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Fault analysis and countermeasures for seal leakage caused by low-flow operation of pumps: During the operation of pumps, if they are operated at low flow rates for an extended period of time, it is very likely that seal leakage will occur, which severely affects the safety of the equipment and the stability of the system. The typical characteristics of this fault are: a significant increase in the pump body temperature, vaporization of the liquid in the sealing chamber due to heat, which destroys the integrity of the liquid film between the mechanical seal surfaces, thereby causing leakage. Analysis shows that the root cause lies in the fact that during operation at low flow rates, the circulation of the fluid inside the pump is poor, preventing effective release of energy and resulting in severe heating of the pump. Prolonged exposure to high temperatures can cause the mechanical seal faces to deform or wear due to thermal stress; the sealing rings age more rapidly, lose their elasticity, and may even develop cracks ； In mechanical seals that utilize a bellows structure, high temperatures can also cause the bellows to fatigue and crack, ultimately leading to seal failure. To address such issues, the following solutions are proposed: First, a return pipeline can be added at the pump outlet and connected to the pump inlet; by adjusting the valve, a portion of the fluid can be directed back, ensuring that the pump operates at a flow rate above the minimum allowable level. This helps to reduce the temperature rise of the pump and maintain the stability of the sealing fluid film. It should be noted, however, that this approach will result in certain energy losses, affecting the system’s operational efficiency; therefore, the return flow rate should be designed appropriately based on the actual operating conditions. Second, optimize equipment selection at the source. During the system design phase, it is necessary to accurately assess the process flow requirements and select pump types that suit the actual operating conditions. This prevents the pumps from operating at low load for extended periods due to their rated flow rates being much higher than the actual needs, thereby eliminating potential safety hazards associated with low flow rates. In summary, it is necessary to adopt a dual approach of operational management and equipment optimization in order to ensure that the pump operates stably under efficient and safe conditions, extend the lifespan of the seals, and maintain the reliability of the production system.