Pump corrosion is a significant problem in industrial processes, leading to reduced efficiency, increased downtime, and higher maintenance costs.
Industrial pumping systems are crucial in transporting various liquids such as raw water, sewage water, wastewater, and mud throughout diverse operations. As energy demand rises worldwide, the industry seeks to adopt pump systems that optimize efficiency, dependability, and affordability.
Three types of losses can lower pump efficiency: Mechanical, Volumetric, and Hydraulic. Mechanical losses pertain to moving parts such as glands and bearings. Volumetric losses result from fluid leaks between the pump’s suction and discharge sides. On the other hand, hydraulic losses stem from the frictional forces generated between the fluid walls in the hydraulic passageway, which hastens and alters the direction of fluid flow.
Advanced pump designs and coating techniques have greatly enhanced the prolonged effectiveness of industrial pumps. Operators can heighten output and diminish operational expenses by mitigating the impact of corrosion and erosion. Research into the mechanisms that diminish pump efficiency continues, concurrent with the evolution of improved protective coating application methods. An in-depth comprehension of the pumping process and its influencing factors can substantially elevate maintenance tactics.
What is Pump Corrosion?
Pump corrosion pertains to wear and tear caused by erosion or corrosion on components such as the suction side plate, nozzle, pump, or impeller. Such wear or material loss can cause the pump to deviate from its best efficiency point (BEP) curve, leading to decreased mean time between failures (MTBF) and challenging identification of the root cause.
The overall maintenance, production, and downtime expenses often exceed the original pump cost. The rapid loss of metal resulting from the movement of a metal component through a corrosive fluid or the presence of a moving corrosive fluid is known as erosion-corrosion.
What are the causes of Pump Corrosion?
Pump corrosion occurs when the corrosive properties of a fluid are combined with the mechanical impact of its flow or velocity, leading to accelerated metal loss. The process starts with the mechanical stripping of protective films from the metal, followed by corrosion of the exposed metal by the corrosive flowing fluid. This cycle is usually repetitive unless a component failure occurs. Corrosion-erosion typically occurs near tube blockages, at the ends of tube inlets, or within pump impellers.
The degradation of a mechanism can become increasingly intricate when corrosion and erosion occur in the operating environment, and it is subject to substrate and fluid chemistry. For example, corrosion generates oxide layers that adhere poorly to the substrate and are susceptible to erosion. Erosion, in turn, can damage passive layers, leading to surface activation and accelerated corrosion. The key solution in such cases is to implement surface protection measures.
Effects of Erosion and Corrosion on Your Pumping System
The mechanism can quickly degrade if an industrial pump system’s erosion and corrosion occur. The efficiency of the entire pumping system can be affected by erosion and corrosion, resulting in increased operational costs and reduced industrial output. This can lead to increased downtime for repairs and maintenance.
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Select the Right Material for Your Pump
To prevent problems caused by corrosion and erosion, it is essential to choose the appropriate material for your industrial centrifugal pump. If you opt for cast iron or carbon steel pumps, the maintenance cost increases due to the high corrosion rate, which may offset any potential savings. However, if you are willing to manage the maintenance costs associated with the corrosion rate, then carbon steel or cast-iron pumps may be suitable for your needs. Stagnant conditions and the presence of high levels of chlorine in the displaced fluid are also significant factors that can lead to erosion and corrosion in stainless steel pumps.
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Coating for Safety
By utilizing advanced coating techniques, you can increase the durability and efficiency of your industrial water pump. For example, applying a polymeric coating such as fusion-bonded epoxy to pump components can reduce the impact of corrosion and erosion while also enhancing the hydraulic performance of the pumping process. Other options for corrosion-resistant coatings include tungsten carbide coatings containing nickel, cobalt, and chrome. These custom coatings can be tailored to meet the specific needs of your applications.
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Upkeeping of Legacy Equipment
By incorporating contemporary coating techniques as a component of a plant refurbishment plan, it is possible to increase the operational life of an industrial centrifugal pump. If a new pump design is necessary, selecting the most suitable base material and providing the best coating system for increased longevity is important.
Industrial processes, such as manufacturing, oil refining, paper production, wastewater treatment, and energy generation, require pumps to operate effectively. Liquids must be moved from the pumps in each of these processes. To minimize downtime and operational costs at your plant, it is necessary to enhance reliability and efficiency.
Corrosion and erosion are the biggest culprits for the loss or depreciation of these plants. Unlike domestic pumps, industrial pumps face continuous threats from erosion and corrosion in harsh environments.
Conclusion
Pump corrosion is a significant problem in industrial processes, leading to reduced efficiency, increased downtime, and higher maintenance costs. The causes of pump corrosion include chemical reactions, high temperatures, and stagnant conditions. Therefore, selecting the appropriate pump material, coatings, and maintenance practices is crucial to prevent corrosion.
Overall, understanding the causes of pump corrosion is essential for plant operators and maintenance teams to take the necessary preventive measures and ensure the longevity and reliability of pumping systems in industrial processes.
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