Skip to main content Scroll Top

Typical centrifugal pump failures: causes, impacts, and prevention

As key components for fluid transfer in sectors such as chemical, oil and gas, and water treatment, a company must not only select a high-quality pump but also be able to anticipate signs of wear, foresee critical situations, and ensure proper operating conditions. Typical failures in a centrifugal pump—such as dry running, cavitation, and shut-off—are not mere hiccups: they are symptoms of a mechanical, thermal, or hydraulic imbalance that often stems from suboptimal system design, a lack of monitoring systems, or operating cycles that fall outside specifications. Thoroughly analyzing these operational issues means learning to prevent them with technical precision, avoiding the progressive degradation of impellers, seals, bearings, and magnetic supports. It also means designing smarter systems capable of protecting themselves through the integration of sensors, advanced materials, and electronic controls. At CDR, we are well acquainted with the typical failures of a centrifugal pump, and our departments are constantly working to ensure products that are increasingly safe, durable, and efficient.  TYPICAL FAILURES OF A CENTRIFUGAL PUMP: CRITICAL ISSUES AND AN INTEGRATED APPROACH TO PREVENTION It is important to note that these two failures (dry running, cavitation, and shut-off) often do not occur as isolated phenomena. For example, a system prone to cavitation may experience dry running due to a consequent lack of circulating fluid in the system; similarly, a malfunction of the suction valve can create conditions that foreshadow a dry-running failure. The best form of prevention for any type of technical or mechanical failure therefore consists of careful design and timely monitoring of the system: the use of level detection and energy absorption systems, as well as bypass valves, constitutes a structured strategy to prevent uncontrolled increases in pressure, temperature, consumption, and internal degradation. DRY RUNNING: WHY IT’S A PROBLEM AND HOW TO PREVENT IT Dry running is one of the typical failures of a centrifugal pump. This condition occurs when the pump operates without liquid or with inadequate lubrication. Under these conditions, the pump loses the necessary cooling, and the internal components—which are normally lubricated—experience direct friction, leading to overheating. Most pumps, including CDR models, are not designed for this scenario: while some configurations with excellent wear resistance—such as those made of diamond-coated silicon carbide or graphite—may withstand brief periods without liquid, these are not substitutes for proper design and use. Typical consequences include increased power consumption up to the point of thermal overload, deformation of internal plastic components, and, in the most severe cases, failure of the pump housing itself due to severe friction. Prolonged dry running can also lead to total pump failure. To prevent serious failures such as dry running, it is essential to integrate control systems such as discharge pressure gauges, flow meters, and level switches that detect the absence or shortage of fluid. Furthermore, installing equipment such as watt-hour relays provides an additional level of protection, as they detect abnormal increases in electrical consumption—a sign of possible dry running. CAVITATION: THE INVISIBLE FORM OF WEAR THAT ERODES EFFICIENCY Cavitation is one of the most dangerous types of failure for a centrifugal pump. It occurs when the pressure in the suction line drops below the fluid’s vapor pressure, causing vapor bubbles to form: as pressure increases, these bubbles implode, generating micro-impacts that are highly erosive to internal components. Cavitation in a pump can have serious consequences, such as excessive vibration and a significant reduction in operational efficiency, with major impacts on flow rate and head. Structurally, these implosions can erode the impeller blades and damage seals and housings, leading to sudden and costly failures. One of the most effective ways to prevent and control cavitation is to rely on the NPSH (Net Positive Suction Head) parameter. The ideal condition is for the available NPSH (NPSHa)—determined by the pressure at the suction point, pipeline losses, and fluid temperature—to consistently exceed the NPSH required (NPSHr) by the pump. To ensure this margin, solutions range from reducing pressure drops in the suction piping to optimally positioning liquid sources (such as tanks located higher than the pump), to the possible integration of boosters or inducers.  SHUT-OFF: THE INSIDIOUS FAILURE CAUSED BY A CLOSED VALVE Shut-off—or a closed discharge valve while the pump is running—is another common failure mode in a centrifugal pump that can lead to significant malfunctions. In a shut-off condition, since the fluid cannot flow into the discharge line, it begins to recirculate internally within the pump. This results in an increase in internal temperature and the gradual vaporization of the liquid. This condition can be caused by: the discharge valve closing while the pump is running; or a pressure drop in the discharge line greater than the head the pump is designed to deliver. Although not as immediate as in dry running, the end result is similar: overheating and loss of lubrication damage plastic components, while seals and bushings gradually fail until they break. The installation of a bypass or pressure switches is one of the most effective technical and structural solutions to prevent the damage from becoming irreversible. CDR POMPE: RELIABILITY, EXPERTISE, AND INNOVATION TO COMBAT TYPICAL FAILURES IN CENTRIFUGAL PUMPS Thanks to an advanced technical consulting service, CDR Pompe assists in selecting the most appropriate configuration, ensuring optimal installation, and implementing the best strategies for preventing failures. Our product line is specifically designed to operate in harsh environments and offers various special configurations, such as diamond-coated silicon carbide, along with the continuous development of new materials like zirconium oxide. typical centrifugal pump failures
(emoji)
News Centrifugal pumps June 10, 2025

Summary

Centrifugal pumps play a crucial role in fluid transfer, but they are prone to common failures such as dry running and cavitation. Preventing these failures requires careful design and timely monitoring. CDR Pompe offers innovative solutions and support to ensure the operational reliability of the pumps.

As critical components for fluid transfer in sectors such as chemical, the petrochemical and the water treatment, a company is not only responsible for choosing a good pump, but also for being able to read wear signals in advance, predict critical contexts, and set up the right operating conditions. Typical failures of a centrifugal pump, such as Dry marcia, cavitation, and shut-off, These aren't just operational glitches: they are symptoms of a mechanical, thermal, or hydraulic imbalance that often stems from suboptimal design choices, a lack of monitoring systems, or out-of-spec operating cycles.

In-depth analysis of these operational criticalities means learning to prevent them with technical precision, avoiding the progressive degradation of impellers, seals, bushings, and magnetic supports. It also means, design more intelligent systems that can protect themselves thanks to the integration of sensors, advanced materials, and electronic controls.

In CDR We are very familiar with the typical failures of a centrifugal pump, and our departments are continuously working to ensure products that are increasingly safe, resistant, and efficient. 

Typical failures of a centrifugal pump: criticality and an integrated approach to prevention

It's important to know that these two faultsdry cleaning, cavitation, and shut-off often they do not manifest as isolated phenomena.

For example, a plant subject to cavitation it may encounter dry running due to a consequent lack of circulating fluid in the system; similarly, valve malfunction in suction, it can generate conditions that anticipate a dry running failure.

The best form of prevention for any type of technical or mechanical failure therefore consists in careful design and timely monitoring of the plantthe use Level detection systems, energy absorption systems, and bypass valves constitute a structured strategy to prevent uncontrolled increases in pressure, temperature, consumption, and internal degradation.

Dry Marcia: why it's a problem and how to counter it

Dry running is one of the typical failures of a centrifugal pump. This condition occurs when the pump works without liquid or with inadequate lubrication. Under these conditions, the pump loses necessary cooling and internal components, usually lubricated, experience direct friction, resulting in overheating.

Most pumps, including the CDR models, they are not designed for this scenario: some configurations with excellent tolerance, such as those made of diamond silicon carbide or graphite, can accept brief episodes without liquid, but these are not alternatives to correct design and use.

Typical consequences include increased electrical absorption until the thermal breaker trips, deformation of internal plastic components, and, in more severe cases, breakage of the bushing itself due to severe friction. Prolonged dry running can also lead to total pump failure.

To avert serious failures such as running dry, it becomes essential integrate control systems such as supply pressure gauges, flow meters, and level sensors that detect the absence or shortage of fluid. Additionally, the installation of equipment such as Wattmetric relays it's an additional level of protection, as they detect abnormal increases in power consumption, a sign of possible dry running.

Cavitation: The Invisible Degradation That Erodes Efficiency

The cavitation represents one of the most feared failures for a centrifugal pump. It occurs when the pressure in the intake duct drops below the fluid's vapor pressure, causing the formation of vapor bubbles: As pressure increases, these bubbles implode, generating micro-shocks that become highly erosive to internal components. Cavitation in a pump can have enormous consequences such as high vibrations and a significant reduction in operational efficiency, with major impacts on flow rate and prevalence. Structurally, implosions can erode the blades of rotating and damage seals and housings, resulting in sudden and costly failures.

One of the most effective ways to prevent and control cavitation is to rely on the parameter NPSH, or Net Positive Suction Head. The ideal condition is that the available NPSH (NPSHa) — determined by the pressure at the suction point, pipe losses, and fluid temperature — consistently exceeds the NPSH (NPSHr) required by the pump. To ensure this margin, solutions range from reducing head losses in the suction piping to optimally positioning liquid sources (e.g., tanks placed at a height relative to the pump), up to the possible integration of boosters or inducers. 

Shut off: the insidious fault due to a closed valve

Closing the valve, or closing the feed valve while the pump is running, is another typical characteristic of a centrifugal pump that can lead to significant malfunctions. The shut-off head provides that the fluid, unable to flow in the discharge line, begins to recirculate internally within the pump. This results in an increase in internal temperature and progressive vaporization of the liquid. This condition can be caused by:

  • from closing the discharge valve during pump operation;
  • a pressure drop on the upper supply line compared to the head the pump should have.

Although not as immediate as in dry marching, the final result is similar: Overheating and loss of lubrication damage plastic components, while bearings and bushings progressively yield until they break. The implementation of a bypass or pressure switches is one of the most effective technical-structural solutions to prevent irreversible damage.

CDR Pompe: Reliability, Expertise, and Innovation to Combat Common Centrifugal Pump Failures

Thanks to a technical consulting service advanced, CDR Pump assists in choosing the most correct setup, in optimal installation, and in implementing the best failure prevention strategies. Our product range is specifically designed to work in harsh environments and offers various special configurations. such as diamond silicon carbide and the continuous development of new materials like zirconium oxide.

The after-sales service also, Planned maintenance and predictive analytics, fundamental tools for preventing the main problems of centrifugal pumps, reducing downtime and ensuring operational continuity.

If you'd like a specific assessment of your system, or a quote for a custom-made solution, our experts are ready to assist: contact us to have all the necessary information on how to avoid typical centrifugal pump failures and the best configurations for your system.

Frequently Asked Questions