Reciprocating Slurry Pump Erosion/Corosion Issues- Coating Options?

[killswitch06]

Application : Reciprocating plunger pump used to pump water+sand+acid slurry at pressures up to 18000 PSIG. cyclical pressure 300 - 18000 PSIG MAXIMUM At frequencys up to 300 Hertz

Pump Material: Alloyed Steel

Problem: We are experiencing acclerated erosion and corrosion on our pump internals (currently no coating is used pump internals are bare metal), i am looking for a relativly cheap and easy to apply coating that can extend the life of our pump internals. I have allready looked at things such as nitriding, various claddings ect, ect . The problem with all of these processes are that they are too exspensive and also we really need a process that can be performed in house at our fabrication facility. Shipping charges are too much to send these parts out to have them cladded , nitrided ect ect by a vendor.

looking for recomendations

 

[stanier]

You are probably experiencing accelerated wear because of your pre occupation with the cost of a technical solution. The pump was most likely selected using this criteria rather than life cycle cost. If the operational is so marginal shut the pump down and walk away.

Ceramic coated liners and plungers are available that may improve wear life. The pump may be running too fast and is too small for the duty.

“The beautiful thing about learning is that no one can take it away from you.”
---B.B. King

http://waterhammer.hopout.com.au/

 

[bimr]

One would think that you must know the answer to your question is not feasible and you are just letting off steam.

 

[Artisi]

Change pumps to one suitable for the application.


It is a capital mistake to theorise before one has data. Insensibly one begins to twist facts to suit theories, instead of theories to suit facts. (Sherlock Holmes - A Scandal in Bohemia.)

 

[MikeHalloran]

Automate the replacement operation.
I.e.,
-modify the pump so that each plunger is used just for one stroke, then removed and discarded.
-set up an automatic screw machine to make replacement plungers as fast as you need them.
-set up a robot to remove the used plunger, discard it, retrieve a new one from the screw machine, and install it.
-arrange for automatic delivery of bars to feed the screw machine,
and automatic removal of the used plungers for recycling.

- similarly for the seals, retainers and miscellaneous parts.

...

...

... sounds absurd? Not as absurb as what you're asking for, unless you want to equip your internal fab shop for nitriding or ceramic fabrication or whatever...



Mike Halloran
Pembroke Pines, FL, USA

 

[DubMac]

If shipping charges are the prohibitive cost, then you need to find a new shipping company; you're getting screwed.

Hopefully you have gathered from the posts above; THERE IS NO CHEAP SOLUTION to pumping sand. It is the worst abrasive you can pump; get realistic about looking for a solution.

First, make certain the pump is sized/applied properly for your service, as the posts above are saying.

There have been huge advances recently in high velocity coatings (HVOF, Google it). The University of Calgary poured many millions into researching a newer "Nano-Tech" HVOF process that has some astounding results. Their patents were bought by a company in Calgary that specializes in using this process on pump parts. DOn't want to give their name as this is not a plug for them, but if you look, you can find them. Really some fascinating advances made in some of the SAGD (oil sands project)equipment wear parts.

If it is too expensive for you, then you are in the wrong business.

 

[psv1990]

There is not cheap solution. You have to balance the down time of your process with the insistance of using the wrong pump for the job.