Pump repair vs pump replacement
Pumps are essential in many industrial processes and manufacturing facilities, transferring liquid ingredients, chemical fluids, pastes, and slurries that keep the whole factory working.
Certain fluids and duties present challenges for pump longevity; aggressive pH, temperature extremes, abrasiveness, high or fluctuating pressure, or large suspended solids.
Maintenance engineers and managers will often face the dilemma of a broken or failing pump at some point; do we buy a new one, or keep this one going with spare pump parts?
Here in this blog, we share our experience helping hundreds of processing managers, site managers, and site engineers decide between pump repair or replacement. Either way, Atlantic Pumps are here to support you as required.
Sometimes, the decision is a ‘no-brainer’ but often it is more nuanced, requiring a balanced consideration of short-term and long-term benefits – with the limitations and pressure of meeting time and budget constraints.
If a repair costs more than 75% of the cost of a new one, then most would say go new. However, there are other operational factors to consider:
- Is this pump often failing? A better-matched pump for the application might solve this issue for the long term, especially if the fluid has a particularly challenging characteristic such as abrasive grit-laden slurry, or aggressive chemical properties.
- Downtime cost: is waiting for the ultimate solution worth it, or is it rationally better to go with the ‘best solution available today’?
- Standby pumps: In critical processes that rely on pumping, it is common to have two pumps on a duty standby arrangement. One will be operating, while the other is at rest - and can be safely locked out for servicing, pump repair, and replacement of wearing parts. This is particularly important for those pumps that are difficult to repair/purchase. If you’re ever faced with a faulty or dying pump and unable to find a replacement soon, this might create delays or downtime which can prove to be extremely costly, depending on your industry.
If a standby pump isn’t feasible, then plan for outages alongside your chosen pump and pump parts supplier. A close partnership can drastically cut downtime and waiting for part deliveries and service. From our experience at Atlantic Pumps, a good partnership involves condition monitoring, PPM (planned preventative maintenance), pump asset registration, and pre-ordering of genuine or OEM wear parts.
- Age & condition: What is the expected lifetime of the pump? Are there other parts that are due to fail anytime soon? Regular conditioning monitoring provides insights into the pump’s expected remaining lifespan and potential future repair costs. Replacing old diesel pumps with new energy-efficient ones can significantly reduce energy costs and site emissions. Different pump types are best for particular duties, with some pumps designed for a lower purchase price and others optimised for a lower lifetime cost. The failed pump might therefore not be worth repairing.
Speak to your supplier and industry colleagues to compare the lifetime you are getting from your pumps with others in similar applications.
- Pump Hire: Hiring a pump allows a longer-term solution to be worked out and can also allow you to test a potentially better-suited pump. A pump hire is a good idea when a critical process needs to continue during repairs and maintenance.
- Repair Time: Factor in time to repair (and engineer availability). Some pump parts can be switched out with relative ease, whilst others can be more complex and time-consuming, maybe requiring specialist skills, additional lifting equipment, or extra H&S controls.
- Stock & Availability: What is the lead time/stock availability? Sometimes your pump supplier might be able to ship a completely built-up new pump faster, other times it might be quicker to source and fit spare parts.
- Existing Systems: Does a new pump fit the existing system? If there isn’t a direct like-for-like replacement, it might be worth keeping an old pump going until the wider system can be upgraded. That said, always tell your pump supplier what the actual duty is, rather than simply ask for a replacement of the failed pump. In our experience of switching out pumps, we often find the original pump was over or under-specified, or can recommend a more effective type of pump for the task.
- Environment: Replacing just what is broken can have better outcomes from an environmental resources point of view, but bear in mind that newer equipment is generally more energy efficient.
- Multiple Repairs: If your pump has already been through several repetitive repairs in the past, it might be worth replacing your pump with a new one. Imagine if the pump keeps breaking down and needs repairing regularly, not only will the repairs cost you more than a new pump, but it will also create downtime that your industry could do without.
- Need: How many hours a day/week/month do you need your pump to work at an optimum level? If the pump is used on a regular basis, consider its condition. If the pump is still in overall good condition, then a repair might be the most cost-efficient and sensible solution. If it is showing oter signs of higher wear and tear, a replacement might be the best option. This is a good time to ask if there are now better pumps available for your particular industry and duty.
Don’t walk alone
To replace or repair is a big decision, with time and budget realities putting pressure on you. Reach out to our pump engineers and technical staff for help – we have engineers with 30 years of invaluable pump building and repair experience alongside apprentices and engineering graduates who bring a fresh approach.
Pump breakdown can be costly, especially if it comes as a surprise 'out of the blue'. Avoiding premature failure, extending the lifetime of pumping assets, and reducing the total cost of ownership is what we at Atlantic Pumps are passionate about.
Discuss your industrial pump failure concerns and speed up your repairs and replacements today with Atlantic Pumps.
