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VIChoosing the right pump might seem easy, but a lot of people make sneaky mistakes. These mistakes don’t always show up right away. But later on, they can waste energy, raise costs, or even break the pump. Whether you’ve been doing this for years or you’re just getting started, it helps to know what to avoid. In this post, we’ll go over five common pump mistakes that often get missed. If you catch them early, you can save money and keep your system running well.
Too much focus on flow/head only
It’s easy to get stuck on flow rate and head when picking a chemical pump. These numbers show how much liquid the pump moves and how high it can push it. And yes—they matter. But if you only look at these, you might miss other key details.
For example, a water treatment plant needed to boost water pressure. The team chose a pump based only on flow and head. But they forgot to check how efficient it was or where it ran best. Because of that, the pump worked far from its ideal point. It used too much energy and wore out fast.
To avoid this, don’t stop at flow and head. Look at the pump’s performance curve. Try to find the best working point where it saves power and lasts longer. Also, think about the type of liquid, pressure losses in the system, and any future changes. When you look at the big picture, you’ll choose a pump that works better and lasts longer.
Neglecting NPSHA → cavitation risks
Many people forget to check the Net Positive Suction Head Available (NPSHA). It sounds technical, but it’s just about making sure the pump doesn’t suck in air or vapor bubbles. If it does, the pump can get cavitation—tiny bubbles that pop and damage parts.
At a chemical plant, one pump started making loud noises and shaking not long after install. The team checked it and found cavitation was eating away at the impeller. They had to stop work and pay for repairs. Why? Because the suction setup didn’t match what the pump needed.
To stop this from happening, always compare your system’s NPSHA to the pump’s NPSH required (NPSHR). The system must give the pump more head than it needs. If it’s too close, you can raise the liquid level, shorten the suction pipe, or pick a pump made for low NPSH.
If you check NPSHA early, your pump will run smoother and last longer. And you won’t waste time or money fixing damage later.
Ignoring motor-environment match (explosion-proof etc.)
Some people forget to match the motor to the place where the pump will run. But pumps often work in rough spots—like oil fields, factories, or chemical plants. These areas may need special motors, like explosion-proof or waterproof ones. If you use a regular motor in a risky place, it can cause danger or break down fast.
At one mining site, a regular motor was used near flammable gas. This was a big safety risk because a small spark could start a fire. The site had to shut down and fix the mistake, which cost a lot. But using a heavy, costly explosion-proof motor where it’s not needed is also wasteful.
So, know your site’s conditions. Ask if the motor needs special labels or ratings—like for heat, water, or dust. Check the temperature, air quality, and safety rules. A good match keeps people safe and helps the pump run longer without surprise issues.
Overlooking sealing compatibility
Many people don’t think about whether the seals fit the liquid being pumped. But seals stop leaks. If they’re made from the wrong material, they can wear out fast or even fail. This can lead to spills, mess, and shutdowns.
For example, a food plant used pumps with seals that didn’t work well with cleaning chemicals. The seals broke down fast, causing leaks. They had to stop work to clean up and replace parts. That cost time and money.
To avoid this, make sure the seal material matches the liquid type, its heat, and its pressure. Some jobs need seals made of Viton, Teflon, or EPDM. Ask the pump maker for advice on which seals to use and how to care for them.
Using the right seals means fewer leaks, less mess, and a pump that keeps going strong.
Bonus: When a more expensive pump saves more money
At first, buying a cheap pump might seem like a smart way to save. But usually, spending a bit more upfront saves more later. Better pumps run more efficiently, last longer, and need less fixing. That means lower bills and fewer headaches down the road.
A dairy farm once bought a cheap pump for moving milk. It worked at first, but soon broke down often and used too much power. They later switched to a better, food-safe pump that cost more. After that, their energy bill dropped by 15%, and the new pump ran with no issues.
So don’t just look at the price tag. Think about total cost—like energy use, repairs, and downtime. A better pump may cost more at the start, but it can save you a lot more later.
