Case Studies
How We Rebuilt a Critical Process Pump in 48 Hours
By WTPS Team•
A case study of our emergency pump rebuild for a local chemical plant facing production shutdown.
When a critical process pump fails unexpectedly, every hour of downtime costs money. This case study shows how WTPS responded to an emergency call and returned a pump to service in just 48 hours.
The Challenge
A chemical processing facility in central Indiana called us on a Friday afternoon. Their main product transfer pump had failed catastrophically—the shaft had broken at the impeller connection. Without this pump, their production line was shut down.
The pump was a specialty chemical-duty design with exotic metallurgy. The original manufacturer quoted 6-8 weeks for replacement parts. That wasn't acceptable.
Our Response
Our team arrived at the plant within hours to assess the damage. We removed the pump and transported it to our shop for complete disassembly and inspection.
What We Found
Beyond the obvious shaft failure, inspection revealed additional damage: the impeller was cracked, wear rings were severely worn, and the mechanical seal was destroyed. The casing and back plate were salvageable with some machining.
The Solution
We machined a new shaft from appropriate material stock we had in inventory. Our machinists worked through the weekend to turn, grind, and finish the shaft to specification. We sourced a replacement impeller from our network of suppliers and expedited shipping.
48-Hour Turnaround
By Sunday evening, we had completed the rebuild: new shaft, new impeller, new wear rings, new mechanical seal, and machined running fits. We performed dynamic balancing and thorough quality checks.
Monday morning, we reinstalled the pump and assisted with startup. The plant was back in production less than 48 hours after the initial failure.
The WTPS Difference
Emergency response like this is only possible because of our capabilities and inventory. We stock common materials and replacement parts. Our experienced machinists can work quickly without sacrificing quality. And we understand that production downtime has real costs.
If you need emergency pump service, call WTPS at (317) 862-1432. We're here when you need us.
About WTPS Team
The Wayne Total Pump Solutions team brings decades of combined experience in pump repair, maintenance, and wholesale distribution.
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