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If I were you I'd put a valve on the outlet and restrict the flow as much as I could to see if that will stop your issue. There's so many variables here. My advantage is I can consistently recreate the problem by just turning the pump on. It doesn't happen after 30 minutes or inconsistently...

I'm not sure. I'm not familiar with your system layout. Nothing at all has changed in the 9 months? Maybe you changed tubing size, have your HLT in a new location vertically, temps are slightly different, you moved to a place higher in altitude? I have a system where after the boil I try to...

Thermodynamics. Pump creates significant pressure drop causing hot liquid to super-heat (vapor). Kinda like running the pump dry. Same reason why water boils at lower temps in the mountains and CO2 liquefies when pressurized into a tank. The typical Chugger pump has 17 ft head pressure which...

Depending on your pump ability, there is a pressure delta across the impeller. Increased fluid velocity decreases pressure and if you're at hot temperatures, it will cause the fluid to superheat into vapor and cause cavitation. Here's an example: Assuming no additional losses due to plumbing...