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Pump Troubleshooting Guide: Common Faults, Causes, and Solutions
XBD-HY Vertical Fire Pressure Stabilizing Pump Set
This technical guide summarizes common pump operating problems, their likely causes, and recommended corrective actions. It is designed for industrial users, maintenance technicians, and operators who require fast and accurate diagnostic information.
1. Pump Fails to Deliver Water
Possible causes:
- Inlet or outlet valve not opened; suction or discharge pipeline blocked; impeller passage clogged
- Incorrect motor rotation direction; motor running slowly due to phase loss
- Air leakage in the suction pipe
- Pump not fully primed; air trapped in the pump chamber
- Insufficient inlet water supply; excessive suction lift; foot valve leakage
- Pipeline resistance too high; improper pump selection
Recommended solutions:
- Inspect and remove blockages in pipelines or the impeller
- Correct motor rotation direction and secure motor wiring
- Tighten all sealing surfaces to eliminate air ingress
- Open the pump cover or vent valve to release trapped air
- Shut down pump and inspect water supply conditions; adjust as needed (common in municipal supply or suction-lift installations)
- Reduce pipeline bends or resistance; reselect a suitable pump model
2. Pump Flow Rate Is Insufficient
Possible causes:
- Causes listed in Section 1 may also lead to low flow
- Pipeline, pump passages, or impeller partially blocked; scale buildup; valve not fully opened
- Low power supply voltage
- Impeller wear
Recommended solutions:
- Follow corrective actions from Section 1
- Remove obstructions and readjust valve opening
- Stabilize voltage supply
- Replace worn impeller
3. Excessive Power Consumption
Possible causes:
- Pump operating at a flow rate above its rated value
- Excessive suction lift
- Worn pump bearings
Recommended solutions:
- Adjust flow rate by partially closing the discharge valve
- Reduce suction lift
- Replace worn bearings
4. Abnormal Noise or Vibration
Possible causes:
- Unstable pipeline support
- Air mixed with the pumped liquid
- Cavitation occurring inside the pump
- Bearing damage
- Motor overloaded or overheating
Recommended solutions:
- Reinforce pipeline supports
- Increase suction pressure and vent trapped air
- Reduce vacuum level to eliminate cavitation
- Replace damaged bearings
- Adjust operation based on recommendations in Section 5
5. Motor Overheating
Possible causes:
- Excessive flow causing overload
- Mechanical friction inside pump or motor
- Motor bearing failure
- Low power supply voltage
Recommended solutions:
- Partially close discharge valve to reduce load
- Inspect and remove friction points
- Replace damaged motor bearings
- Stabilize voltage supply
6. Pump Leakage
Possible causes:
- Mechanical seal wear or failure
- Pump casing defects such as sand holes or cracks
- Uneven or damaged sealing surfaces
- Loose installation bolts
Recommended solutions:
- Replace the mechanical seal
- Repair casing by welding or replace the pump body
- Rework sealing surfaces to achieve proper flatness
- Tighten all installation bolts
Conclusion
Proper diagnosis and timely correction of pump failures help maintain system stability and reduce downtime. Regular inspection, correct installation, proper suction conditions, and timely replacement of worn parts are essential for long-term pump reliability. Fo