Thermal Degradation of Water Pumping Systems: Analyzing Oil Leaks and Bearing Failures When Temperatures Go Above 45°C

Water pumping systems operating in extremely hot regions such as the GCC are exposed to severe thermal stress, especially when ambient temperatures exceed 45°C and pump room temperatures rise to 55–60°C due to poor ventilation. These harsh conditions accelerate the thermal degradation of electric pump motors, particularly affecting lubricating oil, shaft seals, and bearings. This study investigates how elevated temperatures reduce oil viscosity, trigger seal deformation, and ultimately lead to lubrication loss and bearing failure. Field inspections from multiple pumping stations revealed a consistent pattern: standard rubber seals lose structural integrity under sustained high heat, allowing low‑viscosity oil to bypass the seal lip and leak. As oil levels drop, the motor loses internal cooling, causing bearings to operate under near dry‑running conditions, resulting in overheating, cage deformation, and premature failure. The paper reviews mitigation strategies including thermal insulation, improved HVAC cooling, high‑temperature synthetic lubricants, and preventive maintenance practices. A cost comparison shows that proactive thermal management is significantly more economical than unplanned motor failures, rewinding, or oil spill cleanup. The findings aim to support water utilities in improving pump reliability and preparing for increasingly hotter summers.