ENERGY AND EFFICIENCY COATINGS
For Pumps, Valves, Pipework and Fluid Flow Environments
ThistleBond Polymers are
heavily involved in assisting industry by helping to reduce
operating costs with a range of products that increase fluid
flow efficiency.
ThistleBond
products can:
Reduce manufacturing costs
Increase cash flow
Reduce spares inventory
Reduce unscheduled plant shut
downs
Reduce plant downtime and maintenance
costs
Help to protect the environment
by reducing power consumption
Increase company PROFITABILITY
Typical applications:
Internal Tank Coatings
Repair any damage with the ThistleBond
Product Range of Super Metal and Ceramic Carbide Repair
Systems. Coat all the surface area with a ThistleBond
chemical resistant coating.
Any damage to the inside of the tank can be repaired
by the following products:
TR100 Rapid Setting Super Metal - Fast curing
repair paste ideal for tank seams.
TR105 Super Metal Rebuilding System - Engineering
grade repair paste ideal for rebuilding and heavy
duty applications.
After rebuilding the structure of the tank, it can
then be coated with either of these chemical coatings:
TPC Hycote 175 - Solvent free coating ideal for
use on Steel and Concrete.
TL500 152 SFE - High build system ideal for manually
prepared Steel (Approved by Lloyds for Ballast tank
coating).
Pipe Elbow/ Flange options
Repair any damage with the ThistleBond
Product Range of Super Metals or Ceramic Carbide Repair
Systems. Coat and protect the repair with the Fluid
Ceramic Carbide Product Range.
On the outside of any damaged flange or pipe elbow
the leak can be stopped by using the following products:
TR100 Rapid Setting Super Metal Repair Paste
- Easy to use fast setting repair paste.
TRK19060 PlasSteel Twist Stick - Quick Curing
Super Metal Putty packaged in stick form.
On the inside of any damaged pipe work the following
ThistleBond products can be used:
TR200 Ceramic Carbide Wearing Compound - Engineering
grade Ceramic Paste ideal for rebuilding badly corroded
or eroded components.
TR205 Abrasion Resistant Ceramic Carbide Fluid
- To be used in conjunction with the paste to protect
the repair and give added protection.
Pumps
Flanges
Repair and Rebuild the damaged flange with
the ThistleBond Super Metal Repair product range
Any damage to the flanges can be repaired using:
TR105 Super Metal Rebuilding System Engineering grade
repair paste ideal for rebuilding and heavy duty applications.
After rebuilding the structure the flanges can be coated
with the following coating:
TPC675 Hycote 175 High Performance Chemical protection
coating, ideal for protecting Steel surfaces from corrosion.
Volute
Repair any damage with the ThistleBond
Super Metal and Ceramic Carbide Repair Systems.
Any damage to the inside of the Volute can be repaired
by using the following products:
TR105 Super Metal Rebuilding System Engineering
grade repair paste ideal for rebuilding and heavy
duty applications.
TR200 Ceramic Carbide Wearing Compound Multi
purpose repair compound containing Ceramic and Carbide
particles, ideal for repairs in a fluid flow environment.
After rebuilding the Volute, it can then be coated
with any of the following products:
TR205 Abrasion Resistant Ceramic Carbide Fluid
High performance coating ideal for protecting metal
components and equipment in a fluid flow environment.
TPC 675 Hycote 175 High performance Chemical
coating, ideal for protecting steel surfaces from
corrosion.
Impeller
Repair and rebuild and damage using
ThistleBond Ceramic Carbide Repair Systems Coat the
repaired impeller with a ThistleBond Ceramic Carbide
or Chemical coating.
Any damage to the impeller can be repaired by using
the following product:
TR200 Ceramic Carbide Wearing Compound Multi
purpose repair compound, ideal for rebuilding and
repairing metal components in a fluid flow environment.
After rebuilding the impeller it can then be coated
with the following products:
TR205 Abrasion Resistant Ceramic Carbide Fluid
High performance Coating, ideal for repairs in fluid
flow environment.
Shaft
Repair and Rebuild a damaged shaft
by using the ThistleBond Super Metal Repair range.
A damaged shaft can be repaired by using the following
product:
TR105 Super Metal Rebuilding System Engineering
grade repair paste ideal for rebuilding and heavy
duty applications.
Bearing Housing
Repair a damaged or oversized Bearing Housing
with the ThistleBond range of Super Metal Repair Systems.
Any damage can be repaired using the following ThistleBond
products:
TR105 Super Metal Rebuilding System Engineering repair
paste ideal for rebuilding and repairing Metal components
and mechanical equipment.
TR100 Rapid Setting Super Metal Repair Paste Fast curing
super metal ideal for emergency repairs or where reduced
down time is essential.
Back Plate
Repair any corrosion or erosion using the
ThistleBond Ceramic Carbide repair systems.
Damaged back plate can be rebuilt and coated with the following
ThistleBond Products:
TR200 Ceramic Carbide Wearing Compound Multi purpose
engineering repair compound, ideal for repairs to components
and equipment in a fluid flow environment.
TR205 Abrasion Resistant Ceramic Carbide Fluid High
performance brushable coating ideal for protecting equipment
in a fluid flow environment.
Pump Efficiency
and Energy Consumption
Pumping systems account
for nearly 25% of the world's industrial electrical
energy demand and range from 25%-50% of the energy
usage in certain industrial operations. Pumping systems
are used in everyday life life from, domestic appliances
to the water we drink from the tap.
World Industrial
Electrical Energy Demand 25 % Pumping Systems
Industrial Plant
Energy Usage Pumping Systems 25-50%
Life Cycle cost
of an Industrial Pump
32% - Energy cost throughout
working life
20% - Cost of maintenance
14% - Actual cost of pump when
purchased
9% - Installation
9% - Downtime
9% - Operation costs
7% - Environmental costs
As we can see from the
information above, the actual cost of the pump accounts
for only 14% of the overall operating cost through
the life of the pump. Energy and maintenance account
for over 50%, with downtime adding another 9%.
Although in many cases it is not practical to change
pumps and adjust operating efficiencies, there are
ways of improving:
a) The flow rate in the pump
b) The Energy consumption
c) The cost of Maintenance
ThistleBond has developed a low
friction coating that is proven to:
a) INCREASE the flowrate through the pump
b) REDUCE the Energy consumption
c) REDUCE the cost of Maintenance
The Super Low Friction Efficiency
coating is a high performance solvent free coatings
designed for use as a resurfacing and lining system
to improve the efficiency in fluid flow environments.
Best Efficiency
Point
All pumps when first installed
are designed to work at their Best Efficiency Point, however
there can be many reasons for the pump not to be operating
at its B.E.P.
Discharge Valve is throttled back
Pump is started with closed discharge valve
Closed valve on the system
Suction pipework is corroded
Damage by cavitation, abrasion and chemical attack
to the wet end of the pump
The ThistleBond TR210 Super Low Friction Efficiency Coating
can help in the latter areas!
By rebuilding the damaged areas such as the Volute, Impeller,
Back Plate, Flanges, Pump Casing etc, with the ThistleBond
TR200 Ceramic Carbide Wearing Compound, we have extended
the life of the component and equipment.
However, to increase the efficiency and reduce the maintenance
of the pump, a smooth and hard wearing surface must be applied
to the repaired area.
The TR210 Super Low Friction Efficiency Coating is brush
applied and has self leveling properties which enable the
user to have a smooth finish to the repair.
As we can see from the image to the right,
normal Ceramic Carbide Coatings leave brush marks across
the surface, these offer areas of resistance when the fluid
is pumped over the surface.
However the self leveling properties of the ThistleBond
TR210 Super Low Friction Efficiency coating means the majority
of the brush marks are smoothed away, allowing the fluid
being pumped to run more easily over the surface, Reducing
Friction, Wear and Energy Consumption, while Increasing
the Flow Rate of the pump.
Furthermore, the high concentration
of Ceramic and Carbide particles within the coating offers
a higher level of protection to the Metal component and equipment
being repaired.
Over the TOTAL LIFE
CYCLE OF THE PUMP, the majority of operating costs
will be caused by:
A) Energy Consumption - 32%
B) Maintenance - 20%
C) Downtime - 9%
TOTAL - 61%
By using ThistleBond TR210 Super Low Friction Efficiency
Coating we can work to reduce all three of the above.
FOR EXAMPLE:
Cost of Pump - £14,000
Energy Consumption - £32,000
Maintenance - £20,000
Operating - £ 9,000
Downtime - £ 9,000
Installation - £ 9,000
Environment - £ 7,000
TOTAL LIFE CYCLE COST OF PUMP - £100,000
ThistleBond TR210 Super Low Friction Efficiency
Coating is proven to increase flow rates by up
to 10%, thus reducing energy consumption, maintenance and
downtime.
Before and After Impeller was coated with TR210 Super
Low Friction Efficiency Coating (Red)
Pump Impeller blasted and cleaned with ThistleBond Universal
Cleaner and coated with TR210 Super Low Friction Efficiency
Coating (Grey)
Pump Impeller
blast prepared and coated with TR210 Super Low Friction
Efficiency Coating
The ThistleBond
Product Range from Start to Finish
Pump Impeller
ready to blasted
Pump Impeller
blasted and then degreased with ThistleBond Universal Cleaner.
The damaged blades rebuilt with TR200 Ceramic Carbide Wearing
Compound
The Impeller
is coated with TR210 Super Low Friction Efficiency Coating
and left to cure
