Maintenance Costs Reduced on Coal Ash Pump with Devcon

Epoxy Coatings

Problem:

At a coal plant, high solids slurry caused severe abrasive wear to the

bottom of their coal ash transfer pump housing. As a result of continuous

abrasive wear, this coal plant had to frequently replace the entire pump

housing, when required. By fully replacing the pump housing, the coal plant

faced high maintenance costs, and a prolonged period of equipment

downtime.

Solution:

As a cost-effective solution over a full pump housing

replacement, the coal plant utilized Devcon Ceramic

Repair Compound, Devcon Wear Guard Fine Load and

Devcon Brushable Ceramic coatings.

• The repair area was sandblasted to white metal and the area

cleaned with Devcon Cleaner Blend 300, to remove heavy grease

and oil deposits on the metal.

• Devcon Ceramic Repair Compound was applied to rebuild wear

ring seats, fill holes, and cavitation deeper then 1/8”.

• Devcon Wear Guard Fine Load was applied to a thickness of ½”

to 1 ½”, depending on the depth of wear. Acetone was then used

to achieve a smooth finish.

• Devcon Brushable Ceramic Red & Devcon Brushable Ceramic

Blue were individually applied to a total thickness of 30 mils.

Sandblasted coal ash transfer pump

NA: cs@itwpp.com +1-855-489-7262 • EMEA: customerservice.shannon@itwpp.com +353 61 771 500 • itwpp.com

Coal ash

The high levels of productivity that need to be maintained at a coal plant

make unplanned repair work difficult. When the pumps and machinery are

taken offline, the equipment downtime costs substantial amounts of time

and money.

Brushable Ceramic Red applied to

transfer pump

Brushable Ceramic Red finish on

transfer pump

Project Outcome:

Cost-Effective Solution

�� Full replacement of the pump housing would have cost this plant

over $30,000. These costs add up as this pump housing is

frequently exposed to abrasive wear.

• Devcon repair cost was less than 10% of their typical spend,

effectively lowering maintenance and repair costs at this coal

plant.

Highly Durable Coatings

• By applying Devcon Wear Guard Fine Load to areas of high

wear, this epoxy coating will extend the pump housing life.

• By implementing both Devcon Brushable Ceramic Red and

Devcon Brushable Ceramic Blue, the pump housing will be

equipped with long-lasting abrasion and chemical protective

coatings.

Quick Inspection

By utilizing both Devcon Brushable Ceramic Blue and Red layers, worn-

out areas of the pump housing are easily visible as the first color

appears in the worn areas.

NA: cs@itwpp.com +1-855-489-7262 • EMEA: customerservice.shannon@itwpp.com +353 61 771 500 • itwpp.com

With Devcon repairs costing less than 10% of the typical $30,000 spend, the coal plant saved

approximately $27,000 effectively reducing maintenance cost and prolonging equipment life.

The technical information, recommendations and other statements contained in this sheet are based upon good faith tests or experience that

ITW Performance Polymers believes are reliable, but the accuracy and completeness of such information is not guaranteed. This information is

not intended to substitute for the customers’ own testing.