The 5 Most Common Pump Failures — And How to Prevent Them

Pumps are the unsung workhorses of industrial, commercial, and agricultural operations. When they fail, the cost can be steep — not just in repairs, but in lost productivity, water damage, system downtime, and even safety risks.

At Global Pump Solutions, we’ve worked with hundreds of clients across New Zealand and Australia to identify early warning signs, streamline maintenance, and match the right pump to each job. Here are the five most common pump failures we see — and what you can do to stop them before they start.

What it is: Cavitation occurs when vapor bubbles form in the pump due to low pressure at the suction side — and then collapse violently as they hit high-pressure zones. This causes pitting on the impeller and internal surfaces.

Signs to watch for:

Loud grinding or rattling noise
Drop in flow rate or pressure
Damage to impeller vanes

How to prevent it:

Ensure proper NPSH (Net Positive Suction Head) is available
Avoid long suction lines or too many elbows
Keep suction strainers clean
Size your pump correctly for flow/head

🛠️ Cavitation is often a result of poor pump selection — our team can spec the correct model and review your inlet conditions to avoid it entirely.

What it is: Seals are used to keep fluid inside the pump housing and prevent leaks. Over time, seals can degrade, crack, or wear due to temperature, friction, or chemical exposure.

Symptoms:

Visible leakage from seal area
Unusual vibration or noise
Increased energy use or poor performance

Prevention tips:

Don’t run pumps dry — seals rely on fluid for lubrication
Use seals compatible with your liquid (e.g. chemical resistance)
Monitor pressure fluctuations and avoid surges
Replace seals as part of a scheduled maintenance plan

💡 All Global Pump Solutions units can be serviced locally — just ask about our OEM-compatible seal kits.

What it is: A pump motor burns out when it overheats due to electrical overload, poor ventilation, or mechanical overloading (e.g. pumping too much head).

Tell-tale signs:

Tripped circuit breakers
Strange smell or heat from motor casing
Pump stops and won’t restart

How to avoid it:

Install thermal overload protection
Use a motor matched to the actual system demand
Keep cooling vents clear
Don’t oversize the pump (which can increase motor draw)

🔌 Consider adding a Variable Speed Drive (VSD) to prevent overdriving — we can help recommend a compatible option.

What it is: The impeller is the heart of a centrifugal pump. Foreign debris or abrasive particles can wear it down or block it entirely.

You might notice:

Reduced flow or pressure
Abnormal vibration
System shutting down due to low output

Prevention tactics:

Install strainers or filters before the inlet
Use abrasion-resistant impeller materials
Clean tanks or sumps regularly
Avoid oversized piping that allows sediment settling

🌊 The GPS-T3 Bore Pump, for example, includes anti-sand features ideal for NZ bore conditions.

What it is: Many pump failures occur not because of manufacturing defects — but due to how they’re installed. Misalignment, poor anchoring, or incorrect wiring can lead to immediate or long-term issues.

Look for:

Leaks at flanges or joints
Excessive vibration or “walking” pumps
Startup faults or blown fuses

Fix this by:

Following manufacturer guidelines
Ensuring baseplates are level and vibration-isolated
Using licensed professionals for electrical setup
Always priming the pump before startup (if required)

🧰 We provide product-specific install guides and can refer trusted contractors in your area.

Build a Maintenance Schedule

Preventative maintenance is always cheaper than emergency repairs. A basic checklist includes:

Monthly: Check for leaks, monitor noise/vibration
Quarterly: Inspect seals, lubricate bearings
Annually: Clean impellers, flush lines, test overload protection
Post-storm/flood: Inspect motor insulation and pump housing

Need Replacement Parts or a Service Kit?

We stock seals, bearings, and service kits for all major lines — including NGX, MXH, MXP, and GPS-T3 series pumps.

📦 All stocked locally and available via our website.

Supplying Reliable Pump Solutions Across NZ & AU

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