Polymer solutions to improve the efficiency of water systems

25 September, 2015

Testing of the Belzona 1341 coated pump gave a maximum of 6 per cent increase in the peak efficiency and a reduction in power consumption of 5.1 kWh at duty point. Assuming a 5000 hours operating cycle/annum, the power savings over this period would amount to 25,500 kWh.

Similar results have been measured by many pump manufacturers around the world, and feedback on industrial equipment protected with this coating show that it is possible to achieve a return in excess of new pump.

Pump efficiency enhancement with 4 months return of investment

In 2013, a water elevation plant in Portugal was looking for a solution to improve its hydraulic efficiency. This plant was chosen because of its high energy consumption and costs, with an annual consumption of 1.7 GWh/year and a volume of water propelled of 1.2 Mm3/year recorded in 2012.

The client was looking for a reliable and long-term solution to restore the damaged pump while reducing internal friction in the impeller and volute to enhance hydraulic efficiency. An internal pump coating was chosen to maximise water flow and reduce energy consumption while reducing internal wear and minimise future maintenance actions.

The pump was disassembled and all internal surfaces were grit blasted to remove the previous coating, creating a substrate cleanliness of at least SA2,5 and a surface profile of at least 75μ. The surface was then cleaned and examined to ensure that it was free of dust and other particles.

After grit blasting, the application areas were masked for the application of Belzona 1111 (Super Metal), an epoxy paste grade composite for metal repair. Simply applied using an applicator provided with the product, this material was used to reconstruct the areas damaged by corrosion, rebuilding the original surface profile. This solvent free composite provides excellent corrosion resistance and ensures the substrate is protected when it comes in contact with an abrasive material.

Within the two-hour over coating window, the first coat of Belzona 1341 (Supermetalglide) was applied by brush, followed by a second coat to obtain a total dry film thickness of 500μ. This coating was specified because it provides protection against erosion and long-term corrosion of equipment, whilst improving the efficiency of the pump.

Main results

The main results after coating the pump and changes to the programming of the water elevation plan were:

• Reduced energy consumption during non-peak hours 44.9 per cent to 39.3 per cent (-12.5 per cent).

• Reduced energy consumption by 14.9 per cent (kW/m3), 147,247 KW/h recorded in eight months.

• 20.3 per cent cost reduction.

• ROI: 4 months of operation.

www.belzona.co.uk