Borehole Maintenance Checklist — Annual, Monthly & After Load Shedding

A borehole is a long-term asset — most last 20–40 years with proper care. But the pump, casing, and associated components all require regular attention. This checklist is designed for South African conditions, including our specific load shedding challenges, high-iron groundwater areas, and dolomite risk zones.

Why Regular Maintenance Matters

The most common and expensive borehole failure is a burned-out submersible pump caused by dry running — when the pump runs without water, overheating the motor within minutes. Dry running is almost always preventable with a working float switch or dry-run protector. Yet it's the number one call-out that borehole service companies receive.

Other costly failures caused by neglected maintenance:

• Scale and iron bacteria buildup on pump impellers (reduces flow by 30–60% over 2–3 years)
• Corroded drop cables causing pump trips and control box damage
• Borehole casing corrosion leading to sediment ingress
• Failed pressure switch causing pump to cycle on/off rapidly, burning out the motor

Monthly Maintenance Checklist

• ✅ Check water flow rate — if the tap pressure at the furthest point has dropped noticeably, investigate immediately.
• ✅ Inspect control box — look for moisture ingress, corrosion on terminals, or burn marks. Control boxes exposed to weather degrade quickly in the SA climate.
• ✅ Test float switch — manually trigger the float switch (in the storage tank) to confirm the pump stops when the tank is full. A stuck float switch is a silent borehole killer.
• ✅ Check pressure gauge (if fitted) — your system should maintain consistent pressure (typically 2–4 bar). Fluctuating pressure can indicate a failing pump or pressure tank waterlog.
• ✅ Water colour and smell check — increased turbidity (cloudiness) or a sulphur/rust smell can indicate casing damage, a drop in water table, or bacterial growth. Test immediately.

Annual Service — What Your Contractor Should Do

Once a year, have a qualified borehole contractor perform a full service. This should include:

Electrical Inspection

• Measure motor insulation resistance (megger test) — any reading below 10 MΩ indicates deteriorating insulation
• Check starting current draw vs nameplate specifications
• Inspect all above-ground cable joins and conduits
• Test capacitor condition (on single-phase motors)
• Verify control box relay and contactor condition

Hydraulic Check

• Measure static water level (before pump runs) — compare to original commissioning data. A rising static level is fine; a significantly lower level may indicate aquifer stress.
• Measure pumping water level — should be within the design drawdown range
• Time-fill test — measure how long it takes to fill a known volume (e.g., 200L drum) and compare to previous years

Water Quality Test

Annual SANS 241 microbiological testing is strongly recommended. Bacterial contamination can develop over time as the borehole ages or after nearby construction or flooding. A basic microbiological test costs R400–R800; a full chemical panel costs R1,500–R3,000.

After Every Load Shedding Event

Power cuts are the leading cause of pump failures in South Africa. When power returns after a cut, voltage surges and phase reversals can damage pump motors — especially with ageing control boxes. Add these checks after each significant load shedding event:

• ✅ Listen for unusual sounds when the pump restarts (grinding, vibration, high-pitched whine)
• ✅ Check flow rate returns to normal within 2–3 minutes of restart
• ✅ If your pump uses a VSD/soft starter, check the display for fault codes
• ✅ Inspect the control box for tripped breakers or blown fuses
• ✅ For properties with a pressure tank: check the pressure reading returns to normal range within 5 minutes

Warning Signs Your Pump Is About to Fail

Don't wait for complete failure — these symptoms indicate a pump under stress that needs attention within 2–4 weeks:

• 🔴 Reduced flow that hasn't recovered after load shedding
• 🔴 Pump running longer than usual to fill the storage tank
• 🔴 Pump cycling on and off rapidly (waterlogged pressure tank or failing pressure switch)
• 🔴 Discoloured water (rust, grey, or sandy) after previously clear water
• 🔴 High electricity draw — a failing pump motor draws more current as windings deteriorate
• 🔴 Pump tripping the breaker at startup (motor winding failure or seized bearings)
• 🔴 Sulfur or metallic smell in the water that wasn't present before

Pump Lifespan & When to Replace

A quality submersible pump (Grundfos, Franklin, KSB) should last 10–15 years with proper maintenance. Budget brands typically last 3–7 years. Warning signs above appearing before 8 years suggest installation problems or poor maintenance history.

When you do replace, consider upgrading to a more efficient pump with better energy ratings — pump technology has improved significantly over the past decade, and a new pump may use 20–30% less electricity for the same output.

Frequently Asked Questions

How often should I service my borehole pump?

A full professional service once a year is the minimum. Monthly self-checks (flow, control box, float switch) between services are strongly recommended, especially in the first year after installation when any manufacturing defects will typically present themselves.

My borehole pump makes a grinding noise — is that serious?

Yes. Grinding typically indicates worn pump bearings, impeller damage, or sediment ingress. Stop using the pump and call a contractor. Continuing to run a grinding pump will result in complete motor seizure within hours to days.

How do I know if my pump has dry-run protection?

Check your control box — it should have a label or indicator for "dry-run protection" or "undercurrent detection". If it doesn't, or if you're unsure, ask your contractor to install a standalone dry-run protector (R800–R2,500). This is the single most important safety device for any borehole pump.

Can I pull my pump myself to inspect it?

Technically yes, but it's not recommended without experience. Pulling a submersible pump requires a pump-pulling device or strong tripod, knowledge of the drop cable and rising main configuration, and a clean working area to prevent contamination. An inexperienced pull can damage the cable, drop the pump, or contaminate the borehole. Professional pump pulling costs R1,500–R4,000.