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Saving the higher cost of hire costs
When is a relatively reliable diesel-driven pump more expensive than an unreliable one? When it’s a hired pump. So, when ERIKS replaced a customer’s hired pump with a new electric alternative, there were savings all round.
The customer – who operates in the heavy industry sector – uses the pump to pump effluent from a catchment lagoon to their own treatment plant, which is a distance of several miles away. The distance, the static head and the inherent frictional losses in the pipework mean that a high head pump is required.
Historically, two single-stage vertical Mather & Platt pumps had been used: one as a duty pump and one on permanent standby.
The age of the pumps and parts obsolescence also meant there were long lead times for replacement parts, which had to be specially manufactured.
The unreliability and high repair costs eventually drove the customer to take action. But rather than invest in a replacement pump with more efficient technology, their decision was to hire another diesel-driven pump.
When rental goes mental
As a short-term solution, hiring a pump was better than nothing. But then the short-term lasted for eight years.
Unfortunately, these pumps required daily routine maintenance (refuelling and checking oil and coolant levels) which meant a one- to two-hour shutdown every day. They were also notoriously unreliable. The high levels of vibration inherent in a single-stage pump resulted in a short Mean Time Between Failure, as the pump virtually shook itself to death. In fact, the vibration was so bad it was impossible to mount the standby pump next to the duty pump – meaning more downtime whenever the pumps needed to be changed.
That was before ERIKS’ engineers identified the scale of the annual hire costs and diesel fuel.
When these figures were presented to the customer, it was obvious another solution was required, and ERIKS were tasked with finding a more cost-effective proposal.
The first recommendation – in the face of ever-increasing diesel fuel charges – was to change to an electric-driven three-stage Caprari pumps, for far smoother and more reliable operation.
This would not only reduce fuel costs, but also eliminate the need for daily refuelling and other maintenance. With no need for daily shutdowns, the flow of effluent to the treatment plant would also be constant, making it easier to manage.
Everyday savings
The savings resulting from ERIKS’ solution were every day, but far from ordinary.
With a more reliable electric-driven pump installed, every day saw a saving in maintenance costs and downtime. Electric power meant that every day also saw a saving on diesel fuel costs. And every day saw a saving in breakdown and repair costs, as the new solution extended the pump service life from 6 months to 3-4 years.
Even based on fuel prices at the beginning of 2020, the customer would be realising savings of £204,000 per annum on hire fees and diesel. And in line with the recent rises in fuel prices, those savings have hugely increased.
Repair or replace?
ERIKS always maintains a repair or replace neutrality – carefully and accurately costing both options and giving the customer the choice.
In this case, the cost of replacing the current solution with a new electric-driven Caprari pump and motor together was only the same as the cost of repairing the original Mather & Platt pump. Taking into account the savings on the hire of the ‘temporary’ pump, and the savings in labour costs for refuelling and other maintenance, the most cost-effective decision was obvious.
The customer made the right choice. And the savings compared with the original pump and the ‘temporary’ pump are now significant – and permanent.
For more information on Flow Control solutions and to get in touch with one of our ERIKS Pumps Specialists or Valve/Flow Control Engineers, please contact your local ERIKS Service Centre, who will be happy to discuss your options.
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