Tag: increase reliability

  • The Chesterton Connect IIoT Solution Significantly Increases the Reliability of Pumps and Rotating Equipment

    The Chesterton Connect IIoT Solution Significantly Increases the Reliability of Pumps and Rotating Equipment

    Whether drinking water, raw water, process water or wastewater – municipal and industrial applications involve the transport, distribution and treatment of water. Various types of pumps are used for pumping and transferring water and sewage sludge. The aim of all plant operators is to ensure that the pumps and rotating machinery function smoothly and reliably in order to keep the operating costs of the plant as low as possible. After all, every pump failure costs money and disrupts operations.

    In addition to high-quality seals and lubricants for technical equipment in water and wastewater plants, Chesterton offers a pump specific IIoT-based monitoring solution designed to maximize the uptime and reliability of rotating machinery.

    Chesterton ConnectTM System monitors and records the performance attributes of your pumps

    The Chesterton Connect System provides reliable monitoring of mechanical seals and rotating equipment such as pumps, motors and gearboxes. As most pump installations issues are caused by process problems, the Chesterton Connect System was designed to monitor both the process as well as the equipment, maximizing the ability to predict problems before they happen.  The following parameters can be monitored and compared around the clock in near real time:

    • Process temperature
    • Process pressure
    • 3-Axis vibration (Acceleration and Velocity RMS)
    • Surface temperature
    IIOT Technologie from Chesterton for wastewater sector

    All sensing metrics listed above are ergonomically packaged into a single sensor, which can be viewed from your mobile device using the Chesterton Connect iOS or android app. Using thresholds, you can quickly recognize if there are any anomalies that could lead to downtime or malfunctions. This can streamline maintenance planning, optimizing the operational efficiency of the device and therefore increase the productivity of pumps.

    Retrieve and compare machine performance via remote monitoring

    If several pumps or rotating machines need to be monitored, the Chesterton Connect gateway and cloud is the solution. Chesterton Connect sensors are connected wirelessly via Bluetooth to the Chesterton Connect Gateway, which forwards the bundled data to the Chesterton Connect Cloud Wi-Fi monitoring platform in nearly real time. Here you can call up the data and reports conveniently on your desktop or mobile device – wherever you are in the world.

    You can receive notifications, alerts and automated reports by email via an optional cloud signup process. The Chesterton Connect System facilitates proactive maintenance planning and helps you to minimize downtime and extend the service life of your devices.

    Valuable experience in the wastewater sector – Chesterton ConnectTM System enables immense cost savings

    Typical applications for the Chesterton Connect System are split case pumps, submersible pumps, slurry pumps and centrifugal pumps.

    Pump failure due to clogging are very common in the wastewater sector, resulting in high maintenance costs and long downtimes. Non-dissolving materials in wastewater, such as wet wipes, cause blockages and contamination in pipes and pumps. These blockages lead to cavitation and consequently to excessive vibrations, which can cause serious damage to the pump.

    The Chesterton Connect Sensor can be placed directly on the discharge pipework of the pump and alerts the system personnel to increasing vibrations caused by blockages in the pump intake. In this way, the maintenance team can remove the contamination before it causes damage to the pump and its failure.  The Chesterton Connect sensor can also be place directly into the stuffing box, now in addition to vibration information, you can get the critical process information.

    Here you can gain an insight in these experiences: Wastewater Challenges: The Flushable Wipes Issue

    See more reports on successful projects here:

    Chesterton ConnectTM Sensor Detects Vacuum Malfunctions in Centrifugal Pump

    New Pump Problem Solved with Chesterton ConnectTM System

    Chesterton ConnectTM System Detects Faulty Valve

    Conclusion

    The Chesterton ConnectTM System offers water and wastewater plant operators real added value by helping them to increase the reliability of their plants, reduce operating costs and minimize the downtime of mechanical equipment.

    After all, this is what matters if you want to work efficiently in the future. Chesterton is a significant enhancement to plant equipment with advanced IIoT technology.

    You can also make a preliminary selection using our product selector. Our product consultants will gladly assist you in selecting the ideal product for your application.

  • Optimization of Hydropower Plants with Chesterton Coatings: A sustainable Solution for higher Efficiency and longer Service Life

    Optimization of Hydropower Plants with Chesterton Coatings: A sustainable Solution for higher Efficiency and longer Service Life

    Many cubic meters of water shoot through the pipes, turbines and filters of a hydropower plant every second. Although these components are very durable and specially designed for constant contact with water, corrosion damage is inevitable over time. As hydropower plants are not usually shut down completely, systems and equipment need to be overhauled gradually when necessary. It can take years to refurbish a hydropower plant. High-quality protection systems are therefore crucial to ensure a long service life for the plant.

    Protective coatings can protect various components and equipment from deterioration and if suitably selected and applied, can ensure decades of smooth operation of hydropower plants. They act as a protective barrier against corrosion, erosion and cavitation, extending the service life of operating equipment and reducing maintenance costs.

    Another advantage of Chesterton’s protective coatings in hydropower plants is that they create a smooth surface over which water can flow easily. This is particularly important for turbines, where a smooth surface means optimization of the flow conditions of the water and thus an increase in hydraulic efficiency. The result is increased power generation at lower operating costs.

    Extreme environmental conditions – high demands on the coating systems

    The high flow velocities of water combined with friction from entrained solids such as mud, gravel and sometimes even pieces of ice require an extremely abrasion resistant protective coating.

    Very low water temperatures with ice formation in winter or permanent exposure to sunlight for exposed components require flexible temperature resistance or UV resistance of the coatings.

    With the ARC and Ceramic-Polymer coating lines, Chesterton offers high-quality protection systems specially tailored to meet the requirements of the different areas of application in the hydropower sector.

    Chesterton high-performance coatings – protection against corrosion, erosion and cavitation

    With the ARC and Ceramic-Polymer range of coatings, you get unique solutions that have been proven to increase the reliability and performance of machinery and equipment, maximizing the efficiency of hydropower components.

    The intake structures filter and divert the water for the turbine. The intake systems, such as shut-off devices, bar screens, plenums, valves and penstocks, have large volumes of water flowing through them, sometimes with a high proportion of entrained solids. Chesterton specializes in protecting these systems from premature damage and maintaining maximum efficiency with high-performance coatings.

    The turbine is the heart of a hydropower plant. To ensure reliable and efficient operation of the guide vanes, volute casing, turbine blades and draft tubes, these surfaces must be resistant to erosion and cavitation over long periods of time due to the long operating times in this industry. Requirements that the Chesterton Coatings series fully meets.

    We provide effective solutions for protecting and rebuilding plant metal and concrete infrastructure and equipment that is subjected to corrosion, wear, and environmental damage.

    Our low-VOC, 100% solids, protective coatings are engineered to offer long-term protection to hydro station components and equipment including:

    • Trash racks and stop logs
    • Penstocks and valves
    • Turbine components
    • Spillways
    • Concrete structures
    Repairing of Draft Tube with ARC 791

    Proven coating experiences for your success

    Choosing the right coating system depends on several factors, including the type of plant, the environmental conditions, the type of surfaces to be protected and other specific requirements. It is important to carefully analyze the requirements of your hydropower plant before coatings are selected and applied. With our versatile portfolio of high-performance coatings, we can help you make the right choice of protection system.

    Case Study #1 – Wicket Gates Protected with ARC S1HB

    • Our customer was seeking a single layer Ultra-High-Build coating to repair and protect the 45 & 60 year old stay vanes.
    • A total surface area of 400 m2 (4400 sq ft) had to be coated.
    • Our high-performance coating ARC S1HB, 100% solids, 0% VOC, could be applied by spray application in a single layer with a thickness of at least 3mm (120 mils).
    • Another special feature of this coating system is that it contains fluorescent pigments, so that a continuous holiday free application can be easily checked with UV light as it is being applied.
      It is a non-destructive visual QC for both wet and cured ​coatings.
    Application of ARC S1HB on Stay Vanes by simple airless spraying
    Check of uniform coating layer by UV light.

    Result of this successful project:

    • 3 mm (120 mils) of Chesterton ARC S1HB coating was applied in 12 hours to 400 square meters (4400 sq ft). 
    • Our customer praised the 0% VOC and odorless factors. Previously, a vinyl coating containing 85% VOC and posing a safety risk was used for the stay vanes.
    • The foreman and his team were positive about the ease of application of Chesterton ARC S1HB.  They said it was the best high build coating they had ever sprayed.  They pointed out the advantage of carrying out visual quality control under UV light.
    • The Chesterton ARC S1HB coating will protect the blades of the turbine at the Ice Harbor dam from erosion and corrosion for many years.

    Please see the case study on our Website:

    Case Study 601453 – Wicket Gates Protected with ARC S1HB

    Case Study #2 – Draft Tube Repair with ARC 791

    • The draft tube is made out of concrete (sometimes also in solid rock), covered with bolted steel plates. These are also welded together to form a solid construction.
    • The diameter of the tube depends on the size of the turbine, often up to 4-5 meters.
    • Large amounts of water (up to 50m3/sec) lead to heavy hydraulic forces and vibrations inside the draft tube, which often causes the steel plates to loosen in exposed area and pieces can fall off causing damage to equipment further downstream. To repair it with new steel plates is a very time consuming and costly job, and in most cases will not last.
    • To inspect this area, they need to stop the turbine and empty the draft tube.​ Today it is also an option to do 3Dscanning.​ In both cases, it is a very costly operation, especially concerning loss of energy production.
    ARC 791 applied in damaged area instead of new steel plates.
    Edge on remaining steel plates coated with ARC 855
    Before bolting, injection of low viscosity mortel is needed to avoid “air pockets”.

    Result of this successful project:

    • Solid material, coated directly to the base.​
    • No need for bolting​.
    • No risk for mechanical distortion​.
    • No risk for «air-pockets»​.
    • No additional surface treatment​.
    • Easier and quicker repair​.
    • Less downtime, security of power supply and increased income for the plant owner.

    Please see the case study on our Website:


    Case Study 351041 – Power Plant Draft Tube Repaired and Protected with ARC 791

    Case Study #3 – Coating of Lock Gates and further Components of Corumana Dam in Mozambique

    • The corroded lock gates and further components like linkages, lashing strips and gate wheels, were refurbished with our high-performance coatings.
    • Proguard CN 200 was applied on all metal components
    • The metal parts, which are exposed to air and sunlight were additionally coated with Proguard 169, our UV stable topcoat
    Lock gate, coated with PROGUARD CN 200.
    With PROGUARD 169 coated external hood of jet valve.
    Gate wheels, protected with PROGUARD CN 200.

    Result of this successful project:

    • Easy application in one layer
    • Reliable and durable protection against corrosion in aggressive marine environments according to ISO 12944-2 / classification CX
    • High-grade resistances against high mechanical friction
    • Best temperature and humidity resistance due to the changing humid climate in Mozambique

    Please see the case study on our Website:

    Ceramic-Polymer Newsletter – Coating of Lock Gates and further Components of Corumana Dam in Mozambique

    Conclusion

    The application of Chesterton coatings in the hydropower industry represents a forward-looking solution to increase efficiency and extend the service life of equipment. By protecting against wear, corrosion and reducing friction, these coatings not only contribute to cost efficiency, but also promote sustainability in energy production. The hydropower industry can therefore benefit from the many advantages of this innovative technology and make a contribution to the global energy transition.

    We gladly help you in any question regarding surface protection. Please ask our Expert Desk for further information.

    Furthermore, on our website you can find this interesting blog article:
    https://blog.chesterton.com/wear-protection/industrial-coatings/coating-corrosion-hydropower-facilities/

    You can also make a preliminary selection using our product selector. Our product consultants will gladly assist you in selecting the ideal product for your application.

  • Polymer Sealing Solutions for the Mining and Ore Processing Industry

    Polymer Sealing Solutions for the Mining and Ore Processing Industry

    In the mining busi​ness, your operation must meet critical demands and anticipate the unexpected every day to help reduce the costs of downtime. Challenging environments and destructive loads take their toll on your equipment.

    Chesterton’s industry-proven hydraulic sealing solutions provide maximum value by extending the hours of operation between maintenance intervals of your equipment and increasing overall asset life. Our custom and turnkey cylinder repair kits combine proprietary polymer technologies with unique seal geometries to increase reliability and improve productivity.

    Mega-Machines have to run constantly

    Nowadays, gigantic hydraulic excavators shovel the valuable raw materials out of the ground and continuously load huge dump trucks. The mega machines are crucial for high mine production, but they have to run reliably. Any breakdown has a significant impact on production and means financial losses for mine operators.

    The hydraulic systems on these vehicles do amazing work: they dig, lift, lower and move extremely heavy loads in dusty environments.  The performance, life and reliability of a hydraulic system is determined by several factors. In addition to the design of the components themselves and the choice of a high-quality hydraulic oil, it is the seals that ensure that the cylinders operate efficiently for a long time.

    Our hydraulic sealing solutions effectively help to increase the productivity and service life of large machinery

    Choosing high-quality polymer seals from Chesterton allows miners to:

    • Increase equipment service life
    • Increase operating hours between maintenance intervals
    • Reduce breakdowns and costly downtime
    • Reduce hydraulic fluid consumption
    • Extend leak-free operating time

    The quality of the selected sealing system determines the reliability and performance of the cylinders

    The various hydraulic systems and their different functions, such as lift cylinders, stick cylinders, steering cylinders or bucket cylinders, also differentiate in the demands placed on the sealing system. This can be, for example, higher speed, higher pressure or excessive radial load.

    Our sealing kit for heavy-duty hydraulic cylinders consisting of Wear Ring, Piston Seal, Rod Seal, Static Seal and wiper can efficiently improve the performance of the cylinder and the machine.

    What does Chesterton provide?

    We use high-performance, thermoset or even wear-resistant polyurethane material combinations that withstand high speeds, pressures and operating temperatures, have low friction, are highly elastic and have excellent tear and abrasion resistance.

    Our custom-built sealing systems allow customization to meet existing performance requirements. “Mobile Mining Kits,” individual high-performance cylinder repair kits have been proven to achieve longer off-highway machine uptime between maintenance intervals. These kits help companies control costs and maintain your profit margins by optimizing the value of equipment investments.

    Chesterton’s proprietary thermoset polymer technologies provide high abrasion and wear resistance. Our unique seal geometries are specifically designed to offset known sealing issues related to pressure spikes, side loading, contamination, and low pressure leakage.

    Please get more information about the mining applications of our sealing technology:

    Chesterton Blog “Reliability Matters” – Hydraulicseals – Reliability for Mega Mining Hydraulic Excavators

    Chesterton Blog “Reliability Matters” – Hydraulicseals – Selecting right retrofitting Mining Equipment

    If you would like assistance selecting the best hydraulic seal solutions for your specific cylinder application, feel free to contact our Ask the Expert desk.

    You can also make a preliminary selection using our product selector. Our product consultants will gladly assist you in selecting the ideal product for your application.