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UNIQUE POLYMER SYSTEMS is committed to delivering high-performance repair and protection solutions for critical industrial equipment. This case study details the successful refurbishment of a wastewater pump at a UK local water authority using our UPS 210 CR EFFICIENCY FLUID CERAMIC and UPS 105 EG THISTLEBOND METAL REPAIR PASTE.
A wastewater pump at a local water authority in the UK was experiencing reduced efficiency due to extensive cavitation and corrosion damage. This deterioration threatened the pump's ability to operate effectively, necessitating a comprehensive refurbishment to restore its functionality and prevent further damage.
The challenge was to rebuild the worn and pitted sections of the pump and apply a protective coating that would prevent future corrosion and cavitation. The solution needed to ensure the pump's long-term performance and efficiency while withstanding the harsh conditions of wastewater processing.
UNIQUE POLYMER SYSTEMS provided a thorough repair and protection solution using UPS 105 EG and UPS 210 CR. The refurbishment process included the following steps:
Surface Preparation
- The pump was disassembled, and all internal surfaces were abrasive grit blasted to achieve a surface cleanliness level of ISO 8501-1 Sa 2.5 with a 75-micron angular profile. This preparation ensured that the repair materials would adhere effectively to the substrate.
Application of UPS 105 EG THISTLEBOND METAL REPAIR PASTE
- The pitted sections of the impeller and casing were rebuilt using UPS 105 EG. Once cured, these areas were machined back to a smooth finish, restoring the pump's original dimensions and structural integrity.
Application of UPS210 CR EFFICIENCY FLUID CERAMIC
- The impeller and internal casing were coated with two layers of UPS 210 CR, applied to a nominal total dry film thickness of 500 microns. This protective coating provided robust resistance against future cavitation and corrosion.
External Surface Protection
- The external surfaces of the pump were coated with two layers of UPS 405 EPC EPOXY PROTECTIVE COATING also applied to a nominal total dry film thickness of 500microns. This additional layer of protection further ensured the longevity of the pump by preventing external corrosion.
The refurbishment process successfully restored the wastewater pump to its original efficiency levels. The application of UPS 105 EG and UPS 210 CR provided durable protection against future wear, ensuring the pump's long-term reliability. Post-refurbishment, the pump's performance was monitored to record efficiency gains achieved through the coating system.
This case study demonstrates the effectiveness of UNIQUE POLYMER SYSTEMS' products in refurbishing and protecting critical equipment in wastewater management. Our advanced materials and precise application process provided a cost-effective solution that restored the pump's performance and extended its service life.
