Fuel pumps may encounter a variety of problems during operation, the following are some problems related to fuel pumps and how to fix them:

Contaminated fuel

The main cause of fuel pump performance degradation and premature failure is the contamination of fuel flowing through the system. Particulate contaminants such as dirt, rust and sand particles can accelerate wear on internal pump components, which are very sensitive to abrades. Over time, microbial growth and stagnant water may also corrode the pump. Therefore, strict control of fuel quality and effective filtration are essential to prevent contaminants from reaching sensitive pump components.

Seal and diaphragm wear

Fuel delivery pumps rely on seals, O-rings, and flexible diaphragms to guide fluid through the displacement chamber and prevent leaks. However, these elastic parts degrade over time. Exposure to high temperatures and pressures can cause damage, and chemical deterioration of fuel additives or incompatible fuels can cause expansion and hardening. Therefore, it is necessary to ensure that the wetting material of the pump can withstand the specific fuel chemicals.

Underlubrication

Many transfer pumps rely on the fuel itself or an external lubricant reserve to lubricate internal components during operation. Dry running of the pump can lead to accelerated wear and damage. High-speed rotating parts can cause metal-to-metal contact when they lose lubrication. Even high quality pumps will have a longer service life if pre-filled and idling is avoided.

Fatigue spring

Diaphragm pumps use multiple springs to bend the diaphragm itself and apply suction and discharge pressures. These springs suffer from permanent cyclic fatigue due to repeated compression movements, and their tension characteristics eventually decline to a level where they cannot keep the pump chamber sealed. It is recommended to replace the spring and diaphragm in sets according to the manufacturer’s guidelines to maintain pump performance. The upgraded spring has a longer service life under harsh conditions.

High pressure peak

Peak pressure is an inherent feature of reciprocating positive displacement pump design. However, excessive pressure can expose components and joint seals to pressures that exceed their pressure ratings. Using a pulsation damper helps eliminate harmful pressure spikes. Cavitation caused by insufficient inlet flow can also produce spikes and accelerate wear. Avoiding long periods of idle operation can also help reduce this problem.

Avoid misuse

Improper use is also a cause of pump failure. This includes operating the pump beyond the pump’s pressure, temperature, or viscosity rating. Exceeding recommended work cycles and running times can lead to early fatigue. Poor alignment can put stress on the coupling or mounting. While pumps designed by reputable manufacturers can accommodate occasional spikes, persistent misuse can accelerate failure. Therefore, it is essential to closely match the function of the pump to the application.