Case Studies

Blogs, Case Studies | January 4, 2026

Evaluating the Cost-Benefit of Motor Rewinding vs. Replacement in Mining Operations

When two critical motors—rated at 18.5 kW (25 hp) and 90 kW (120 hp)—burned out, the maintenance team faced a common decision: rewind or replace. While rewinding is often less expensive upfront, it can result in reduced efficiency. This case study presents a comparative cost analysis, revealing that motor replacement offers greater long-term value, with a break-even point reached within two years.

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Blogs, Case Studies | December 1, 2025

After a Fall in Pump Efficiency, Refurbishment Offers Pay Back in Under 2 Years

After pump efficiency fell from 90.5 to 85.5 percent, a water distribution pump was refurbished. The refurbishment resulted in the pump being able to provide a higher head with a better efficiency at the same flow rate. Because the pump output could be matched to the system requirements by the installed variable frequency drive, the refurbishment reduced the power absorbed and achieved a payback period of under two years.

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Blogs, Case Studies | November 1, 2025

Reducing Impeller Size for Oversized Pump to Reduce Energy Consumption by 25 Percent

Analysis of the pump was showed the pressure generated was considerably higher than required. Reducing the impeller size was explored which reduced the power demand by 25 percent. Fitting an alternative motor to the pump allowed more energy consumption reductions.

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Blogs, Case Studies | October 3, 2025

Replacing Heating System Pumps with Smaller Pumps to Reduce Life Cycle Cost

The heating system in an office building required renovation. The options considered were replacing the 3 existing pumps with ones that were the same power and eventually replacing the thermostatic valves, as well as redesigning the system to have four sub-systems with optimized dimensions using equal friction loss per pump. The latter option allowed for smaller pumps to be used which cut down on the life-cycle cost.

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Case Studies, Blogs | September 20, 2025

Second Pump Installed in Parallel to Improve Energy Efficiency of Water Circulation System

A pump used in an open system for pumping water from circulation tank into two wire tanks was worn down and had decreased efficiency. Analysis was done to compare the cost benefit of installing two modifications to the existing system. With an increased demand required only during startup, the conclusion was installing a new smaller pump parallel to the old pump to provide the base load duty. The old pump would only be used during the start up period.

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Blogs, Energy Efficiency, Case Studies, Commercial Building | August 1, 2025

Downsizing a Residential Circulator to Reduce Life Cycle Cost

A 30-year-old circulator needs to be replaced in a one-family house. An analysis on the system was done, which concluded that the electronic circulator could be downsized due to the existing hydraulic resistance in the system.

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Blogs, Case Studies | August 1, 2025

Cost Analysis of Replacing Power Plant Cooling Water Volute Casing Pumps with Mixed Flow and Variable Pitch Propeller Pumps

Overview: Replacements are being considered for a cooling water system that currently consists of four volute casing pumps. A cost analysis is done comparing the baseline versus variable pitch propeller pumps and mixed flow pumps with variable inlet guide vanes. Mixed flow pumps have the fastest payback in this application with a payback time of 0.4 years.

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Water/Wastewater, Case Studies, Blogs | March 20, 2025

Complex Flooding Issues in Alaska Town Leads to Unique Lift Station Design

Overview: August 2024 – Stormwater – Upgrade of the system to accommodate storms and mitigate flooding. If the flooding wasn’t addressed then the problem would continue potentially affecting homes, utilities, and infrastructure. With existing utilities, a stepped-down wet well was utilized to prevent any problems with those utilities.

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Blogs, PSM Newsletter, Case Studies | December 12, 2024

Field Evaluation of Different Check Valve Designs and Surge Pressure Measurement in a Municipal Water Pumping Station

Overview: During a municipal water pump station upgrade, hydraulic engineers got approval to perform field tests to assess the waterhammer (pressure surge) transients. Surge pressure measurements were taken after an induced pump power loss and subsequent check valve slam. They also developed a computer model to see how well available software could simulate the produced transients. This data was gathered to provide guidance to the municipality on future project work.

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Blogs, PSM Newsletter, Case Studies | June 18, 2024

Minimizing Maintenance Costs by Right-Sizing Dry Weather Pumps

Overview: The Norchester Pump Station was rebuilt in 2016 with dedicated dry weather and wet weather pumps. Between 2016 and 2018, the dry weather pumps required more than 5,000 hours of labor and $20,000 in parts for corrective maintenance due to pump ragging and pump failures. These pumps were replaced with smaller, properly sized pumps in late 2018 and have operated without significant issues since saving time and labor and increasing the reliability of the station.

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