibration, temperature, and pressure can detect early signs of failure long before a breakdown occurs. Predictive maintenance programs use this data to schedule repairs at optimal times, minimising disruption.

Documented maintenance procedures and well-trained staff will also ensure consistency and accountability. Over time, these practices reduce emergency repairs, extend equipment lifespan, and lower lifecycle costs, all while improving safety and operational reliability.

Reliable Pumps: A Critical Foundation of Manufacturing Performance

Water pump failures in manufacturing plants are rarely random. Issues like cavitation, seal leaks, bearing damage, impeller wear, and misalignment all have identifiable causes that can be prevented. Through thoughtful planning, selecting proper equipment, precise installation, and consistent maintenance, manufacturers can dramatically reduce pump failures, cutting downtime and energy costs while improving safety and efficiency. Reliable pumps are not just a maintenance concern; they are fundamental to operational success.

Evan West is the Chief Marketing Officer of ePumps.