The Problem

A major water plant was facing a critical issue with their 1,500-horsepower water pump they needed industrial water pump corrosion repair. The pump, essential for the plant’s operations, was suffering from severe erosion and corrosion. This damage not only threatened the pump’s functionality but also risked significant operational downtime and high replacement costs. To address this challenge without resorting to an expensive replacement, the plant reached out to Unconventional Solutions (USI) for their specialized repair and protection services.

The Substrate

The water pump in question was constructed of steel – a material known for its strength and durability but also susceptible to corrosion and erosion, especially in high-moisture environments like water plants.

The Solution

USI’s approach to repairing this industrial water pump corrosion involved a multi-step process:

• Abrasive Blasting to NACE #2 Standards: The pump was first abrasive blasted to achieve a near-white metal standard, in line with NACE #2 specifications. This thorough cleaning was crucial to remove all existing corrosion and prepare the surface for the repair materials.
• Rebuilding with RESIMETAL 201 Ceramic Repair Paste: Given the extent of the damage, the pump required rebuilding in areas where metal had been lost. RESIMETAL 201 Ceramic Repair Paste was used for this purpose, known for its robustness in restoring and reinforcing metal surfaces.
• Protective Coating with RESIMETAL 203 Ceramic Repair Fluid: To safeguard against future erosion and corrosion, two coats of RESIMETAL 203 Ceramic Repair Fluid were applied. This coating not only provided a protective barrier but also enhanced the pump’s efficiency. An interesting aspect of the coating was its dual-color application, which aids in regular maintenance checks.
• Efficiency and Cost Savings: Remarkably, the application of RESIMETAL 203 led to a significant reduction in the pump’s electrical consumption, translating to over $30,000 in annual savings for the customer.

The restoration and protective measures undertaken by USI were a resounding success. The water pump was not only saved from replacement but was also revitalized to operate more efficiently, leading to substantial cost savings for the water plant. This case stands as a testament to the efficacy of USI’s repair solutions, demonstrating their ability to extend the life of industrial equipment while improving operational efficiency.

Products Used

• RESIMETAL 201 Ceramic Repair Paste: Employed to rebuild the eroded and corroded sections of the water pump.
• RESIMETAL 203 Ceramic Repair Fluid (2 colors): Applied as a protective coating to prevent future damage and enhance efficiency.

For expert solutions in industrial equipment repair and protection, trust Unconventional Solutions. Our approach ensures your equipment is not just repaired but optimized for long-term efficiency and cost savings. Contact us for your repair and protection needs.