# Can a broken PSA oxygen plant be repaired or refurbished?

**Can an existing PSA oxygen plant that has stopped working be repaired or refurbished?**

A PSA plant that has stopped working can be repaired if an assessment finds it repairable, but not always economically: a PATH analysis (November 2023) found that, depending on a plant's value and age, advanced repairs may be less economical than buying a replacement.

## What usually goes wrong

PATH, with contributions from Build Health International, Partners in Health and Assist International, reviewed 50 PSA plants at 45 facilities. Common issues in the plants in disrepair were:

- clogged filters and drains, reducing flow or causing overheating;
- contamination of the sieve beds, giving low purity;
- compressor failure, with error codes or overheating;
- booster failure, with slow cylinder filling or overheating;
- leaky valves, giving low purity, fire or noise.

Deferred maintenance makes later repairs larger: PATH explains that missed oil-separating filter changes can lead to downstream oil contamination of the sieve beds, requiring full disassembly, cleaning and zeolite replacement. For plants with low initial cost and poor quality assurance and customer support, it says repair may not be worth the time, cost or effort, because something else may break down in relatively short order. PATH and CHAI (2021) note that corrective maintenance may mean rebuilding a valve assembly or a compressor.

## How a repair is decided

- Assessment: for the Global Fund's Project BOXER, Build Health International publishes a PSA plant repair assessment form (March 2025) and a training course (April 2025) that prepares teams to assess existing PSA plants and determine whether they can or cannot be repaired, with a separate electrical assessment form.
- The team: at least one person able to assess a PSA plant, such as a biomedical engineer, technician or operations staff member, and at least one person with a background in electrical systems.
- Service agreement: UNDP's 2025 requirements ask for supplier obligations on maintenance, repair and post-warranty services to be set out in a service level agreement that specifies response times for emergency repairs, maintenance intervals, spare parts availability and technical support.

## After the repair

Global Fund sustainability guidance (August 2024) says that, where there is no local service agent, for example for previously installed and repaired plants outside warranty and maintenance contract, a maintenance plan for the host facility engineers should be developed, and staff may need advanced training. It recommends a spare parts inventory of at least two years, funds set aside for unexpected repairs, and a back-up plan with a maximum number of days of plant shutdown and an escalation procedure. See [why PSA plants stop working](https://library.ultracontrolo.com/answers/why-do-psa-oxygen-plants-stop-working/).

For Ultra Controlo systems, the UltraCare programme covers preventive maintenance, corrective service, original spare parts and emergency support, 7 days a week, 24 hours a day. ULTRAOX plants are designed for a minimum life cycle of 150,000 hours. See [what maintenance a PSA plant needs](https://library.ultracontrolo.com/answers/what-maintenance-does-a-psa-oxygen-plant-need/).

### Is it cheaper to repair or replace a PSA plant?

It depends on the plant: PATH notes that, depending on its value and age, advanced repairs may be less economical than a replacement, especially for low-cost plants with poor quality assurance and customer support.

### Who should assess a broken plant?

Global Fund Project BOXER training pairs at least one person able to assess a PSA plant, such as a biomedical engineer, technician or operations staff member, with one who has an electrical systems background.

## Sources

- [PATH, Pressure swing adsorption plants: Common issues and solutions to prevent future disrepair (November 2023)](https://media.path.org/documents/Root_cause_analysis_report_external_clean_v2.pdf)
- [PATH and CHAI, Oxygen Generation and Storage: Pressure/Vacuum Swing Adsorption Plant (July 2021)](https://media.path.org/documents/O2_generation_and_storage_PSA_VSA_v1.pdf)
- [Global Fund / Build Health International, PSA Plant Repair Assessment form (7 March 2025)](https://resources.theglobalfund.org/media/r0ebzmsy/cr_c19rm-plant-repair-assessment_form_en.pdf)
- [Global Fund / Build Health International, Repair and Electrical Assessment Training for PSA Medical Oxygen Plants (25 April 2025)](https://resources.theglobalfund.org/media/4fqjxjjm/cr_c19rm-repair-electrical-assessment-training-psa-plants_overview_en.pdf)
- [Global Fund / Build Health International, Overview: Sustainability Guidance for PSA Oxygen Plants (22 August 2024)](https://resources.theglobalfund.org/media/bwrp43cm/cr_c19rm-psa-oxygen-plant-sustainability_overview_en.pdf)
- [UNDP, REQ-OXY-001 v01, Technical and regulatory requirements for oxygen plants (effective 1 January 2025), section 6.5](https://healthimplementation.undp.org/wp-content/uploads/2025/01/REQ-OXY-001-v01-UNDP-TECHNICAL-REGULATORY-REQUIREMENTS-FOR-OXYGEN-PLANTS.pdf)
- [ultracontrolo.com: UltraCare](https://www.ultracontrolo.com/technical-assistance-center)
- [ULTRAOX datasheet 2022, p. 4](https://www.ultracontrolo.com/ultraox)

Reviewed: 2026-10-22. Ultra Controlo engineering. https://library.ultracontrolo.com/answers/can-an-existing-psa-plant-be-repaired/