Challenge: Reduce the high costs and frequency of maintenance associated with transferring waste mixed with water in an industrial process. The previous equipment, a centrifugal pump, required quarterly maintenance and the intervention of multiple technicians, in addition to presenting electrical risks.
The Scenario
The transfer of industrial waste to the effluent treatment plant (ETE) is a fundamental step, but it can generate serious operational and financial challenges. The centrifugal pump used in the operation suffered from constant wear caused by the abrasive fluid, which resulted in:
- High Frequency Maintenance: Corrective and preventive interventions were required every three months.
- High Costs: Each maintenance required the mobilization of an electrical technician and a mechanic, adding up the costs of labor and spare parts.
- Operational Risks: Operating the electric pump in a liquid environment and complicated access for maintenance presented risks of electric shock.
- Downtime: Maintenance stops directly impacted the continuity of the process, generating inefficiency.
The Solution
To solve these problems, the company chose to replace the centrifugal pump with the pneumatic diaphragm pump. Graco Husky 3300. The choice was based on the following advantages:
- Robust and Durable Design: Diaphragm technology allows the Graco Husky 3300 pump to handle abrasive fluids much more efficiently, minimizing wear and the need for repairs.
- Reduction in Maintenance Frequency: The new equipment was designed to require preventative maintenance only once a year, a drastic reduction compared to the previous model.
- Ease of maintenance: The simplicity of the pneumatic pump design facilitates access for maintenance. The process is now carried out by just one mechanical technician, eliminating the need for an electrician.
- Operational Security: Pneumatic drive eliminates the risk of electric shock, making operation safer for technicians and the work environment.
Results and Benefits
The implementation of the Graco Husky 3300 pump resulted in a complete transformation in maintenance management and operational costs:
- Annual Savings of 75% on Maintenance: A redução na frequência das manutenções (de quatro para apenas uma por ano) e a diminuição da mão de obra necessária resultaram em uma impressionante economia de 75% nos custos anuais.
- Aumento da Disponibilidade do Equipamento: A bomba agora opera de forma confiável por longos períodos, aumentando a produtividade e a eficiência do processo de transferência.
- Melhora da Segurança: A eliminação do risco de choque elétrico tornou o ambiente de trabalho significativamente mais seguro.
- Otimização de Recursos: A empresa pôde realocar o tempo e a mão de obra economizados para outras atividades estratégicas.
Conclusion
A substituição da bomba centrífuga pela bomba de diafragma Graco Husky 3300 demonstrou ser uma decisão estratégica e financeiramente sólida. A solução não apenas resolveu o problema inicial de altos custos de manutenção, mas também trouxe benefícios adicionais como maior segurança, confiabilidade e eficiência operacional. O case da Graco Husky 3300 é um exemplo claro de como a tecnologia certa pode gerar retornos significativos e de longo prazo.
