Customer background
A medium-sized fine chemical enterprise, mainly engaged in the production of polymer synthetic materials. During the daily production process, it needs to transport various organic solvents and raw liquid materials. This enterprise has three continuous production lines, with an annual output of 50,000 tons.
Facing challenges
The enterprise encountered a series of difficult problems during the production process:
The mechanical seals of the raw material conveying pump need to be replaced on average every 6 to 8 weeks.
The monthly production downtime caused by pump maintenance exceeds 24 hours.
The pump impeller is severely worn out and needs to be replaced 3 to 4 times each year.
The maintenance cost is very high, with the annual expenses for spare parts and labor exceeding 100,000 yuan.
After the technical team conducted an investigation, they identified that the root cause of the problem lay in the metal debris, welding slag and impurity particles in the pipeline system. These contaminants entered the pump body along with the fluid, causing severe wear and tear of the equipment.
Solution
After conducting on-site inspections, our technical team has specially designed a pipeline basket filter solution for them:
Equipment Configuration:
Install stainless steel basket filters in the critical sections before the pump.
With a multi-layer filter screen design, the effective filtration accuracy reaches 100 micrometers.
Equipped with a differential pressure indicator, it can display the status of the filter in real time.
Quick-opening design, facilitating maintenance and cleaning
Installation location:
A total of 8 filters were installed at key locations such as the main raw material conveying pipeline, solvent supply pipeline and process water pipeline.
Implementation effect
Improvement in equipment performance:
The service life of the mechanical seal of the conveying pump has been extended from 2 months to 18 months.
The frequency of impeller replacement has been reduced from four times a year to once every two years.
The overhaul period for the pump body has been extended from half a year to three years.
Economic benefits:
Annual savings in maintenance costs amount to approximately 80,000 yuan.
Reduce downtime losses by approximately 150,000 yuan per year
Reduce spare parts inventory costs by 30,000 yuan
The investment payback period is only 4.2 months.
Operational Improvement:
Production continuity has been ensured, and the monthly plan completion rate has increased to 99.8%.
The maintenance staff’s workload has been reduced by 60%, allowing them to focus on preventive maintenance.
The stability of product quality has significantly improved, and the customer complaint rate has decreased by 45%.
Customer evaluation:
“The pipe basket filter has solved the problem of equipment wear that has long plagued us. Now our production line operates more stably and the maintenance costs have been significantly reduced. This is indeed a technological renovation project with low investment and high returns.”
Post time: Sep-18-2025