In a recent project Mechanical Rotating Solutions received a Sulzer AHLSTAR A series centrifugal single stage pump that had bearing failure and required complete refurbishment.
With the decline in profits from the mining industry as well as the continued rise in energy and labour costs mining companies are looking at solutions to save money in making up for this deficit. As pumping accounts for a major part of mining expense there has been a marked increase in mining companies turning towards pump refurbishment instead of pump replacement. Pumps are high-wear process equipment with pump casings and impellers extremely sensitive to changes in fluid characteristics.
As different challenges require different solutions Mechanical Rotating Solutions has called upon various Belzona products tailor made for its needed applications such as Belzona 5811 and Belzona 1321. Belzona® 5811, a two component solvent free system for the protection of metallic and non- metallic surfaces operating under immersion conditions in contact with aqueous solutions was used in the refurbishment of the pump casing and its related parts avoiding the need for replacement, reducing repair and maintenance costs, and above all, downtime.
Sulzer A32-100 as received from the client
After refurbishment of the outside using Belzona 5811
Having gained extensive experience servicing collieries around the Mpumalanga province MRS has frequently made use of Belzona® 1321 (Ceramic S-Metal), a two component high strength coating for the protection and refurbishment of metal surfaces subject to severe erosion-corrosion as found in coal mines. Typical applications of this innovative protective coating includes impellers, water box ends and flange faces. This material can also be used as an injection material for the shimming and bonding of components or as a high strength structural gap filler.
Not only was the Sulzer pump’s bearing replaced and fitted with a new mechanical seal, all internal parts were sandblasted and coated with Belzona 1321.
Before refurbishment of internal parts and impeller
Pump impeller refurbished with Belzona 1321
Heavily damaged pumps can be restored to their original profile by using Belzona cold-curing, reducing further deterioration, increasing pump efficiency and reducing frequent maintenance costs. Additional specialist coatings incorporating chemical, high temperature, erosion or an amalgamation of these properties ensure that MRS has the Belzona product for almost all service conditions. Once applied and in-service, any local damage to Belzona coatings can be easily repaired allowing a rapid return to service, minimising outages.
The fully refurbished pump
While erosion, corrosion and physical damage pose a threat to many industries, the real issues are downtime, efficiency decline, profit loss and safety hazards created by the root problem. Belzona products are manufactured to resolve these problems by:
- Reducing labour by eliminating the need for disassembly, welding, and post weld heat treatment
- Decreasing costs through increased asset availability
- Enhancing safety by allowing in-situ cold work with solvent free materials
Belzona 1341 (Supermetalglide) being applied to a fan blower at the MRS facility. Belzona 1341 is a 2-part epoxy coating designed to improve efficiency of pumps, pipes, valves and other fluid handling equipment while protecting them from the effects of erosion and corrosion. This high performance product is proven to reduce energy consumption, provide excellent chemical resistance and lower maintenance costs.
Among its product offering and related turnkey solutions, Mechanical Rotating Solutions is currently servicing the Mpumalanga area with the AESSEAL® product range of mechanical seals and systems, Labtecta Bearing Isolators, Belzona Engineered Coatings and Superbolts, as well as supplying the whole of South Africa with innovative Straub pipe couplings, KSB pumps and valves, Amandla pumps, and the full HCP range of pumps.