For many industries, replacing worn or damaged pumps is often considered the default solution when equipment performance declines. However, repair and refurbishment can frequently provide a more economical and practical alternative, particularly for specialised or critical pumping systems where new equipment may involve lengthy lead times and significant capital expenditure.
Through its SupremeServ division, KSB Pumps and Valves offers comprehensive repair and refurbishment services that restore pumps and valves to original OEM specifications at a fraction of the cost of purchasing new equipment. In addition to servicing its own products, KSB also repairs pumps and valves from other manufacturers, often restoring them to performance levels that meet or exceed original specifications.
Supported by advanced engineering facilities and specialist technical expertise, KSB is able to undertake complex repairs locally, including reverse engineering and the manufacture of obsolete components that are no longer available from original equipment manufacturers. This capability helps industries extend the operational life of critical assets while reducing downtime.
According to David Mathonsi, Operations Manager at KSB SupremeServ, repairing worn equipment should always be considered before opting for complete replacement.
“A professionally executed OEM repair can restore equipment to reliable operating condition at a significantly lower cost and in a much shorter timeframe than replacing the entire unit,” he explains.
A recent refurbishment project involving two KSB FBL pumps demonstrates the value of this approach. The pumps had been operating continuously at a major water utility pump station responsible for supplying bulk water to Bothaville, Welkom, Odendaalsrus and surrounding mining operations. Given their critical role in maintaining water supply, prolonged downtime was not an option.
Years of continuous operation had resulted in severe hydraulic wear, erosion and cavitation damage, leading to declining performance and reduced reliability. Detailed inspections revealed extensive wear across key components, including diffusers, stage casings, suction casings, bends, wear rings and other internal parts.
Rather than waiting for replacement equipment and new cast components, KSB’s engineering team undertook a complete refurbishment programme. Impellers, diffusers and casings were rebuilt to OEM specifications, while mechanical seals, bearings and worn consumable components such as shafts, wear rings and fasteners were replaced to restore full system integrity.
The project delivered substantial cost and operational benefits. Refurbishing the pumps cost approximately 30% of the price of purchasing new units, while the entire project was completed within six to eight weeks, considerably faster than sourcing and installing replacements.
Beyond restoring the pumps to their original performance, the engineering team incorporated improvements identified during the inspection process. Specialised machining techniques and advanced protective coatings were applied to wet-end components to minimise future erosion and cavitation, helping extend service life and improve long-term reliability.
Once rebuilt, the pumps were assembled and aligned to precise OEM tolerances before undergoing comprehensive quality assurance procedures to ensure dependable operation under demanding service conditions.
In addition to repair and refurbishment services, KSB SupremeServ provides condition monitoring, equipment diagnostics, field services, installation, commissioning and lifecycle maintenance solutions. These services enable customers to optimise pump performance throughout the entire operating life of their equipment while benefiting from OEM-compliant workmanship and technical support.
Every refurbishment project is backed by a comprehensive warranty of 12 months from installation or 18 months from delivery or readiness for dispatch, giving customers additional confidence in choosing repair over replacement.
As industries continue to seek ways of reducing operating costs while improving asset reliability, professional pump refurbishment is proving to be a practical strategy that delivers significant financial savings, shorter lead times and extended equipment life without compromising performance.
