Client Background
Our client is a leading textile manufacturing unit operating a thermic fluid heating system requiring high-flow and high-temperature pumps. The application demanded a pump capacity of 300 m³/hr flow, 80 meters head, and continuous operation at 350°C.
The pumps were supplied along with a thermic fluid heater by another vendor. However, frequent operational failures led to production disruptions and increased maintenance costs.
Challenges Faced
The client experienced multiple critical issues with their existing thermic fluid pumps:
- Frequent leakage due to poor-quality sealing arrangement
- Repeated bearing failures, causing unplanned shutdowns
- Unstable pump performance above 300°C
- Rapid wear of carbon bushes, resulting in high maintenance frequency
These problems severely impacted plant reliability and increased downtime.
Sujal Engineering’s Solution
Our engineering team conducted a detailed site visit to understand the operating conditions, system parameters, and root causes of the failures.
Based on our analysis, we implemented the following solutions:
- Replaced the existing pump with a heavy-duty thermic fluid pump designed for continuous operation at 350°C
- Installed a high-quality mechanical seal suitable for high-temperature thermic fluid applications, eliminating leakage issues
- Introduced a robust double-bearing design, significantly improving bearing life and overall pump stability
- Resolved frequent carbon bush wear through optimized internal design and bearing arrangement
- Customized the pump to fit on the existing foundation and base plate, avoiding civil modifications and unnecessary additional costs for the client
This approach ensured a smooth replacement without disturbing the plant layout or increasing project expenditure.
Our supplied pumps(2 working + 1 standby):
Results & Performance
- Zero breakdowns for nearly 2 years of continuous operation
- No leakage, even at elevated temperatures
- Stable and smooth pump performance above 350°C
- Significant reduction in maintenance and downtime
The solution delivered long-term reliability and restored the client’s confidence in their thermic fluid system.
Our thermic fluid pumps have been operating continuously for over two years without a single breakdown.
Client Feedback
After successful operation, the client shared this internal directive across departments:
“For any pump-related requirement, go only with Sujal Pumps.”
This trust and recognition reflect the value of our engineering expertise and commitment to delivering reliable pumping solutions.