Pump Parts Last Twice as Long
Using genuine parts enables Weir customers to achieve higher equipment efficiency and extended lifespan, thanks to ongoing enhancements integrated into every component. Says John West, Regional Manager Slurry Aftermarket at Weir, “In many cases, replacing an old generation part with a newly designed one actually enhances the overall performance and efficiency of the equipment.”
John highlights that energy consumption represents an ongoing and significant portion of a pump’s total lifecycle costs, yet many users remain focused solely on the purchase price of spare parts.
Fault finding
“Our global studies show that the capital cost of a pump and spare parts represents less than about 10% of its total cost of ownership (TCO) over its lifespan,” he explains. “Since energy accounts for nearly 60% of this lifetime cost, opting for a cheaper but less efficient pump can quickly lead to significantly higher operating expenses.”
John states that this is done through correct equipment selection as well as on-site process fault finding. “Manufacturing standards in many non-OEM supplied pump parts are not adhered to, which also presents potential safety risks to the customer.
Extended intervals
“The OEM part incorporates all of our latest technological advancements, enhancing efficiency, optimising hydraulics and extending wear life,” he adds. Precisely engineered to fit perfectly, the original parts also boost the equipment’s production capabilities, supporting smooth operation and maximising uptime.
“The extended service intervals our parts provide contribute directly to the overall efficiency and profitability of our customers’ operations,” John explains. “They also help minimise the risk of unplanned downtime due to premature component failure.”
TCO approach
He points out that users who source non-genuine replacement parts often overlook the significant costs associated with emergency repairs and unplanned production downtime. However, a growing number of customers are adopting a TCO approach, leveraging Weir’s technical studies to identify more effective ways to reduce long-term operational expenses.
“Many of our larger customers ask us to carry out formal assessments to help reduce the operating costs of specific equipment,”John explains. “In many cases, we collaborate directly with their dedicated reliability engineers. For smaller companies without such specialised roles, we step in with our expertise and insights to help lower running costs while enhancing both production efficiency and safety.”
Case study
One such example was a tailings recovery plant in South Africa, where profitability was closely tied to controlling operational costs. The plant’s owners sought to reduce their total equipment ownership costs by cutting downtime and energy usage.
After discovering that replicator parts on the wet end of their Envirotech Alpha D-Frame pumps were lasting only two months, Weir recommended upgrading to its Wear Resistance Technology – WRT impeller and throatbush for improved durability and performance.
Collaboration
“These WRT parts are a great example of how advanced materials and enhanced hydraulic design can significantly improve efficiency, net positive suction head (NPSH) performance and wear life,” says John. “In this particular application, the OEM parts lasted twice as long, reduced power consumption by drawing lower amperage and delivered a higher head.”
He notes that Weir also provided a service technician to support the installation of the upgraded parts and deliver training on general maintenance. This collaboration with the OEM not only ensured proper implementation but also helped enhance the plant’s skill base, contributing to improved equipment longevity and reliability.
Remote operations
“The efficiency benefits of OEM parts are even more significant in remote operations powered by diesel generators, where grid energy is unavailable,” he notes. “In such cases, the high cost of energy can be substantially lowered by ensuring all equipment operates at peak efficiency.”
Power consumption directly correlates with carbon emissions, which mining companies are increasingly required to reduce to meet their corporate sustainability targets, further underscoring the environmental value of using high-quality OEM parts.
