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What We Assess
Operating Point
We compare how your pump runs today with its original performance curve. Running far from the best efficiency point means:
- Higher energy use.
- More mechanical stress on the pump.
- Shorter seal and bearing life.
System Hydraulics
Pipework changes over the years, and pumps rarely get changed with it. We review:
- Current flow and pressure needs.
- System resistance and friction losses.
- Throttling losses across control valves.
- Signs the pump is oversized for today’s duty.
Motors and Drives
Often the quickest gains come from the drive side:
- Fitting a variable speed drive (VSD or VFD).
- Replacing old motors with high efficiency motors.
- Trimming the impeller or reconfiguring the pump.
Servo Retrofits for Hydraulic Machines
Many hydraulic machines run a fixed speed pump all day, even while they wait between cycles. A servo retrofit replaces that with a servo motor and drive that spins the pump only as fast as the machine needs.
- Where it suits: injection moulding machines, presses and machines with long idle times.
- What changes: the motor, drive and controls. The pump and circuit often stay.
- What you notice: less power, less heat in the oil and a quieter machine.
- For the drives and controllers themselves, see servo drives and controls, or our wider servo and proportional range.
Energy Consumption Analysis
From the operating data, we estimate:
- Current power draw.
- Annual energy use and cost.
- Likely energy use after each upgrade.
- Simple payback for each option.
That gives you numbers to take to whoever signs off the budget.
What You Receive
- An analysis of how the pump or machine operates now.
- Where energy is being lost in the system.
- Recommended retrofit or optimisation options.
- Estimated annual savings and payback for each.
- Supply of the drives, motors and parts once you decide.
When an Assessment Makes Sense
- Power bills are higher than expected.
- The pump looks oversized for the job.
- Flow is controlled by throttling valves.
- Pumps or hydraulic machines run long hours.
- The site has energy reduction targets to meet.
Vacuum plant and duty and standby pump sets are worth checking too. See packaged vacuum systems and redundant pump systems.
What We Need From You
- Pump model or datasheet, if you have it.
- Current flow or operating range.
- Discharge pressure or head.
- Motor rating and running hours per year.
- Energy cost, if you know it.
No detailed data? We can start from reasonable engineering estimates and refine later.
Why Work With TSA Hydraulics Engineering
Our energy efficiency & servo retrofits services link the assessment to the hardware. The engineers who find the savings also source the drives, motors and pumps, so the numbers in the report match what gets fitted. You get practical engineering support, clear technical consultation.