When restoring worn pumps makes sense This article from KSB Pumps and Valves argues for the value of restoring worn pumps to OEM specifications rather than replacing them with new equivalents. KSB SupremeServ operations manager, David Mathonsi, outlines this case.
were assembled and restored to the required tolerances and alignments. To further protect the pumps in service, all wet-end components were coated to mitigate future erosion and cavitation. “This type of project shows just a few of KSB SupremeServ’ s capabilities. We also provide other services such as condition monitoring, diagnostics and field services, as well as professional installation and commis- sioning of equipment, all of which allows our customers to manage their pump systems across their entire lifecycle with full OEM- compliant services. “Our projects are also backed by a com- prehensive warranty of twelve months from installation or eighteen months from delivery or readiness for dispatch, which makes a compelling case for our customers to repair or refurbish first,” David Mathonsi concludes.
of cavitation. As a result, their service perfor- mance had already deteriorated, with wear reducing reliability and output. Our inspec- tions confirmed widespread damage across key stationary components, including diffus- ers, stage casings, suction casings and bends, as well as wear rings and other components. “However, due to the urgency and the cost implications of restoring supply for the water authority and its end users, and relatively long lead times for new cast components, it made sense to pursue repair as the only practical route. In addition, by restoring the pumps rather than replacing them, the cost could be reduced to 30% of that of new pumps. Turnaround time was limited to just six to eight weeks for both pumps, which was far quicker than procurement and delivery of replacements,” says Mathonsi. He explains that the success of the proj- ect was due to the depth of skill within the company’s technical division as well as the right equipment and materials to do the job to OEM standards. This enabled them to profes- sionally rebuild the impellers, diffusers and all casings as well as restore mechanical seals and bearings. Worn consumables including fasteners, wear rings and shafts were replaced to ensure full system integrity. Impressively, the SupremeServ specialists were also able to make improvements based on the inspection findings and apply spe- cialised machining and coating processes to prevent or reduce future damage. The pumps
R epair and refurbishment of faulty pumps or valves should be consid- ered a first-line approach, particu - larly for specialised equipment. Through its extensive SupremeServ operation, Pump manufacturer KSB Pumps and Valves can repair a wide range of pumps and valves to original OEM specifications at a cost significantly lower than that of new equipment. In addition to its own pumps and valves, the company can repair other brands to meet or exceed the equipment manufac- turer's original specifications. The German manufacturer is in a unique position to undertake repairs and refur- bishments at its high-tech local facilities in Jet Park, South Africa, where its advanced techniques and in-depth materials knowledge enable full repair services including reverse engineering and manufacturing of parts and components for outdated equipment or equipment that is no longer available from OEM manufacturers. According to KSB SupremeServ operations manager, David Mathonsi, replacement of broken or worn-out pumps need not always be the best course of action. Rather, a properly executed OEM repair can deliver the same performance at a lower cost and in less time. This is often a sensible route for operators and provides a good balance between cost and availability. “We showed this recently with the re- pair of two KSB FBL pumps that have been operating tirelessly within a large water utility pump station. These units are critical to bulk water transport supplying Bothaville, Welkom, Odendaalsrus and surrounding min- ing operations where failure quickly leads to widespread water outages. “These pumps work hard around the clock, and in this instance their condition reflected the severity of their duty. The ageing units showed extensive system-induced hydraulic wear, significant erosion and clear evidence David Mathonsi, KSB SupremeServ operations manager.
SupremeServ workshop supervisor Ashey Pillay with a pump that is nearing completion.
SupremeServ senior pump fitter John Shupinyaneng, at a newly refurbished pump.
8 ¦ MechChem Africa • July-August 2026
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