Retrofitting industrial pumps is a cost-effective approach to improve performance, extend equipment lifespan, and adapt to changing process requirements. However, retrofitting requires meticulous planning, technical knowledge, and adherence to best practices to ensure safety, efficiency, and long-term operational success. Let’s explore some of the best practices for retrofitting an industrial pump with insights into evaluation, planning, execution, and post-retrofit maintenance.
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“The most important thing to keep in mind is to make sure your next equipment retrofit is made to last,” says HOMA Product Manager Nick Terranova. “Retrofits are inherently about problem solving. When we talk about retrofitting a pump, we are taking an existing installation that was designed and constructed to use a given pump and replacing it with a different pump, either from a different manufacturer or a different model from the same manufacturer.”
This is a common practice. A pump station will almost always outlast its initially purchased pump, and when that happens, there are plenty of reasons why you would either want to, or need to, replace that pump with something other than just the same thing.
“Typically, you’re not going to replace a functional pump, which means that whatever pump was in there failed for some reason,” Terranova explains. “That could be that it lived a long, productive life, hit the end of its serviceability, and now you need to replace it with a newer model since the last one is no longer produced. It could also be that the pump never ran correctly, or it was a nightmare to work on and you are sick of dealing with it.”
It’s also common that if a pump goes down, it’s far more important to get a pump in place than to replace it with the exact same model that failed. “This is where the most problems come from in retrofits—acting quickly to fix a problem.”
Common Retrofit Problems to Avoid
The most obvious problems are the physical constraints of the installation, such as the size of the new equipment. Usually these are addressed beforehand however, something that can be missed is that not every pump manufacturer uses the same mounting configuration on their pumps. Some use ANSI flanges, some use DIN flanges, and others use proprietary arrangements.
“If you aren’t careful to verify what you have and what you will be receiving, you may end up with a problem when it comes time to the install,” Terranova says. “That’s why it’s important to communicate what you will be replacing to the supplier, who will have a lot more experience retrofitting equipment and should know all the particular precautions.”
A good supplier should be able to help with any electrical or control requirements. It’s important to ensure that the panel is sized appropriately for the new pump, and that any differences in sensors or controls is considered. Equally important is considering the pump as part of the complete system rather than just as a component.
“It is very common to only provide a single operating point when looking to cross a pump over from one to another,” Terranova says. “There can be a huge differential from what you think the operating point is, or what it was when the pump station was designed 10 years ago.”
If you are retrofitting a pump that failed, remember that there is likely a reason that the pump failed, and replacing it with the exact same pump may cause the new one to fail in the same way.
Top 10 Best Practices for Retrofitting a Pump
Let’s explore some of the best practices for retrofitting municipal and industrial pumps.
1. Conduct a Comprehensive System Assessment
Before beginning any retrofit project, perform a comprehensive assessment of the current pumping system. Gather historical performance data—including flow rates, pressure, temperature, energy consumption, and downtime incidents. Evaluate the mechanical condition of the pump components—including impellers, seals, bearings, and casings, to identify wear or damage.
Examine the compatibility of the pump with associated systems such as piping, valves, motors, and control systems. And perform a root-cause analysis to identify any recurring performance issues, such as cavitation, vibration, or excessive noise, to address underlying problems during the retrofit.
During this step, it’s also important to define your retrofit objectives so that you can align the outcomes with the organizational goals. For example, your goal may be to enhance energy efficiency to reduce operating costs and environmental impact. Another common objective is to upgrade the pump to handle higher flow rates or pressure demands. Many retrofits include replacing outdated components to minimize downtime and improve operational stability.
When making this assessment, ensure that the system meets any updated safety, environmental, or industry-specific standards.
2. Collaborate with Experts You Can Trust
Partnering with experienced professionals is crucial for a successful retrofit. Consult the pump’s manufacturer for recommendations about upgrades or replacement parts and work with specialists to analyze system requirements and design customized solutions.
“It’s important to work with people you can trust,” Terranova recommends. “Sometimes, you don’t need a full pump replacement and sometimes you need many additional upgrades to achieve your goals. You want to work with people who are available to help make any diagnoses and recommendations that are in your best interest.”
3. Develop a Detailed Retrofit Plan
Create a comprehensive plan outlining each phase of the retrofit process. The plan should include the scope of work, the timeline, a realistic budget, and a complete risk assessment.
Define the specific modifications, replacements, and installations to be performed. Establish a realistic project schedule, accounting for procurement, downtime, and testing. Estimate costs, including materials, labor, and contingency funds for unexpected issues. And finally, identify potential risks and develop mitigation strategies, such as backup systems or alternative processes.
4. Evaluate Technology Upgrades to Enhance the Retrofit
Modernizing a pump system often involves incorporating advanced technologies. For example, you may want to implement variable frequency drives (VFDs) to optimize motor speed and match pump output with system demand, improving efficiency. It may be a good idea to replace worn components with corrosion-resistant or wear-resistant materials to extend service life.
A pump retrofit is also a good time to consider an upgrade to advanced mechanical seals or seal-less designs to reduce leaks and maintenance requirements. You may also want to implement IoT-based monitoring systems for real-time performance tracking and predictive maintenance. An experienced technical professional can help advise you on all these potential enhancements.
5. Prioritize Energy Efficiency
Energy consumption is a significant cost factor in pump operations. To improve efficiency, consider an optimized hydraulic design. Redesign impellers and volutes to minimize energy losses.
This is where correct sizing plays a key role. Ensure the pump’s capacity matches the system requirements to avoid over-pumping or under-pumping. Evaluate the entire system for inefficiencies, including pipe friction losses and valve restrictions. Conduct energy audits before and after the retrofit to quantify improvements.
6. Ensure Compliance with Standards
Adhere to relevant industry standards and regulations during the retrofit. Common standards include:
- API Standards: For pumps in the oil and gas industry, ensure compliance with API 610 or API 682.
- ISO Standards: Follow ISO or ISO for general-purpose industrial pumps.
- Environmental Regulations: Address emissions, noise levels, and waste management requirements.
Compliance ensures the retrofit meets legal and operational requirements, reducing liability and enhancing system reliability. A professional technician can help you ensure that these requirements are met.
7. Execute the Retrofit with Precision
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During the execution phase, attention to detail is critical. Inspect all replacement components for defects and verify compatibility. Ensure precise alignment between the pump and motor to minimize vibration and wear. It’s crucial to perform thorough checks during and after installation to verify workmanship. Also, be sure to maintain detailed records of modifications, parts used, and installation procedures for future reference.
8. Perform Comprehensive Testing
After completing the retrofit, conduct rigorous testing to validate performance. Testing should include:
- Performance Testing: Measure flow rates, head, efficiency, and power consumption to ensure they meet design specifications.
- Vibration Analysis: Detect abnormal vibrations that could indicate alignment issues or mechanical defects.
- Operational Simulations: Test the pump under various load conditions to confirm reliability and adaptability.
9. Implement Post-Retrofit Maintenance
A successful retrofit does not end with installation.
“The last thing you want to do is install a brand, new pump, and then ignore regular preventive maintenance,” Terranova says. “Being proactive with maintenance can prevent critical failure down the road and extend the lifespan of your retrofit.”
It is important to establish a proactive maintenance program to sustain performance. Regular inspections should include monitoring critical components such as bearings, seals, and impellers for wear and consider keeping spare wear items available to ensure quick repairs when there are issues. It’s a great idea to leverage digital monitoring tools to track performance metrics and predict maintenance needs. And don’t stop there. Provide operators and maintenance personnel with training on the upgraded system’s features and requirements.
“There’s no better motivation to keep a good maintenance schedule then throwing down thousands of dollars for a brand-new pump,” Terranova says. “You want to protect that investment and prevent future damage.”
10. Evaluate Retrofit Outcomes
Finally, assess the success of the retrofit by comparing pre- and post-retrofit performance data. Evaluate things like efficiency gains by quantifying energy savings and calculating the return on investment (ROI). Measure reductions in downtime and maintenance costs to track reliability and verify that the system meets new capacity or process requirements. Don’t forget to assess reductions in emissions or waste generation.
Retrofits That Are Made to Last
Retrofitting a municipal or industrial pump can yield significant benefits, from cost savings to enhanced operational performance. By following these best practices—from thorough system assessments to post-retrofit evaluations—organizations can ensure a successful retrofit that aligns with their technical and financial objectives. Investing time and resources into proper planning and execution will pay dividends in the form of improved efficiency, reliability, and compliance.
“My best advice is to do your due diligence before the retrofit,” Terranova says. “The more detailed and granular information you have at the start, the better. And make sure you understand why the pump failed in the first place so you can address that problem and avoid it in the future. Then work with professionals like HOMA, who are committed to your best interests. We will help you identify the problem and find the best possible solution for your system.”
For more information about industrial pump retrofit best practices, please follow these links:
https://homapump.com
https://www.wateronline.com/doc/avoiding-common-pitfalls-in-pump-retrofits-
https://empoweringpumps.com/homa-single-vane-non-clog-pump-replaces-chopper-cutter-pump-in-wastewater-facility/
There’s a wide range of individuals who contact us to talk through their custom pump needs. Some are entrepreneurs and inventors while others are large OEM corporations that are established in the pump system market. And, there’s everything in between.
Does your pump application even require a custom solution? Not necessarily. There may be an existing pump product that meets your desired performance requirements.
No matter the scenario, there is typically a set of qualifying questions our engineering team asks to help determine needs and whether a custom pump solution is a fit.
1. What are your application and technical parameters?
Every pump manufacturer will have certain applications and performance parameters that fit in their wheelhouse. If a customer needs a high-flow pump for industrial water treatment plants, for example, our team will quickly determine that we’re not a fit. Pumptec specializes in low flow, high-pressure pump systems.
Some common applications for Pumptec high-pressure plunger pumps include:
- Agriculture (boom sprayers, lawn care, pest control, etc.)
- Misting (dust control, disinfection, evaporative cooling, etc.)
- Soft wash
- Portable sanitation
- Desalination
- Chemical metering/dosing
- Commercial cleaning
- Carpet cleaning/extraction
- Hydrostatic testing
- And more
Be ready to provide your desired GPM and PSI and what type of environment the pump will operate in (dusty, hot sun, truck mount, indoors, etc.) What is the duty cycle (how many hours a day does the pump operate)? The nozzle size is important also, as is reservoir tank size and other technical information. Knowing the basic performance requirements of a customer’s application will help determine whether the project aligns with Pumptec’s core competencies.
2. Are you looking to switch from another pump? Why?
We’re often contacted by manufacturers that already use a pump from another company but are looking for other options. Some reasons include too many warranty returns, not enough pressure, inconsistent flow, or oil runs out when the pump tips over. At Pumptec, we’ll not only help find a better pump but will also explore why the previous pump failed.
3. What chemicals are you pumping?
For pumps that only pump water, there’s a good chance an existing or slightly modified pump can meet your needs. There are many more considerations if a system needs to pressurize chemicals, however. Chemical incompatibility is one of the biggest drivers of pump failure.
We use aircraft-grade anodized aluminum or stainless steel for many of our pumps. Both are extremely strong. PVC, however, might be more compatible with a chosen chemical, but its tensile strength is lower. Ceramic plungers are often used with a wide range of harsh chemicals as well. If a pump needs to take a lot of abuse, a combination of materials can be designed to achieve the right balance of compatibility and durability.
PRO TIP: Know the exact combination of chemicals your pump system will use and contact the chemical manufacturer for compatible material recommendations. Often, compatibility charts found online are not complete or reliable.
4. Is there an existing solution that will work?
A customized sample can typically be delivered within a few weeks. It’s important to consider that you might not need to reinvent the wheel and can expand on what’s already available. In that case, we’ll create part numbers and drawings and will send out a sample for you to try.
There are a few approaches. One is to allow our team to develop CAD drawings and models with plumbing configuration recommendations based on our knowledge of the pump design and how it will perform best in your system. Another is for your OEM engineers to collaborate with our team to optimize your configuration when appropriate. We might recommend fewer elbows, different pressure regulators, an outlet pulse hose, or a stronger inlet hose.
Some pumps, like those for portable sanitation, may be plumbed differently each time depending on the truck they’re mounted to. These inconsistencies can be challenging. It’s best to design the configuration to overcome the most complex and challenging scenario.
5. What is the timeline and number of units?
In cases where we do not have an existing solution, we may be willing to begin an R&D project and develop a new pump. However, prototyping a new pump design can be a lengthy process, somewhere between six months and a year or more. For example, we maintain a sufficient supply of our mainstay motors, but a new motor sample could take as long as six months to arrive due to supply chain issues. From there, the sample motor is tested in a pump design for a month or two to ensure it performs properly. Assuming it does, a pallet of motors is ordered for production (which could be another six-month turnaround time).
Timing is also dependent on good communication. Ideally, once we’ve performed our internal pump testing, we send out our pumps for field testing by actual operators. Their feedback is invaluable, and timeliness of responses helps move a project along.
Also consider that an R&D project won’t be opened up for one or two units as it would be cost prohibitive for both parties. That said, we’ll work diligently to find an existing pump to meet the need.
6. Is your design idea optimized?
Finally, our team will review your design, make recommendations for optimization, and collaborate with your team to inevitably end up with a better product. We’ll not only evaluate the internal workings of the pump, but also help determine the best types of hoses, nozzles, reservoir tank placement, and even whether to use Buna or Viton O-rings.
Those who design pumps often have great ideas, and we enjoy bringing them to life. There are major benefits for those who are willing to leverage our engineering team’s knowledge and experience. They know what works and what doesn’t. They’ll work with you to determine the best outcome that fits in your budget.
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