Feature Maintenance management
Polymer composites breathe new life into components
An automotive manufacturer has been able to save 30 per cent on pump energy costs since it started using Loctite polymer composites which protect parts against attack. These ceramic reinforced epoxies are said to extend the life of new components and restore the worn surfaces of old ones
nance and repair. Castings, impellers and volutes wear due to corrosion, ero- sion, cavitation and mechanical damage and all can be rectified with the Loctite range.
P
A major UK automotive manufac- turer provides an illustration of what can be achieved. To demonstrate poten- tial gains Eriks suggested evaluating the efficiency of one of the company’s pumps that handles process water in the Henkel, metalwork pre-treatment process prior to body coating. This 22kW ELPO pump was put to test at Eriks’ Electro-Mechanical Services workshop in Southampton and it was found to be under-performing by a minimum of 30 per cent against the manufacturer’s original test data. The unit was then dismantled and all components examined for wear. The pump was heavily corroded and
umps are typical examples of plant whose life can be extended and high performance assured by efficient predictive mainte-
the pump impeller worn, burred and imbalanced. The mechanical seal had seized and the pump was out of align- ment with the motor. The volute was cut-water worn, the bearings showed evidence of fretting and corrosion and the motor was not inverter rated.
Repair process
All components that required coating with Loctite polymer composites were first steam cleaned to remove any residue and salts and then bead blasted to achieve a surface roughness of 75 microns. Loctite 7515 was used to pre-treat the substrates to prevent corrosion and improve adhesion between the metal parts and the poly- mer composites.
Next, Loctite 7117 was applied as a ‘hold coat’ to smooth the surface imper- fections and provide a key for the thicker layers required to return the pump to its original dimensions. A ‘build coat’ of Loctite 7226 was used to replace many years of wear and create a
One-stop preventative maintenance shop
reventive maintenance avoids equipment problems before they occur, cutting repair costs and limiting unplanned downtime. It also reduces energy waste, to help ensure that buildings and equipment work at peak efficiencies at all times, at the same time reducing the environmental footprint. The Fluke Preventive Maintenance platform provides advice on how to save plant running costs. From power quality analysers to process calibrators, handheld oscilloscopes,
P
wireless test tools and thermal imagers, Fluke rugged tools are said toprovide the information to help cut plant energy costs and minimise downtime and production stops. Return on Investment calculators for a range of Fluke products help the decision making process. Aimed at industry service and maintenance engineers, process industry engineers, power quality engineers and industrial consultants, the preventive maintenance platform is said to help grow expertise for best practice in maximising uptime, saving costs and optimising processes. Fluke
T: 0207 9420700 24
www.fluke.co.uk/preventivemaintenance Enter 328
Loctite polymer composites have saved 30 per cent on pump energy costs for automotive manufacturer
tough surface, resistant to future wear. In common with others in the range, this Loctite compound offers advan- tages over traditional repair methods such as hard metal welding or flame spraying, both of which are difficult and costly to apply to large surfaces. In contrast the Loctite 7226 is easily applied on all surface sizes and offers the extra benefit of corrosion protec- tion. Also, it does not create any heat stress during its application. Loctite 7226 is one in a family of protective coatings and compounds used by Eriks. This is a trowelable and non-sag epoxy that was chosen for its ability to protect against fine particle abrasion. The range provides a choice of grades for fine particles through to coarse and also specific products for pure chemical attack, corrosion pro- tection and high impact. Temperature resistance across the range typically extends from -30°C up to 120°C but there are also special grades that can be used up to 230°C. Overall, the products provide good protection against fresh and sea water, ammonium sulphate and sodium hydroxide. Following the application of Loctite 7226 another coat of Loctite 7117 was applied to achieve a very smooth finish to reduce friction within the pump and improve its energy efficiency. The pump was then fitted with new bear- ings and both oil and mechanical seals. The impeller was dynamically bal- anced, the pump re-assembled and a new 22kW high efficiency motor fitted. Motor and pump were then fitted to the bedplate and laser aligned.
Huge savings
A second performance test was per- formed. The remedial work had restored the pump to original specifica- tion, increasing its efficiency by 30 per cent. The cost of the repair amounted to £5,542. But offsetting this, in the first year alone, was an estimated energy reduction of £3,936. This was calculated at £0.08/kWh at 12 hours per day with an 80 per cent load. The Enhanced Capital Allowance Scheme, a Government incentive for investment in energy saving equip- ment, also enabled the automotive manufacturer to reclaim £585.90. So, with all the savings taken into account the cost of the pump repair was just £685. But of course substantial savings will continue to be made that will far outweigh this reduced sum. On carbon emission, the figure is 28 tonnes, on energy savings it’s 51.90 MWh and over a five-year period this accrues to a five-year energy saving amounting to £19,680. Henkel T: 01442 278000
www.henkel.com
Enter 326 MAY 2013 Factory Equipment
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64