Rotating Equipment Luke Kirwin, Business Development Engineer - - PowerPoint PPT Presentation

Rotating Equipment

Luke Kirwin, Business Development Engineer

Rotating Equipment Repairs Pumps Screw conveyors Shafts Fans & Blades

Damages may include …

Pumps

General erosion Cavitation Chemical attack Entrainment General corrosion Galvanic corrosion

Pumps: Chemical attack

Chemical co, Texas, 2007

Chemical attack to wastewater pump Pump replaced annually Belzona solution applied 2 years later still in excellent condition

Pumps: Localized damage

• Pump used to transport clay

slurry suffered from severe erosion in the pump casing

• Back plates were rebuilt and then

the system was coated with a Belzona 1300 series product to provide erosion resistance

• The repair was 80% less the cost
• f replacing the system

Pumps: Cavitation resistance

Cavitation resistant coating 2nd Cavitation resistant coating Blasted Surface Efficiency coating applied

▪ Impellors were only lasting 6 months due to heavy cavitation leading to regular replacement of the system ▪ Belzona elastomer system applied providing excellent cavitation resistance ▪ Pump inspected more than 2 years on and still in perfect condition

Chemical plant, Italy, 2007

Pumps: Abrasion resistance

Gold Mine, Guatemala, 2006

• Pump subjected to

severe abrasion from suspended solids leading to through wall abrasion

• Pump was rebuilt and

coated with a ceramic carbide coating to deal with the abrasion

• Welding wasn’t an
• ption here for the

customer

Pumps Pump efficiency improvement

Belzona 1341 (Supermetalglide) provides a surface 15 times smoother than polished stainless steel, proving to increase efficiency by up to 6% on new pumps.

Ceramic coated WW pumps in Grundfos

Q-Eta_gr_B1341 Q-H B1341

GAJAH ANNUAL REPORT 2015 | 12

Shaft Repairs

Shaft Repair

• Particle contamination
• Misalignment
• Impact & Vibration
• Corrosion
• Bearing seizure
• Loss of lubrication

Caused by

Conventional solutions are limited

• Weld Repair

Distortion and hot work required

• Flame Spray

Requires specialist equipment

• Replacement

Dismantling of equipment is required

Common problems and solution

Shaft Repair

• Quickly reinstate failed or damaged

equipment

• Exact profiles can be restored with

the use of forming or machining techniques

• High adhesion and excellent

mechanical properties such as compressive strength and resistance to erosion

Belzona solutions

Shaft Repair

Belzona Solutions – Forming & Machining

Shaft Repair

Shaft rebuilding

Shaft Repair: Submersible Pump

Wales, 2007

Shaft Repair

▪ Bearing spun on the rock crusher ▪ If not back in service → entire quarry and cement plant would shut down ▪ Conventional solution: ▪ Welding ▪ Replace shaft

Problem:

Pictures

Solution:

▪ Use of Belzona paste grade material ▪ Easy application using a former ▪ Cold application / In situ repair ▪ Application still in perfect conditions after 2 years!

Chemical plant, Italy, 2007

Shaft Repair: Housing

Housing repairs

Shaft Repair: Housing

• Bearing housing was severely

worn down from heavy loading

• Housing was grit blasted and

the new bushings were applied with release agent before a 1000 series paste grade was used to repair and rebuild the housing

• Welding/machining was

considered but it would have stressed the metal. The Belzona solution also offer a quick return to service

Shaft Repair: Housing

Recycling facility, USA

Shaft Repair: Keyway

Keyway repairs

Shaft Repair: Keyway

Water supply company, Bulgaria

Shaft Repair: Keyway

• Shaft and keyway worn and

damaged on a jaw crusher used to process minerals

• Keyway was rebuilt through a

milling process

• Belzona 1000 series paste

grade used to repair the shaft

• Belzona saved the customer a

lot of time

Screw Conveyor

• Heavy abrasion caused by wet and dry

particles

• Flight area of the screw conveyor can be

very suspectable to abrasion and can become damaged easily

Common Problems

Screw Conveyor

• Replacing the system
• Expensive
• Welding + Machining
• Requires specialist tools
• Time consuming
• Requires Hot work
• Belzona solutions are cold

applied, easy to use, durable and a fast return to service

Conventional repair methods

Screw Conveyor

Scotland – Screw Conveyor Repair

▪ High level of abrasion of an auger screw was causing the customer to replace the system every year ▪ Welding / hard facing was considered however deemed too expensive and time consuming

Problem: Solution:

▪ Belzona 1000 series ceramic used to rebuild and protect the flights ▪ Still in excellent condition 3 years later ▪ Customer had even doubled the output of the equipment since the application

Screw Conveyor

Pulp & Paper, Portugal, 2016

• Previous screw conveyors

were only lasting 6 months due to severe abrasion

• Conveyor was blasted and

then coated with a Belzona 1800 series ceramic carbide coating

• Customer was so happy with

the results a second screw conveyor was also coated to protect against abrasion

Screw Conveyor

Pictures

▪ Severe abrasion ▪ Customer needed an effective protection system ▪ Conventional repair: Welding every time the metal wears away

Problem: Solution:

▪ Belzona 1800 series product: Highly abrasion resistant ceramic carbide filled epoxy

▪ Can rebuild the substrate and protect it against abrasive attack.

Lithuanian – Screw (Coal transporter) Repair

Screw Conveyor

Pictures

▪ 11 meters long Stainless-Steel screw conveyor ▪ Abrasion of welded flights ▪ Welding of the screw every 12 months ▪ Current service life - 5 years

Problem: Solution:

▪ Belzona Alumina tiles & Belzona 1800 series product ▪ After 12 months; no visible signs of abrasion

• r wear from the tiles or any detachment

France – Screw Conveyor Repair

Fans & Blades

Problems: Dust Particles, Erosion, Corrosion, Chemical Attack Belzona solutions: Rebuild lost structure, apply coating to prevent further erosion/corrosion Benefits: Reduced downtime, in-situ repair, cold applied

Fans & Blades: Blower

• Heavy corrosion and

erosion on the blower

• f an air compressor
• Lost material was

rebuilt with a Belzona erosion resistant paste grade then coated with a chemical resistant coating

• Cold applied system,

eliminating hot work

Mining, Portugal, 2018

Fans & Blades: Fan

Fertilizer Company, Portugal, 2015

• General erosion on the

fan causing a loss of material on the fan blades and edges

• Belzona erosion

resistant paste grade used to rebuild along ceramic carbide system and finally coated with a fluid-grade coating

Fans & Blades: Cooling tower blade

• Leading edge of a cooling tower

fan blade eroded due to high speed rotation, impact of water particles and suspended solids

• Surface preparation: Grit

blasting

• Lost material was rebuilt with

1000 series product then 2 coats of 1300 series erosion- corrosion resistance material

Fans & Blades: Agitator blade

• Customer needed protection

against Abrasion, High temperatures and Chemical attack

• Surface of the blades were

blasted and rebuilt with 1000 series high temperature paste grade

• 2 coats of Belzona 4000 series

high temperature, high chemical resistant coating were applied

Rotating Equipment

Metal repair composites for in-situ rebuilding of rotating equipment

Excellent erosion resistance Fast curing Minimal downtime Solvent free No shrinkage

Application: In-service performance:

Long-term solution High adhesion Self lubricating Low friction Very high compressive strength In-situ application Hand applied Cold applied No hot work

Belzona extends the life of mixing blades

Slovakia, 2018

CASE STUDY 1

Before After 12 months

APPLICATION SITUATION

A plaster production factory was using special anchors for mixing

PROBLEM

Heavy erosion, without any protection, meant a mixing anchor lasted about 3 months. Conventional welding of hard steel wear plates was very complicated.

SOLUTION

1. Surface prepared 2. Belzona 9811 alumina tiles bonded to surface of the blades 3. Grouted with Belzona 1812

Successful 6 month trial proved no damage

Customer requested all future anchors protected with Belzona abrasion resistant systems

OUTCOME

Picture of mixing blades after 12 months in service

Large gearbox restored with Belzona

Kosice, Slovakia, 2006

CASE STUDY 2

Before After

APPLICATION SITUATION

Large gearbox used in production of steel plate

PROBLEM

Wear in the bearing housing was causing vibration. Conventional welding required the gear box to be out of service too long.

SOLUTION

1. Accurate measuring for alignment was a key feature of the process

SOLUTION

• 2. Surface prepared and

cleaned

• 3. Belzona 1111 used to

rebuild the housing

• 4. Machining was able to be

done in situ to an accuracy

• f +/-0.03mm.

Easy to apply and machine in situ

Belzona method achieved exact alignment ensuring smooth performance

• f the gearbox.

OUTCOME

Belzona Proven Cavitation Protection To Francis Turbine

Slovakia 2004 and 2007

CASE STUDY 3

APPLICATION SITUATION

Francis turbine runner at hydroelectric plant

Key Stats:

Diameter = 800mm Head = 40-50m Rotation = 600rpm Power Output = 2.1 MW Flow Rate = 4m³/s

PROBLEM

Cavitation had caused erosion of the metal and loss

• f turbine

performance.

SOLUTION

1. In 2004, Belzona 1331 used to rebuild damage 2. Belzona 1341 specified for protection 3. Inspected 2 years

After 2 years (2006)

SOLUTION

4. Belzona system upgraded for superior cavitation protection 5. Surface prepared 6. Belzona 2141 applied directly on to runner 7. Inspection after 2 years revealed no damage

OUTCOME

2 years with no damage Belzona 2141 offers long term protection against aggressive cavitation 6 year later (2013) minor repairs to coating, with no damage to the runner