ENERGY SAVING

COATING FOR WATER

HANDLING PUMPS BY
Demech Chemical
Products Pvt Ltd,
Pune
Problems affecting the performance of pump

• Pitting, cavities caused by cavitation's erosion

process
• Surface wear by Abrasion Erosion process
• Corrosion of the surface because of electrochemical
reaction process

THESE PROBLEMS DAMAGES THE CASING AND

IMPELLER SURFACE WHICH RESULTS IN MORE
FRICTIONAL LOSS AND INCREASES POWER
CONSUMPSION
 Cavitation's - Erosion

• The phenomena of cavitations erosion is due to the implosion of

bubbles
• Abundant Water vapor bubbles are formed because of pressure
differences in fluid flow
• These bubbles will grow and become repository of vapor or gas
and when enter in the reduced pressure zone, they compelled
to reduce their size because of condensation of vapor they
contain. These physical changes are very rapid and cause the
implosion (internal explosion) of bubbles
• The implosion in the water body create shock waves and
pushes others to the surface of metal
• The bubbles in contact or very close to the solid / rough
surface, they implode (collapse) and micro jet is formed.
(impingement).
• The continuous, innumerable implosions create a dent or pit
over the surface (erosive effect)
• Since the effect is continuous, pit will turn into cavity – cause
more turbulence, more generation of bubbles and recurring
damage (cavitation's)
• The implosion effect and magnitude of damage varies with
the size of bubbles and pressure differences
• The surface roughness increases the rate of contact and
bubble implosions (surface profile)
• The impingement force create a plastic deformation in grain
boundaries of surface (on rigid metal surface – No resilience)
The bubble creation, growth and implosion
pattern
 Abrasive Erosion

• Abrasive Erosion is removal of metal by suspended

solids, silt in the water flowing through turbine.
• The rate of wear is directly related to the velocity of
liquid.
• The surface roughness will aid in increasing the
contact time of silt
• Wear will be more pronounced at the leading edge of
pump blades, shrouds or exit vanes.
• Ultimately, the total
surface of the steel will
have rusted.
• Once the anodic areas
have rusted, the surface is
more inert and so the
polarities swap.
• Areas that once were
anodic change to being
cathodic, and areas that
were once cathodic,
change to being anodic.
Across the surface of the metal
there are sites of differing electrode
potentials, creating a multitude
of electrolytic cells in the
presence of an electrolyte.
•The areas in the surface that
form anodes will lose their
electrons and allow faster
formation of corrosion
products.
Demech chemical products offers

Repair - Damaged metal surface

Protects – From severe working
condition
Improves – Fluid flow & life
Non destructive repair and protection methods

• Are advised by many Manufacturers with

specialized coatings with NO HEAT INPUT and
to protect the surface to an extent by self
wear in order to safe guard the ORIGINAL
equipment.
 Products for application

• Tuff metal – Steel putty (to repair or rebuild) –polymer

resins combined with polyamino curing system reinforced
with phosphorous steel alloy to enhance mechanical
strength & resistance to cavitations
• Tuff Wear – Anti Stick (to protect and improve) – Nano
ceramic particles embedded in zero-solvent epoxy to give
excellent abrasion resistant and anti-sticking property.
• Tuff wear – Super glide (to improve)- high gloss finish
epoxy coating with low co-efficient of friction.
 Surface preparation method

Copper slag blasting

method
• To achieve good profile
over the casing surface
which is most important
to have good bonding of
coatings
• To achieve better
cleaning to get near to
white metal surface ie
SA2.5 std.
Before blasting After blasting
 Repair Application

Steel putty applied over the casing where the surface

was damaged due to severe cavitation's and erosion.
Before application After application

The easy paste application without using any heat input, reclaims the cavities and
facilitates easy grinding, emery, enable to obtain the desired surface finish.
 Tuff wear Anti-stick
100% solids, nano-ceramic material and is ideal
for RESURFACING the fluid handling equipment
where protection from impact, abrasion, erosion
and corrosion is required. And also its smooth
profile provides low co-efficient of friction.
This tough material offers protection against
“impingement, entrainment, cavitations, erosion
and corrosion” in fluid flow environment
 Protection from Corrosion

Apart from this electrochemical reaction, WATER (with

its impurities like salt, dissolved oxygen, acidic or
alkaline (pH)) is corrosive.

Tuff wear coating is tested for AGGRESSIVE SALT FOG

EXPOSURE as per ASTM B117 and passed for most
critical 5000 hours unaffected.

(normal metal if exposed to 100 hours of this salt fog

environment, corrodes heavily)
 RESISTANT TO CAVITATIONS - EROSION

The happening of cavitation's erosion process can not be

prevented BUT… the resultant action over the surface can
be addressed with TUFF WEAR ANTI-STICK COATING.

The surface roughness – which is aiding the collapsing of

bubbles over the surface can be further reduced with the
coating because…. Tuff wear coating gives a non-porous,
extremely smooth, low friction surface with average (Ra)
surface roughness < 6 microns. This low friction surface is
attained by its SELF LEVELLING PROPERTY
The impact caused by implosion of bubbles - The coating
has designed to absorb the impact without passing to the
Metal and regains to the normal shape. It is designed to
take impact pressures up to 175 in lbs (20 Joules)

The resilience of the coating reduces the deformation

effect, but metal surface being rigid will allow the plastic
deformation to happen aiding to create pit and cavity

Tuff wear anti-stick coating’s hardness is 80 shore D

RESISTANT TO Abrasion Erosion effect

Abrasion erosion is caused mainly by the silt or suspended particles

in the water, which is directed with high velocity.

Here two important properties of coating are required to resist.

ABRASION RESISTANCE: Tuff wear anti-stick has been tested as per

ASTM D4060 and obtained excellent abrasion resistance of 0.08ml
loss / 1000 cycles – the coating will resist to abrade and reduce the
contact time of silt on its surface

TENSILE STRENGTH: to withstand the combined effect of silt and

velocity, the adhesion and tensile strength of coating help to a great
extent to adhere and remain over surface
Tensile Strength as ASTM D412 : 200 kg/cm2
Tuff wear – Anti stick coating
Super glide (top coating)
IMPELLER – Dynamic balancing & coating application
Before blasting After blasting
Dynamic balancing – for a smooth and vibration less
rotation

NC dynamic balancing m/c Two plane balancing display

Required quantity
of Steel putty was
added on each
plane of impeller to
achieve perfect
balancing
 Tuff wear Anti stick
coating was applied

Super glide (top

coating) was applied
Testing and measuring
Measurement of water flow using Ultra
sonic digital flow meter (Before
application and after application). Keep
all delivery valves in full open position
Testing and measuring

Measurement of Electrical
parameters (before & after
application of coating)

• Power in KW
• Current in Amps
• Volatge in KV
• Power factor
Testing and measuring
Measurement of coating
thickness (after application of
coating)

• The coating thickness is

approximately 1000 microns or
1mm.
Important points to be taken care during assembling
the Pump casing & impeller

• Impeller should rotate freely, excess coating over the

sides of impeller if any, which arrests the rotation of
impeller, shall be grounded

• Proper alignment of Pump and motor

• Proper alignment of inlet and outlet pipe lines with

casing.
• Proper fixing of glad packing and bearings with
specified clearance.
Application Procedure at a glance

Pump surface to be blasted with copper slag to

obtain a good surface profile.

Surface Deformities to be rectified with steel putty

Tuff Metal anti-stick coating to be applied by brush @

1 mm DFT in two to three coats all over the casing
and balanced impeller surface and applying anti-stick
coating.

Super glide compound to be applied by brush @ 300

microns as top coat all over the casing and impeller.
Test results
POWER SAVING ACHIEVED
6.28% of power saving achieved against
committed 4%
 Return on investment and other savings

• Total investment of Rs 6.85 lakh (for 5 pumps) will

be returned in just 1 month 21 days.

• Also coating is guaranteed for 1 year, so remaining

10 months 9 days saving amount will be approx. Rs
35.00 to Rs 40.00 lakh.

• Coating protects pumps & impeller life and

extends the its life further.
 Thank you
From
DEMECH CHEMICAL PRODUCTS P LTD,
Pune
P L Maharana
prafulla.maharana@demechchemical.com

Area Expert
boben2005@gmail.com