Detecting Early Signs of Pump Failure: Prevention Measures to Keep Your Building Running Smoothly

The Critical Role of Pumps

In today’s buildings, pumps can provide water supply, heating, cooling and waste management. A single pump failure can have a significant impact on the entire building. They can be the difference between a business operating smoothly or complete closure.

It's not just a matter of the pump itself breaking down; it often leads to larger problems. For example, if a sewage pump fails, it can cause severe flooding and back-ups in areas we don’t want to happen. Likewise, if a heating pump malfunctions during the winter, the building could be without heating or hot water. Or a failure in the cold-water booster set could result in the entire building being without water.

Despite their critical importance, pumps usually go unnoticed until something goes wrong, and that’s when we get called. But there’s many proactive tactics and early signs of failure that can help prevent downtime and maintain the health of your system.

Spotting Early Signs of Pump Failure

There are several tell-tale signs that your pump is not functioning properly. Not reacting could cause the issue to escalate and become a more serious issue, which could then result in longer lead times for repair and it’s likely to be more costly – reacting quickly can prevent minor issues escalating into major failures.

Here’s what you can look out for:

Excessive or unusual noise: Sounds like grinding, whining or banding can indicate mechanical issues such as worn bearings, cavitation or misalignment.
Leaking pumps: Leaks around the pump can signify seal failure, cracked casings or loose fittings, potentially leading to further mechanical damage or efficiency loss.
Reduced flow or pressure: If the pump is not delivering the expected flow rate or pressure, it could indicate issues like impeller wear, clogging or a failing motor.
Overheating: Excessive heat generation can be a sign or motor overload, lack of lubrication, or internal friction due to worn components, which can lead to motor burnout.

Mitigating Risk of Pump Failure

There are plenty of budget-friendly tactics to extend the life of your pump. Simple adjustments like reducing pump speed and implementing improved system designs can make a big difference. Here are our top tips for managing and mitigating the risk of pump failure.

1) Avoiding Single Point of Failure

In recent years we’ve seen significant innovations in pump technology, particularly in designing systems to avoid single points of failure.

A typical setup now includes a two-pump system, featuring both a standby/duty pump and a backup pump, to ensure continuous operation even if one pump fails.

2) Introduce Remote Monitoring and Diagnostics

Another impactful advancement is the development of remote monitoring systems. These systems allow you to log onto booster sets and wastewater pump stations from your desk, providing real-time data and flagging potential issues before they become major problems and before the client even knows about them.

Xylem for example have introduced a system where you can log on to booster sets and wastewater pump stations from your desk and you can actually see a real-time display of what’s going on in those systems. Read more here or get in touch with us for advice.

3) Implement Inverter Drives

We regularly recommend that our clients introduce inverter drives to their systems. These drives will control pump speed based on demand and significantly improve efficiency, reduce wear and tear, and make significant savings.

For example, a traditional chiller system in an office building will likely be switched on in the Summer and unless there’s an external control (whether that be temperature or flow) it’ll likely run at full capacity 24/7 regardless of demand.

By introducing an inverter drive the client can program that pump to switch off at night or run at a lower speed when there’s no occupants in the building. This can be done automatically, and by running the system for 12 hours a day instead of 24, will reduce operational costs, improve energy efficiency and will in theory, double the lifespan of your pump. We can even control the pump depending on the demand that day – let’s face it, Summer in the UK is unpredictable and demand for cooling and chilling is not always required.

Often, we think of inverter drives as large and complex, but Grundfos Magna pumps have small built-in inverters that are easy to install and affordable. They also come with automation functions that help you save energy immediately. View the range here, or get in touch with us for guidance.

4) Use Energy-Efficient Motors

Upgrading to high-efficiency motors, such as IE4 or IE5, can significantly reduce energy consumption while improving the overall performance and lifespan of your pumps.

Energy efficiency is a big factor in driving pump technology forward, and innovations like IE5 motors and inverter drives are very much leading the way. Upgrading to IE4 will achieve up to 20% energy savings instantly.

This is underscored by EU regulations, who in July 2023 mandated the requirement of IE4-level standards if you’re running motors between 75kW and 200kW. Read more about the regulations here.

5) Carry Out Regular Maintenance and Servicing

And of course, establishing a routine maintenance schedule will prevent unexpected failures. Regular servicing can detect early issues and ultimately prolong your pump's life.

But the challenge arises when everything seems to be operating smoothly; it's easy to assume that maintenance is unnecessary since the system has been working fine for a long time. Which is precisely when things can go wrong.

Find out more about the importance of PPM regimes for pumps in our recent article here.

By focusing on both preventative maintenance and the latest technological innovations, we help our clients avoid the severe consequences of pump failures and improve overall system reliability.

Watch the Podcast

In our recent podcast Technical Manager, Joe Smith, discusses all of these innovations in detail and makes his predictions for the future of pump technology. Watch in full here.

Get in Touch

Reach out to us today and discover how you can improve your system reliability. Our team can visit to inspect your pump systems and offer advice – free of charge.

A specialist deckpro account manager will have a chat with you and, if needed, help set up service plans. We'll provide a recommendation report based on our survey (not a quote for works). It's important to act quickly especially if you notice a noisy or leaking pump—remember, addressing small issues right away can prevent bigger, more expensive problems and longer repair times.

Book your visit today.