Retrofitting is an excellent alternative to buying a new product. It can be performed on all pumps, intended use notwithstanding.
With its wide range of existing services that help users get the most out of their pumps, local pump manufacturer, KSB Pumps and Valves is leading the way in pumping requirements change or prolonging the life of existing pumps.
According to David Jones, KSB regional sales manager for Sub-Saharan Africa, retrofitting is equally applicable in industrial, water supply and waste water disposal as well as in the power supply industry. The benefits of a retrofit solution are the creative combination of state-of-the-art technology and expert service.
Changing requirements
Changes in circumstances often require a new approach which applies to pumps used where increased energy efficiency is required; to oblige to new legal requirements, extend service life or adjust the technology to new operating data.
The areas of use for retrofit solutions are diverse, so are the requirements set for pump systems in question. As a result, retrofit solutions, hydraulic and mechanical modifications as well as material changes go together.
“A number of benefits can be applied to lower maintenance costs. These applications reduce power consumption while achieving longer service life, increase system availability and/or even comply with legal requirements for example, TA-Luft and ATEX,” says Jones.
Optimised systems
By optimising pump systems with retrofits, good can be made better.
Here are some examples of what can be done:
Hydraulic modifications
- Re-machining of existing impellers
- Installation of new impellers for conditions that are off-design
- Reduction of NPSH-required value through the installation of an inducer or suction impeller
- Optimisation of volute casing for off-design conditions
- Adjustment of the number of stages on multi-stage pumps
Mechanical adjustments
- Closed bearing brackets improve the smoothness of operation and extend the bearing life
- Mechanical seal systems installation
- Application of cellular surface wear rings to improve efficiency, rotor dynamics and dry running properties
Use of optimised material
- Super duplex stainless steel grades or nickel alloys
- Ceramic mineral castings for impellers, wear plates, cover and casing – for use with finely dispersed, highly abrasive solutions
- Non-metallic rings and bushes
- Ceramic plain bearings
- Surface coatings
Practical example
Jones explains that practical examples exist locally and abroad throughout the company’s global footprint and that in some known residential cases, Installation of simple modifications in pump stations have significantly reduced emissions of noise.
In others, due to changing materials or chemicals, retrofits can solve premature wear or chemical corrosion. Power stations pumps may be critical and require retrofits to prolong their lives. This may reduce the need to manufacture purpose-built pumps with potentially long lead times. Without doubt, there is a lot of sense in considering retrofitting rather than replacing pumps.
Jones suggests that contractors, engineers, as well as users should always weigh-up the benefits of retrofits.
“As an OEM manufacturer, KSB will offer real expert advice and provide services in accordance to global standards requirements,” he concludes.
