Single Stage End Suction Pump Repair: A Case Study

13th December 2024

At a copper mine in South Africa, a single stage end suction pump was experiencing severe abrasion due to handling process water containing trace elements of sulfuric acid and high levels of copper particulates. These conditions were causing significant wear to the cast pumps, leading to the need for regular maintenance. The plant manager, specifically requested a single stage end suction pump repair solution that would last at least six months, due to the current wear rate of their process pumps.

Resimac’s Single Stage End Suction Pump Repair Solution

Grit blasted to ensure proper adhesion.
Two coats of 202 Ceramic Repair Fluid applied to protect components exposed to process fluids.

Application Details

The end suction pump’s cast surfaces were grit blasted to Sa2.5, ISO 8504-1, SSPC SP-10 (NACE 2 Near White Metal) with a minimum 75-micron angular profile, ensuring the complete removal of corrosion, old coatings, and surface contaminants. This surface preparation step created an ideal profile for maximum coating adhesion. Resimac 202 Ceramic Repair Fluid was applied in two brush applied coats, each with a nominal thickness of 300-350 microns. All internal components exposed to process water and abrasive particulates were thoroughly coated, ensuring full coverage in critical areas such as impeller surfaces, pump volutes, and casings. The high-performance ceramic coating provided abrasion and corrosion resistance, offering long term protection against the severe operating conditions within the mining facility.

Products Used

202 Ceramic Repair Fluid

Results and Benefits

The application of 202 Ceramic Repair Fluid provided effective protection for the pump, allowing it to withstand the erosive and abrasive conditions caused by sulfuric acid and copper particulates. This single stage end suction pump repair exceeded the general manager’s expectations for durability, offering a cost effective solution that reduced the need for frequent replacements. The successful application led to the coating of additional pumps, further supporting the mine’s maintenance strategy.