Why Does My Industrial Water System Keep Breaking Down?

One of the most crucial parts of day-to-day manufacturing, utility, and processing operations is industrial water systems. But if your system is constantly breaking down, not only is that hurting your production numbers, but it is also hurting your wallet. Something no one wants to deal with!

However, the problem may not be what you think it is. We have listed the most common reasons for a breakdown in industrial water systems. Everything from corrosion to lack of maintenance can cause risks in productivity, safety, and your bottom line. Stop patching systems and start getting to the root of the problem.

Some of the most catastrophic reasons for failure can be silent, progressive ones. Scale buildup and corrosion are some of the most damaging issues your industrial water system can face. Scale buildup occurs when minerals like calcium and magnesium deposit on different surfaces in your water system, especially in hard water areas. This can result in clogged pipes, reduced flow, and heat exchangers working much harder than normal.

Corrosion can be just as damaging to your system as scale buildup. Things like temperature changes, chemical imbalances, high oxygen content, or aggressive water can eat away at metal surfaces. This will lead to leaks, unsafe operating conditions, and even system failure.

There is a solution! A comprehensive water analysis to understand your system and what is in it is a great place to start. Proper treatment can be easy and cost-effective, rather than replacing things in the long run, solutions like softener, chemical dosing, and pH balancing can reduce scaling and corrosion. Things like protective coatings or linings may be necessary in extreme circumstances.

Recurring breakdowns can come from systems that were not right from the beginning. An industrial water system that was not designed properly for the application can fail prematurely. Things like improper fittings, inefficient flow paths, and incompatible components can make a huge impact on your system’s functionality. Cutting corners will ensure that your system will need repairs or even a full-scale replacement sooner rather than later. 

Have you seen issues like pressure drops, uneven distribution, or overworked pumps? What do you do if this sounds like your system? A full system audit can identify layout or equipment issues. Customizing the design to your needs will benefit your system, business, and your wallet!

Even industrial water systems with flawless designs need regular maintenance and care. A busy industrial environment, high demand, and constant usage can all let maintenance of your machines fall through the cracks… until it is too late. Get ahead of the catastrophe! Filters get clogged, membranes foul, and bacteria can spread, all meaning that performance can and will decline over time. 

This is an easy and simple solution: get it on the calendar. Maintenance of your industrial water systems should be akin to changing the oil on your car; you always know when it needs to be done. This is an essential part of keeping your system in tip-top shape. Scheduling regular inspections, replacing parts, and testing your water can extend the life of your equipment and reduce the need for costly emergency repairs.

Everything has a lifespan, including the equipment in your industrial water system. Pumps, sensors, and control valves all wear out over time. If you find yourself constantly replacing the same part over and over again, you may be dealing with equipment that is simply past its prime. The simple solution to this is to constantly monitor and evaluate your system. Upgrades to your system are not the enemy. Newer equipment often offers better performance and easier monitoring. Evaluate the repair cost of older equipment against the cost of long-term savings from a system upgrade.

If you have any of these problems with your industrial water system, it may be time for a deeper look into the system itself. Frequent failures often point to underlying issues that require much more than a quick fix. Do your machine and your wallet a favor and call the professionals. 

At Complete Water, we specialize in solving and identifying the root cause of the issue with your machine. From design upgrade to scheduled maintenance, we help you build a more reliable and efficient system. 

Ready to stop the breakdowns? Call us, let’s schedule your system evaluation today!