Pump repairs save £4,000 at UK automotive plant 03 October 2013

An unnamed UK automotive manufacturer is making annual energy saving of £4,000 since adopting a pump repair plan from Eriks, according to the company.

The plan, which included pump repairs conducted with Henkel, has also achieved a CO2 saving of 28 tonnes in the first year, says the firm.

Eriks says the project started when it evaluated the efficiency of one of a 22kW ELPO pump that handles process water for a metalwork pre-treatment process, prior to body coating.

The pump was found to be under-performing by at least 30% against the manufacturer's original test data, so was dismantled and examined – revealing heavy corrosion and an impeller that was worn, burred and unbalanced.

In addition, the mechanical seal had seized and the pump was out of alignment with the motor, while the volute was cut-water worn, the bearings showed evidence of fretting and corrosion, and the motor had not been inverter rated.

Repair work was carried out at Eriks' EMS workshop in Southampton, with some of the components requiring recoating with Henkel's Loctite polymer composites. Parts were then blasted to achieve a surface roughness of 75 microns.

With preparation work completed, surface treatment proceeded, using the Loctite family of surface engineering products. The pump was then fitted with new bearings and both oil and mechanical seals. The impeller was dynamically balanced, the pump re-assembled and a new 22kW high efficiency motor fitted. Motor and pump were then fitted to the bedplate and laser aligned.

The results, says Eriks, were outstanding: remedial work had restored the pump to original specification, increasing its efficiency by 30%. An estimated energy reduction of £3,936 was calculated for the first year alone – meaning an ROI of less than 18 months.

Given the savings from a single pump rest and repair, the manufacturer is now said to be evaluating potential energy savings that could result from further repair programmes conducted by Henkel and Eriks.

Brian Tinham

Related Companies
ERIKS Industrial Services
Henkel Ltd

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