Maintenance and Service – Why, When and How

Last updated: 19 Mar 2025

Maintaining the condition of your pumping equipment is vital to maintaining an efficient and reliably operating site. Regular maintenance and scheduled service visits will extend the life of your pump’s components and vastly reduce the chance of a breakdown by helping to identify problems early.

There are two main kinds of maintenance:

Corrective Maintenance

Corrective maintenance includes repairs and emergency breakdown services to resolve any issues that have already occurred, such as leaks or unexpected pump failures. Corrective maintenance is generally more costly than preventative maintenance, requiring more time, parts and unplanned downtime due to the issue having developed to the point that it disrupts your system’s regular operations.

Preventative Maintenance

This is any maintenance work done to prevent an issue from occurring and is either:

Scheduled to suit the needs of your equipment and application, with intervals for inspecting and servicing different components set to ensure they cannot fully degrade before being repaired or replaced
A reaction to anomalies in your equipment’s operating data, collected by a suitable monitoring unit. Over time, this collected data forms a picture of your equipment’s regular performance. When deviations in the data are spotted, they serve as an early warning sign – helping you to identify and address issues before they escalate

Preventative maintenance includes visual inspections, cleaning, oil changes and other regular protective measures. This method is typically less expensive than corrective action because downtime is planned for, parts and labour do not have to be sourced as an emergency and potential issues are resolved before they become more serious.

Why pump maintenance is important?

Keeping your pumping equipment and components in top condition will ensure everything works to its maximum potential in terms of energy efficiency and operational effectiveness, saving on running costs. It also extends to equipment lifetime, saving money on replacements and reducing the risk of a costly and disruptive breakdown from occurring.

Completing visual checks of a pump’s body, pipelines, level control units, impellers and other parts means their wear levels can be monitored, replacing them when they have deteriorated but before they cause a decrease in efficiency or a major fault. This includes checking for cavitation, corrosion and general signs of stress.

Other checks can include pump shaft alignment, motor oil levels, bearing condition and any unusual noises or vibrations that may denote a greater problem. Keeping on top of general cleanliness, such as viewing windows and alert bulbs, will ensure visual checks and reactive maintenance can take place when needed.

When to schedule your pump service?

The frequency at which pumps and larger systems, such as pumping stations, should be serviced and maintained varies between different models and applications. The most effective service and maintenance schedule will be custom-tailored to each product, below is a list of factors to consider when planning your equipment service schedule:

Pumps

The frequency a pump should be serviced depends on factors such as:

Pump type and application – the type of pump (e.g. centrifugal, chopper, hydraulic, electric, etc..), the installation environment and the pumped medium significantly influence the best service intervals. For example, a chopper pump in an agricultural waste processing facility faces a higher risk of corrosion and blockages compared to a domestic clean water pump
Operating hours – pumps that experience rapid start/stop cycles or extended operational periods experience faster wear and tear on their components and should be inspected more frequently
Criticality – pumps that serve more critical roles in an application, such as handling hazardous materials, should be checked more often as their failure can lead to more significant consequences such as environmental harm
Manufacturer recommendations – most pump manuals will include a recommendation for how often to complete certain checks and maintenance activities to keep your pump in optimal working condition

Pumping Stations

A general rule for pumping stations of all kinds is for a full-service to be completed every 6 months, annually at the least. Factors to consider include:

Callout frequency – a pumping station that has had an increased number of issues, breakdowns and callouts should be serviced more frequently until the station’s operations stabilise
Criticality – this varies depending on the function of the pumping station. A station that serves as flood defence in a flood-prone area should undergo more frequent servicing to ensure it functions effectively during extreme weather events, while a domestic rainwater harvesting pump failing may not have as severe consequences

How often should you check your equipment?

Most pump and package pumping station manuals include suggestions for checks and how often they should be completed, see below for an example of a general pump maintenance schedule from T-T.

Monthly checks

Measuring installation resistance:

Cold insulation resistance reference value ≥20MΩ (cold)
Thermal insulation resistance reference value ≥1MΩ (thermal)

Please note: The motor must be inspected if the insulation resistance is considerably lower than that obtained during the last inspection.

Measuring the loaded current:

To be within the rated current

Measuring the power supply voltage:

Power supply voltage tolerance

Continuous running: max + 5% of the rated voltage
Intermittent running: max + 10% of the rated voltage

Inspecting the impeller:

If the performance level has decreased considerably, the impeller may be worn

Semi-annually checks

Inspection of lifting chain or rope
Inspecting and changing oil

Yearly checks

Changing the oil and replacing the mechanical seal in the chamber, every 12 months or after 6000 hours of use – whichever comes first

Please note: Contact the dealer from whom you purchased the equipment or the manufacturer's sales office in your area to inspect and replace the mechanical seal.

Every 2 - 5 year checks

The pump must be overhauled, even if the pump appears normal during operation. The pump may need to be overhauled earlier if it is used continuously or repeatedly

Please note: Contact the dealer from whom you purchased the equipment or the manufacturer's sales office in your area to overhaul the pump.

Always check the manual

Pump manuals generally includes guides for the assembly and disassembly of the pump and its internal components, allowing the operator to complete many of the checks themselves; these are generally the more frequent checks such as visual inspections and measuring the loaded current.

Some manuals also contain a troubleshooting guide for issues such as start fails, unusual noises and lower pumping volume – along with instructions for inspecting and changing the pump’s oil.

Only suitably qualified personnel should maintain the equipment, wearing the correct PPE and following the instructions given.

For complete pump servicing, the equipment manufacturer or a reputable and accredited company should be employed. The frequency at which this is needed will vary from pump to pump and can be measured in years or operating hours if the pump is running continuously.

Pump Maintenance Packages

Pumping stations are generally repaired, maintained and serviced by qualified engineers who will attend your site, usually operatives from the original manufacturer of the system. Service Agreements (such as T-T’s Maintenance Package) offer a set schedule for pump station servicing, designed to keep your specific station in optimal working condition and prevent a breakdown.

T-T’s Pump Maintenance Packages are available in three levels that offer different services such as pump replacements, emergency callout priority, comprehensive service reports and 24/7 monitoring.

Find out how our service agreements can optimise your pump station maintenance and operations or chat with one of our experts to discuss the best service level for your station, including our bespoke packages, by calling 01630 647200, emailing response@ttpumps.com or completing our online enquiry form.