Don’t just throw away. Think, Recover and Repair!

In the case of pumps, over time it’s inevitable that they will suffer some degree of abrasive wear, particularly when operating in an aggressive setting. The extent of wear will depend on the fluid being pumped and the concentration of aggressive and abrasive medium, however, it is also the case that even relatively clean fluids can also degrade your equipment, even though more gradually.

When a pump is first specified for any application, efficiency is of course considered. But over time, whether long or short, the wetted parts of a pump will encounter wear and damage caused by abrasive products. It’s just the nature of the application.

But you must consider that this will affect the operating cost as a whole. Not just power consumption but in other ownership elements such as wearable parts including bearings, sealing devices and motors etc. Therefore, it makes perfect sense for pump owners to identify any areas where they can translate to lower operating costs and increased profits.

Historically, the focus has seen engineers upgrade elements such as sealing devices and bearing protection, but one area that is often not considered is upgrading the surface area that the fluid passes over. Where fluids experience turbulence due to damaged surfaces, mechanical seal and bearing life will be affected, therefore it would be a mistake to ignore.

Not so smooth

The unevenness of any surface exposed to a pumped product will decrease its efficiency, thus increasing costs in power required to operate the application. An increase in turbulence in fluid flow will also further aggravate the damage caused.

In many cases, the damage caused can be so excessive that parts will need to be changed out, however, the damage caused by the fluid is only a symptom - meaning that even the new part will still be subjected to the same damage unless action is taken to limit the deterioration.

Smoothing out the cracks

So now you may be asking, how can I maximise the operating life of my pumps and associated equipment that suffers from the effects of operating in an aggressive environment? Well, it’s quite simple… invest in a Unique Polymer Systems (UPS) ceramic carbide engineering grade product.

All pumps would benefit from enhanced reliability and increased service life by introducing one of UPS’ engineering grade ceramic carbide solutions. For example, by introducing UPS 200 EG Engineering Grade Ceramic Carbide Paste to a severely damaged pump, the damaged voids can be filled and unit re-profiled, enabling the application of a ceramic carbide coating of your choice.

Providing that the surface preparation, a process that can be carried out in-house, has been undertaken correctly, extended service life and subsequent benefits will be achieved, essentially saving you money in maintenance, investment in expensive replacement parts, and many other associated costs.

So, which ceramic engineering grade should I use?

UPS’ portfolio is extensive, offering a wide range of options suitable for many applications, processes and environments, starting with UPS 200 EG which can be used to repair any damage prior to coating.

The most commonly used product to help prevent surface wear through general service and abrasive applications, as well effective efficiency is UPS 205 FG, while UPS 2010 CR will provide better efficiency particularly in critical clean fluid flow applications.

For applications where high temperature fluid is being pumped then UPS 225 HT is the best option, capable of operating with fluids up to 70˚C, but for high acid content then UPS 226 HAC will provide the protection you need.

Finally, if you’re encountering severe damage caused by cavitation, UPS 236 TUC is the most suitable option. With all ceramic parts from the 236 containing an epoxy resin base, it has a toughened polyurethane base offering a better solution for the specific problem of the implosion of bubbles created by the pumping application.

It’s also worth noting that, previous layers can be recoated with a flexible ceramic carbide to help your equipment in the future by reducing the effect of the cavitation.

As previously pointed out, don’t ignore your options, particularly with so many available. So, what we advise is, take a moment to reflect and reassess next time you think about simply throwing away your corroded plant machinery. There is more often than not a more cost-effective solution at your disposal.

Contact your local ERIK’S engineering centre for a quote on upgrading your pumps to engineering grade ceramic carbide coatings. HELP YOUR PUMP stay productive longer!