Maintenance of submersible pumps and autoclave systems: practical guide to avoid failures and emergency interventions.
Why maintenance is decisive for submersible pumps and autoclaves.
In the daily work of a hydraulic installer there are two types of systems that generate the highest number of service requests: submersible pumps and booster sets. Not because they are unreliable products, but because they are among the few components that operate continuously and under rather difficult operating conditions. The water level changes, draw-off points open and close, required pressure varies during the day and water often carries air or impurities. Under these conditions the hydraulic pump does not fail suddenly: it progressively deteriorates while continuing to operate.
The result is typical: the system appears operational but small signals begin that are ignored for months (e.g. increased noise, longer filling times, frequent starts, slight pressure fluctuations). When the customer calls, the damage is often already advanced and maintenance turns into replacement. For this reason, maintenance of a hydraulic pump should be the result of periodic monitoring of operating conditions. A hydraulic pump almost never breaks on its own: it works outside its correct operating point for too long.
The most common causes of failure: wells, sand, dry running and frequent starts.
In the case of submersible pumps, degradation is almost always linked to the environment in which they operate. Even a minimal presence of sand in the well acts as an abrasive on the impellers: initially the flow rate decreases imperceptibly, then operating time increases and the pump remains on longer. The user only perceives less stable pressure, but internally the hydraulic pump is losing efficiency. Another frequent phenomenon is partial dry running: the dynamic water level temporarily drops below the suction point, the pump continues to rotate but is no longer properly cooled and over time seals and supports are damaged.
In autoclaves or booster sets, on the other hand, the main enemy is start-ups. When the expansion vessel loses pre-charge, the pump starts at every water request, even reaching hundreds of cycles per day. Each start is electrical and mechanical stress that over time wears out bearings, capacitor and shaft. The hydraulic pump is often replaced while the real cause is the system. The presence of air in the line also causes instability: pressure seems correct but the pump continuously modulates, generating vibrations and premature wear.
Correct maintenance: pre-intervention checks and post-intervention verification.
Preventive maintenance consists of verifying operating parameters before even intervening mechanically. In well pumps it is essential to check pressure variation over time, electrical absorption compared to nominal data and any presence of impurities in the water. A change in absorption without apparent pressure variation almost always indicates internal efficiency loss. In autoclave systems, on the other hand, it is crucial to observe dynamic behavior: cycle duration, start frequency and pressure stability. A cycle that is too short always indicates an anomaly even if the system appears to function.
After the intervention comes the most important and often overlooked phase: checking in real operating conditions. In the first minutes residual air, pressure returns or water hammer emerge that would drastically reduce the life of the new pump. Recording values after maintenance allows understanding whether the machine will operate for years or months. Without this step the same problem will reoccur.
Recommended frequency and benefits: fewer downtimes, more efficiency, fewer replacements.
There is no identical deadline for all systems, but there is a practical rule: submersible pumps should be checked at least annually, while autoclaves or booster sets require more frequent checks because they are subject to continuous cycles, typically every six months. Systems without maintenance operate for a long time apparently without problems, until complete shutdown that always occurs at the worst moment.
Scheduled maintenance is not only to avoid breakdown but to stabilize the system. A pump operating under correct conditions consumes less energy, reduces vibrations, protects pipes and valves and ensures constant pressure. For the customer it means service continuity, for the installer fewer emergencies and interventions that can be planned. Submersible pumps and pumping or autoclave systems do not fail suddenly: they go through an invisible period between operation and failure. Intervening in that phase is what avoids high costs and premature replacements.
FAQ – Maintenance of submersible pumps and autoclaves.
How often should maintenance be performed on a well submersible pump?
Under normal conditions at least once a year, preferably before periods of higher use. In the presence of sandy water, low-yield wells or prolonged operation it is advisable to increase inspection frequency by checking electrical absorption, pressure stability and system filling times, in order to identify early loss of efficiency or partial dry running.
How often should an autoclave system (Booster set) be checked?
Indicatively every 6 months, because it is a system subject to continuous start cycles. During inspection, expansion vessel pre-charge, pump start frequency, presence of micro leaks and pressure stability are checked, parameters that directly determine motor and internal component life.
Why does the autoclave pump start continuously?
The most common cause is loss of air in the expansion vessel, which reduces useful volume and causes frequent starts. System leaks, inefficient check valve, air in the line or poorly adjusted pressure switch can also contribute, conditions that cause the pump to operate out of balance increasing wear.
How to understand if a submersible pump is running dry or under critical conditions?
Typical signs are abnormal noise, unstable pressure, sudden flow variations and increased motor temperature. A change in electrical absorption compared to nominal values is often also noticed: indication of insufficient water level or improper cooling.
Is it better to repair or replace the hydraulic pump?
If the problem concerns seals, bearings or peripheral components, overhaul is generally convenient. If impellers, shaft or electric motor are compromised, replacement is often more reliable and economically advantageous, especially to avoid further short-term system downtime.
