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Studies collected by the Hydraulic Institute and Europump* reveal that pumping systems account for nearly 20% of the world’s electricity energy demand and from 25 – 50% of energy usage in certain industrial plant operations.  This highlights the significant potential that exists to cut a company’s running costs and put a dent in its carbon footprint too by maintaining or improving pump efficiency.

There are several ways to improve the energy efficiency of an industrial pump and the application of a protective coating is one of easiest and most effective.  This is typically a ceramic reinforced epoxy that can extend the life of new pump components and restore the worn surface of old ones.  They create a sacrificial and renewable working surface, protecting the structural integrity of the original substrate.

Castings impellers and volutes all wear due to corrosion, erosion, cavitation and mechanical damage but all these outcomes can be significantly delayed or prevented with the application of a protective coating.  The time it takes to apply is much lower than other remedial methods, such an installation overhaul and impeller trimming and it also achieves the shortest return on investment, typically 4 – 12 months.

30% energy reduction

A UK automotive manufacturer provides an excellent illustration of what can be achieved.  To demonstrate potential gains in pump energy costs a 22kW ELPO pump, used for handling process water, was selected for analysis and it was found to be under-performing by a minimum of 30% against the manufacturer’s original test data. 

The unit was then dismantled and all components examined for wear.  The pump was heavily corroded and pump impeller worn, burred and imbalanced.  The mechanical seal had seized and the pump was out of alignment with the motor.  The volute was cut-water worn, the bearings showed evidence of fretting and corrosion and the motor was not inverter rated.

All components that required coating were first steam cleaned to remove any residue and salts and then bead blasted to achieve a surface roughness of 75 microns.  LOCTITE^® 7515 was used to pre-treat the substrates to prevent corrosion and improve adhesion between the metal parts and the polymer composite coating. 

Next, LOCTITE 7177 was applied as a ‘hold coat’ to smooth the surface imperfections and provide a key for the thicker layers required to return the pump to its original dimensions.  A ‘build coat of LOCTITE 7226 was then used to replace many years of wear a create tough surface, resistant to future wear. This was followed by another coat of LOCTITE 7177 to achieve a finish that would reduce friction within the pump and improve its energy efficiency. 

The pump was then fitted with new bearings and both oil and mechanical seals. The impeller was dynamically balanced, the pump re-assembled and a new 22kW high efficiency motor fitted. Motor and pump were finally installed on the bedplate and laser aligned. 

The second performance test was then conducted and the results were outstanding.  The remedial work had restored the pump to original specification, increasing its efficiency by 30%.  The cost of the repair amounted to £5,542.  But offsetting this, in the first year alone, was an estimated energy reduction of £3,936.  This was calculated at £0.08/kWh at 12 hours per day with an 80% load.

The ‘before’ and ‘after’ analysis from other manufacturing companies confirm similar findings.  One reported a 19.9% energy efficiency increase with 4.55 months payback and a carbon emission saving of 10.2 tons per year and another a 12.67% energy efficiency boost, a 5.11 months payback time and carbon savings of 49.5 tons per year.

Ceramic reinforced epoxy coatings are available in a choice of grade for fine particles through to coarse and also specific products for pure chemical attack, corrosion and high impact. 

For more information on the LOCTITE^® range and advice on surface treatments in general, please visit our website:
www.henkel-adhesives.com

JT Tool & Plant Hire Ltd is a fast growing tool hire service situated in the heart of London.

 We pride ourselves in providing outstanding customer service to our customers by putting their needs and demands first. Offering Access Support, Handling, Air Tools and Compressors, Cutting and Grinding, Heating Cooling and Drying systems for hire.

Our aim is to go above and beyond the requirement of our customers in order to allow for the smooth and efficient progress of their projects by providing a wide range of tools on demand.

King’s Boiler Hire have worked tirelessly throughout the COVID-19 pandemic keeping hospital, care home and food processing clients running during this difficult time.

Offering boiler units ranging from 1,500lb/hr to 17,500 lb/hr with fast, Nationwide delivery available 24/7,  King’s Boiler Hire is the UK’s No.1 choice for emergency boiler hire.

Since 2015, SKF has decreased its manufacturing carbon footprint by 36% and is already operating two carbon neutral factories. Today, SKF announces its aim to achieve a fully carbon neutral manufacturing footprint by 2030.

The 2030 target will cover SKF’s own manufacturing operations, i.e. SKF’s scope 1 and 2 emissions. It will be achieved by a combination of process improvements, energy efficient machinery, and procurement and generation of renewable energy. As a last resort, SKF may also purchase high quality carbon offsets.

Hart Door Systems, the first specialist door company in the UK to manufacture high-speed doors, has moved into a series of short films to high-light its successes.

The most recent is a profile of Hart’s work at Komatsu’s 200,000 sq m plant at Birtley, Co Durham, where Hart has installed over 60 doors across a range of door types including Speedor Cleanrooms, Speedor Storms and electric roller shutters.

Winn & Coales (Denso) Ltd, specialist manufacturers of corrosion prevention and sealing products, recently announced the launch of their newly updated website – Denso.net – with new product pages, a new Surface Preparation Guide and many more exciting new features.

Denso.net is the perfect platform to showcase Winn & Coales (Denso) Ltd’s extensive range of corrosion prevention products. The new ‘Product Finder’ features bespoke and off the shelf solutions, that provide enduring protection against corrosion and chemical attack to buried and exposed pipes, valves, fittings, steelwork, marine structures, tanks and concrete bunded areas. 

As part of United Utilities water quality improvement programme, JMC North West, on behalf of NMCN, recently completed works to bury the above ground timing loop at the Pex Hill Service Reservoir.

The challenge was to provide a durable, reliable corrosion prevention solution to protect over 90 double flanged joints prior to full encapsulation. To provide this high level of protection, JMC North West turned to Winn & Coales (Denso) for its services.

Hart Doors has completed another contract at the Wimbledon Traincare depot, the traction maintenance depot servicing South Western Railway. 

Peter Cairns, Hart’s Area Sales Manager, says there are several Hart doors on site already. “This depot is one of the busiest in the country, with an average of 250 carriages maintained there each night. We have several Speedors on site some of which were nearly 30 years old,” says Mr Cairns.

Planon and MazeMap are partnering to integrate Planon’s software for real estate, space, and asset management and MazeMap’s digital wayfinding solutions. This will enable organisations to offer an improved real-time user experience to building occupants and visitors. 

MazeMap specialises in digital in- and outdoor wayfinding for large campuses such as universities, hospitals, offices, and conference venues. By connecting MazeMap’s technology with Planon’s Integrated Workplace Management Systems (IWMS), building occupants will benefit from enhanced navigation tools.

SMGlobal has released FastMaint CMMS software v.11. It is a computerized maintenance management software program for equipment and facilities maintenance.

Maintenance managers can use FastMaint to schedule and manage preventive maintenance as well as corrective maintenance work. They can send work orders to the maintenance staff and receive their feedback. Managers can track the progress of all outstanding and completed jobs. They can use FastMaint for on-site maintenance programs or field service management.