3 Dangerous Pumping Conditions You Must Avoid

Pumps are often treated like background players in industrial systems. They just spin and do their job quietly. But when something goes wrong, it can happen fast. It can be costly and dangerous.

That’s why spotting warning signs isn’t just helpful—it’s critical. Some failures happen so quickly that you don’t get a second chance. From strange noises to sudden temperature jumps, each warning has a reason behind it.

In this article, we’ll show you three serious pump problems you must avoid. With real examples and simple tips, you’ll learn how to spot problems early and stop a shutdown.

Air in the Pipe

Air in the suction or discharge line might look harmless. But it’s one of the most common and damaging problems in pumping systems.

When air gets into the pipeline, it forms pockets that stop smooth flow. This causes uneven pressure, loud sounds, and lower flow rate. In bad cases, it leads to dry running. That means the pump spins without moving any liquid. This quickly causes overheating and mechanical failure.

Imagine you’re running a transfer pump in a chemical plant. After maintenance, an operator forgets to bleed the suction line properly. The pump starts fine. But after a few minutes, it begins to vibrate. The flow rate drops. Within a week, the mechanical seal fails. The real cause? Air trapped in the suction line. It caused dry running and heat buildup.

Air can enter in many ways. A leaking gasket, a loose pipe joint, or a cracked suction hose can cause it. Bad tank design can also pull in air if vortexing happens at the suction pipe.

Once air gets in, the pump impeller tries to compress it. But air compresses easily, unlike liquid. So the pump loses efficiency. The bearings and seals get damaged.

To stop this, always prime the pump before startup. Use an air release valve at high points where air collects. Check the suction pipe for leaks. Make sure all fittings are tight. In vertical suction lines, use a foot valve to stop liquid from draining back and pulling in air. Keep the tank’s liquid level well above the suction point to avoid vortexing.

Air in the system isn’t just annoying. It’s a silent killer. Catch it early and fix it quickly.

Excessive Backpressure

Too much backpressure can turn a good pump setup into a disaster. Backpressure is the resistance the pump works against to move liquid. A little is normal. It helps keep things flowing. But if it gets too high, problems build up fast.

Picture a pump sending liquid to a tall storage tank. Someone accidentally closes a valve downstream. The pump keeps running. Pressure spikes. The motor draws too much power. Seals start leaking. Bearings wear out faster. In the worst case, the pump casing could crack. That’s the danger of high backpressure. It makes your pump fight harder than it should.

Backpressure often comes from a closed or blocked valve. A clogged filter or narrow piping can also cause it. Sometimes the pump is too big for the system. It pushes more liquid than the piping or valves can handle. This wastes energy and damages the pump.

To avoid this, watch the pressure right after the pump. Install a gauge and set alarms if it goes too high. Make sure valves are labeled and fully open. Use pressure relief valves if needed. These act like safety vents. They release pressure before anything breaks.

When designing the system, size your pipes and valves to match the pump’s expected flow and head. Don’t just pick what’s cheap or easy.

Letting backpressure rise is like driving with the brakes on. You’ll wear the system out fast and risk a sudden stop. Keep it in check so everything flows smoothly.

Dry Running or Deadhead

Dry running and deadheading are two of the fastest ways to ruin a pump. They can happen in seconds if no protection is in place.

Dry running happens when the pump runs without any liquid. Most pumps need liquid to cool and lubricate parts like seals and bearings. Without liquid, friction builds up. Parts overheat. Damage happens fast.

For example, someone starts a chemical pump. But the suction valve is still closed. No liquid is flowing. The motor spins anyway. In a few minutes, the seals burn out. The pump needs repair.

Deadheading is similar but a bit different. It happens when the pump runs but the discharge pipe is blocked. This is usually from a closed valve or clogged filter. The liquid has nowhere to go. Pressure builds up inside the pump.

In the worst case, the casing can crack. The impeller can break. The motor can overheat.

We’ve seen this happen on cooling water systems. A valve was closed during maintenance. No one reopened it. The pump ran with nowhere to send the water. The motor overheated and shut down. When restarted, it failed completely because the internal parts were warped.

To prevent this, always check valve positions before starting the pump. Use pressure or flow switches that stop the pump if no liquid is moving. Temperature sensors can also catch overheating early.

You can also install a recirculation line with a backpressure valve. This keeps a little flow going even if the main line is blocked.



Dry running and deadhead can destroy a pump quickly. A few checks and safety tools can save you thousands in repairs.