UNIQUE POLYMER SYSTEMS specialises in providing advanced repair and protective solutions for industrial equipment. This case study details the successful refurbishment of a heat exchanger, using our UPS 200 EG CERAMIC REPAIR PASTE, UPS 205 FG FLUID GRADE CERAMIC, and UPS 210 CR EFFICIENCY FLUID CERAMIC.

A heat exchanger, critical for maintaining operational efficiency, had developed worn and pitted surfaces over time. These issues not only affected the performance of the heat exchanger but also posed a risk of further damage if not addressed promptly. The unit required comprehensive refurbishment to restore its functionality and protect it against future wear.

The main challenge was to rebuild the damaged areas of the heat exchanger and apply protective coatings that would ensure long-term performance and efficiency. The solution needed to restore the heat exchanger's integrity while providing a smooth and durable finish.

UNIQUE POLYMER SYSTEMS provided a comprehensive refurbishment solution using UPS 200 EG, UPS 205 FG, and UPS 210 CR. The repair process involved the following steps:

Surface Preparation

- The steel substrate of the heat exchanger was abrasive blast cleaned to achieve a surface cleanliness level of Sa2.5 with a 75-micron profile, in accordance with ISO8501/4 Standard Sa2.5 (SSPC SP10 / NACE 2). This preparation ensured a clean and suitably roughened surface for the repair materials to adhere effectively.

Application of UPS 200 EG CERAMIC REPAIR PASTE

- The pitted areas and worn surfaces of the heat exchanger were rebuilt using UPS 200 EG. This step restored the structural integrity of the unit, filling in the damaged areas and providing a solid foundation for the subsequent coatings.

Application of UPS 205 FG FLUID GRADE CERAMIC

- Two coats of UPS 205 FG were applied to the resurfaced areas at a nominal 250 microns per coat.This coating provided robust protection against future wear and corrosion, ensuring the long-term performance of the heat exchanger.

Final Finish with UPS 210 CR EFFICIENCY FLUID CERAMIC

- A final coat of UPS 210 CR was applied to give the heat exchanger a smooth, aesthetically pleasing finish. This topcoat not only enhanced the unit's appearance but also contributed to its overall efficiency by reducing surface roughness.

The refurbishment process successfully restored the heat exchanger to its original condition, with enhanced protection against future wear and corrosion. The application of UPS 205 FG and UPS 210 CR ensured that the unit would continue to operate efficiently, with a durable and smooth finish that contributes to long-term performance.

This case study demonstrates the effectiveness of UNIQUE POLYMER SYSTEMS' products in restoring and protecting critical industrial equipment. Our comprehensive refurbishment solution provided a cost-effective alternative to replacement, extending the service life and improving the efficiency of the heat exchanger.