Pump & Valve

Particularly in the oil and gas and chemical sectors, where the nature of the media is particularly abrasive and corrosive, pumps and valves play a vital role in the transfer of media such as chemicals, fluids, resins, gasses, etc. Throughout the operation, pump components are vulnerable to abrasion, erosion, cavitation, and sliding wear. Even in the absence of abrasive particles, sliding wear can happen as a result of inadvertent contact between rotating and stationary components. Abrasion and erosion are caused by abrasive particles in the media being pumped. Furthermore, because wear and corrosion have a synergistic relationship, these wear rates in pumps are frequently quite high.With time, increasing vibration or leakage and a decline in pump performance are caused by changes in vane angles and clearance between sealing surfaces caused by wear on the pump’s flow path components. Improved wear and corrosion resistance is demonstrated by a variety of thermal spray coatings for various pump and valve assembly components, extending their operating life and lowering downtime expenses.

Ball & Gate Valve

A ball valve is a mechanical device that rotates on an axis to regulate the flow of gases and liquids through it. When the media is oriented in the pipeline’s direction, the bore in the ball’s center permits it to pass.
A gate valve and a ball valve have the same function. On the other hand, it’s a solid, rectangular piece with a thru bore at one end. When the valve is rotated, the gate travels linearly along an axis. A knife gate valve’s operation is similar, except it has a tapered edge on one end and a narrower cross section.
Metal seats hold these valves firmly in place so that, in the off position, they offer adequate sealing. However, the surface of the ball/gate and seat tends to wear out due to repeated action of the valve in certain critical applications where the media passing through the valves are abrasive, erosive, or corrosive in nature, such as slurries, mud, salt water, hydrogen sulfide, hydrochloric acid, high temperature fluids and gases, etc. As a result, the valve’s sealing is disrupted, which leads to leaks and an uncontrollable media flow. Applications where the flow control mechanism is most crucial to the process could result in unsafe conditions or subpar process output.

Wear and Corrosion Resistant Coatings

Our selection of thermal spray coatings and claddings extends the life and improves the functionality of gate and ball valves. Our selection of tungsten carbide coatings is designed to withstand extremely harsh operating environments, including abrasion, erosion, and corrosion. The kind of media being handled, temperature, wear type, and compatibility with the base material all play a role in our choice of coating material. The coatings are applied using a robotically controlled HP-HVOF method, which results in a uniformly thick coating that is mechanically very adherent to the base material. Additionally, we are able to offer weld overlays made of carbide, Inconel, and satellite-based materials that are deposited using our automated and regulated PTAW process.In order to minimize wear on the mating seal sections, the coatings are ground and lapped, which further lowers the coefficient of friction and improves the sliding qualities. Your production will rise, downtime will be decreased, and maintenance costs will go down with our wear and corrosion resistant coatings.

Reciprocating Plunger

Plungers provide a reciprocating motion along an axis using a mechanism (usually rotating) that creates pressure in a cylinder or working barrel to propel fluid or gas through the pump. During operation, these plungers come into touch with abrasive particles in the fluid and corrosive gasses. Because of this, the plunger surface tends to wear down at the mating area during the reciprocating action, destroying the seal and stopping the operation. The fatigue load and impact that the plungers experience in some applications can cause significant damage to both the plunger and its mating portion.

Wear and Corrosion Resistant Coatings

We offer impermeable, chemically resistant to corrosive gasses, extremely wear-resistant coatings based on nickel and carbide. Our selection of coatings can be utilized in wear and corrosion-resistant applications and applied using the HP-HVOF method, which creates a dense and homogenous coating. For applications requiring high impact and fatigue load, self-fluxing alloys based on nickel are sprayed on and fused to plungers. The super-finished and ground coatings improve the sliding characteristics and lessen wear on the mating seal parts. Our selection of coating solutions outperforms hard chrome plated and nitrided plungers, increasing their useful life by a factor of five to eight.Over the years, our coated plungers have been effectively used in high pressure water pipeline services, slurry pumping, hydrogen gas environments, and coal gasification.

Centrifugal Pump Parts

An impeller is a revolving part of a centrifugal pump that accelerates the fluid away from the center of rotation in order to transmit energy from the motor driving the pump to the fluid being pumped. Sand or silt are examples of abrasive and erosive materials that are carried by the medium passing through pumps in critical applications. These materials pass through the pump’s whole fluid channel system, the sidewalls of the impeller, and the pump’s clearances. Abrasive particles move freely and contact the casing at shallow angles, generating erosive wear, if their size is smaller than the clearance. Three body abrasions could result from a blockage between the impeller and casing if the particle size is the same as the clearance.The effects of cavitation, corrosion, and abrasion under harsh operating conditions can accelerate wear rate and cause unplanned breakdowns and high maintenance costs.

PIC DC Range of Coatings

We offer a selection of impermeable coatings made of tungsten carbide that can withstand the impact of corrosive, erosive, and abrasive particles passing through pumps. Our selection of coatings can be utilized in wear and corrosion-resistant applications and applied using the HP-HVOF method, which creates a dense and homogenous coating. To obtain the required tolerances and surface smoothness, the coatings are polished and ground. Pump casings, impeller shaft bearing journals, and impeller guide vanes can all be coated using our coatings. Over the years, our coated pump components have been used with success in power plants, slurry pumping, oil and gas, and other applications.

Progressive Cavity Pump

A progressive cavity pump is a kind of positive displacement pump that uses rotor rotation to move fluids. As the rotor turns, it seals tightly against the stator, creating a set of fixed-size chambers between them. When the rotor rotates, the pumped material travels inside these chambers. Over time, applications involving the flow of slurries and other corrosive and abrasive substances can seriously harm rotors. As a result, the stator will gradually wear down, increasing clearance and lowering pumping efficiency. Extended use will result in unplanned malfunctions and high maintenance expenses.

PIC DC Range of Coatings

Our coatings made of tungsten carbide offer superior resistance to corrosion and abrasion when exposed to abrasive fluids that pass through progressive pumps. Our selection of coatings can be applied using the HP-HVOF method, which uses controlled and repeated deposition to create a dense and uniform coating. To achieve the necessary size and surface finish, the coatings are ultra-precision ground and super-finished. The post-coating finish is essential to the rotors’ operational life and performance. A smooth rotor surface will encourage flow capacity and inhibit the adhesion of corrosive and abrasive particles to the surface. Our selection of coating options outperforms hard chrome-plated and nitrided rotors, increasing their operational life by a factor of five to eight.We have everything we need in-house to coat and superfinish rotors.

Casing and Impeller Wear Rings

Separate types of wear are experienced by impeller and casing wear rings. Wear ring rub can occur when revolving (such as an impeller wear ring) and stationary (such as a casing wear ring) surfaces unintentionally come into contact, leading to sliding wear, also known as metal-to-metal wear, even in the absence of any solid particles in the process fluid.

This is particularly problematic for the majority of corrosion-resistant alloys since they tend to gall and/or wear metal to metal, and they can cause severe seizure in a pump that has wear rings made of austenitic stainless steel.

It is wise to utilize different metals for the impeller wear rings and casing, to make sure there is at least a 50HB hardness difference between the rings, or to apply an appropriate anti-galling coating to the worn surfaces in order to lower the danger of seizure.

If the process medium contains any solid particles, the pressure differential across the wear ring allows the particles to pass through the wear ring interface if they are small enough. Depending on the size of the particle, this can lead to either erosion or abrasion (for example, when the particles are much smaller than the wear ring clearance).

Wear and Corrosion Resistant Coatings

Our coatings made of tungsten carbide offer superior resistance to corrosion and abrasion from abrasive fluids passing through the wear rings and casing. These coatings can be applied using the HP-HVOF technique, which uses controlled deposition and repetition to create a dense, uniform coating. Because the ring’s cross section is so small, extra care is used throughout the coating process to guarantee that the temperature is regulated and the rings don’t get distorted. To attain the required size and surface finish, the coatings are precisely ground and polished using specially designed equipment.In some applications, the Spray and Fuse method is required for the deposition of nickel-based compounds like Colmonoy, while the PTAW procedure is required for the deposition of cobalt-based materials.
Depending on what the customer needs, we can provide fully coated and cladded wear and casing rings. We can produce rings in different sizes and handle large volume requirements thanks to our in-house equipment.

Pump Sleeve

Even with some what clean process mediums, particles in the process medium that become embedded in the gland packing can cause abrasion damage to shaft sleeves used in gland packing service, which can lead to extremely high wear rates. Since abrasion-corrosion accelerates low-stress abrasion, the primary selection criteria for sleeves are their hardness and corrosion resistance.

In order to cool the gland sleeve from the frictional heating produced between the stationary packing and rotating sleeve, the gland packing typically needs a controlled amount of process medium leakage. A ceramic coating may be harmed by extremely high sleeve surface temperatures and thermal gradients caused by inadequate process medium cooling.

Wear and Corrosion Resistant Coatings

Our coatings made of tungsten carbide offer superior resistance to corrosion and abrasion from abrasive particles that come into contact with the sleeves. These coatings can be applied using the HP-HVOF technique, which uses controlled deposition and repetition to create a dense, uniform coating. Because the cross section of sleeves is so tiny, care must be taken throughout the coating process to maintain temperature control and prevent distortion of the sleeves. To obtain the required size and surface finish, the coatings are extremely precisely ground and polished.In some applications, the Spray and Fuse method is required for the deposition of nickel-based compounds like Colmonoy, while the PTAW procedure is required for the deposition of cobalt-based materials. Even ceramic-coated sleeves are employed in some non-critical uses.
We are able to supply fully coated and cladded pump sleeves in accordance with client specifications. We can produce sleeves in different sizes and handle large volume requirements thanks to our in-house equipment.

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Weld Overlay Cladding

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Pump & Valve

Pump & Valve

Ball & Gate Valve

Wear and Corrosion Resistant Coatings

Reciprocating Plunger

Wear and Corrosion Resistant Coatings

Centrifugal Pump Parts

PIC DC Range of Coatings

Progressive Cavity Pump

PIC DC Range of Coatings

Casing and Impeller Wear Rings

Wear and Corrosion Resistant Coatings

Pump Sleeve

Wear and Corrosion Resistant Coatings

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