Imagine what would happen if the human heart suddenly stopped working. In industrial production, centrifugal pumps play a similarly vital role. These unassuming devices silently power the transportation of various fluids, and when problems arise, they can range from minor efficiency losses to complete system failures. While centrifugal pumps are renowned for their simple structure, high efficiency, and low maintenance costs, no mechanical equipment is immune to potential malfunctions. The challenge for every industrial enterprise lies in promptly identifying and resolving these issues to ensure continuous, stable operation.

At the core of centrifugal pumps lies their rotating impeller, which converts mechanical energy into the kinetic and pressure energy of fluids, enabling fluid transportation. Based on impeller structure, centrifugal pumps fall into two categories: radial flow and axial flow. Radial flow pumps primarily rely on centrifugal force to push fluids outward, making them suitable for high-head, low-flow applications. Axial flow pumps mainly use impeller thrust to lift fluids, ideal for low-head, high-flow situations. Despite their relatively simple working principles, even minor faults can significantly impact performance.

The applications of centrifugal pumps span nearly all industrial sectors requiring fluid transport:

• Fire Protection Systems: During fires, centrifugal pumps provide reliable water supply.
• Food and Beverage Production: From raw material transfer to product filling, these pumps play crucial roles throughout manufacturing processes.
• Municipal Water Supply: Urban residents' daily water supply heavily depends on stable pump operation.
• Wastewater/Sludge Treatment: Treatment plants rely on these pumps to handle various effluents and slurries.
• Oil and Gas Industry: Centrifugal pumps are indispensable for extraction, refining, and transportation processes.
• Chemical Industry: Production and transfer of numerous chemicals require pump support.

Air pockets within the pump can disrupt fluid flow, reducing efficiency or causing complete shutdown. The solution involves ensuring complete liquid filling of pipes and pump casing, with proper venting before startup.

When the vertical distance between liquid source and pump exceeds design limits, proper fluid intake becomes impossible. Inspect inlet pipes for blockages and verify actual suction lift against specifications. Solutions may include lowering pump elevation or selecting higher-capacity models.

Impellers spinning backward can damage pumps and prevent operation. Verify motor wiring and rotation direction through brief test runs.

Incorrect rotational speed affects performance—low speed reduces flow and head, while overspeeding risks overload or damage. Check power supply voltage, frequency, and potential phase loss in motors.

Impellers, valves, and filters frequently clog with debris, impairing function. Regular inspection and cleaning are essential, with strainer installation recommended for fluids containing solids.

Leakage poses significant safety hazards beyond material loss. Causes range from excessive temperature and corrosion to pressure imbalances loosening connections. Solutions involve identifying leak sources—tightening joints or replacing aged/damaged seals with materials selected for chemical compatibility and thermal resistance.

Prolonged restart times often indicate excessive clearances reducing efficiency and causing overheating. Additional culprits include leaking gaskets, obstructed recirculation ports, or worn volutes. Thorough inspection guides appropriate repairs or replacements.

Jammed pumps may result from foreign objects, low-flow operation, or exceeding design parameters. Initial steps involve clearing obstructions and verifying impeller mobility and power supply. Chronic low-flow conditions generating excessive heat may require bypass lines or smaller pumps.

Unusual vibrations or sounds typically indicate internal issues—commonly bearing damage or foreign matter. After clearing debris, inspect bearings for wear. Cavitation—bubble formation from low inlet pressure—also causes destructive vibrations. Prevention requires maintaining adequate inlet pressure and avoiding low-flow operation.

Performance drops stem from multiple factors: leaking gaskets, incorrect impeller rotation, damaged impellers or wear rings, open bypass valves, or blockages in intake/discharge lines. Systematic troubleshooting identifies underlying causes for targeted repairs.

Excessive current draw signals overload, potentially from overspeeding, oversized impellers, bearing wear, high-viscosity fluids, bent shafts, misalignment, excessive mechanical seal pressure, component contact, or operation beyond design ranges. Preventive measures include regular maintenance, proper component selection, and adherence to operational limits.

Chemical incompatibility causes corrosion in wetted components made from ceramics, metals, thermoplastics, or elastomers. Pump selection must consider fluid properties, with corrosion-resistant materials like stainless steel or Hastelloy often preferred. Additional protections include coatings or sacrificial anodes.

Excessive heat indicates serious issues—possibly clogged intake filters, recirculation ports, valves, or discharge lines. Left unaddressed, efficiency deteriorates leading to eventual failure. Regular inspection and cleaning prevent overheating problems.

As indispensable industrial assets, centrifugal pumps demand informed maintenance. Understanding common failures and solutions enables effective management, though complex issues warrant professional assistance. Expert teams provide diagnostics, repairs, and preventive strategies—extending equipment lifespan while minimizing downtime and operational costs.