Tag: Wastewater Industry

  • Chesterton® Mechanical Seals: Indispensable in the Water and Wastewater Sector

    Chesterton® Mechanical Seals: Indispensable in the Water and Wastewater Sector

    The water and wastewater industry is grappling with numerous challenges. Rising energy and maintenance costs, stringent environmental regulations, and aging infrastructure demand specific attention and solutions.

    Pumps, mixers, and agitators in water and wastewater treatment facilities must operate continuously. The constant use and long service life of these machines place significant stress on all components. Chesterton mechanical seals have demonstrated their ability to lower maintenance costs and increase equipment uptime. Split mechanical seals, in particular, are designed to extend the life of worn equipment by upgrading from gland packing

    Key Benefits of Chesterton Mechanical Seals

    • 1. Enhanced Safety and Reduced Maintenance Costs: The Chesterton 442C split seal can be installed without disassembling large equipment, significantly reducing maintenance costs and enhancing safety. This innovation allows for quick and efficient seal installation, minimizing downtime and labor expenses.
    • 2. Active Throat Bushing Technology for Water savings: Active throat bushing technology removes particles from the pump’s stuffing box, protecting mechanical seals and extending their life. The combination of a single SpiralTrac® and the Chesterton 442C split seal can significantly reduce, or in some applications, eliminate the need for flush water, further lowering operating costs.
    • 3. Improved Efficiency reduces overall cost: High-quality sealing technologies are crucial for the efficiency of wastewater systems. The Chesterton 442C split mechanical seal enables seal installation without pump disassembly, saving valuable labor hours and minimizing downtime.

    Split Seal Technology from Chesterton

    442 Split Seal from Chesterton, high-performance mechanical seal

    Split seals, as the name suggests, use split components that are mounted on the shaft. The Chesterton 442C Cartridge Split Seal offers superior sealing performance with easy and safe installation. This patented technology ensures reliable operation and long-term leakage protection for various rotating equipment, even under pressure-vacuum cycling and high-temperature conditions:

    Lubricating the seal faces with clean fluids is essential for the longevity of mechanical seals. Traditionally, pump operators have used clean flush water to achieve this, which incurs significant water consumption and costs. Our advanced split seals, combined with SpiralTrac® technology, substantially reduce or eliminate the need for clean flush water, increasing the reliability of the sealing system and cutting operating expenses.

    SpiralTrac Technology, environmental controller, available from A.W. Chesterton

    For more information about our mechanical seals, visit our “Reliability Matters” blog, which covers essential topics such as the “5-key Features for good Mechanical seal Design“

    Here you can gain an insight into our decades of experience in the water and wastewater sector:

    Case Study #1: Wastewater Plant Dramatically Reduces Seal Installation Time with Split Seals

    Case Study #2: Reduce Flush Water Usage by 90% with Chesterton Split Seal 442

    Case Study #3: Split Seals Deliver Reliable Wastewater Pump Sealing for Three Years Running

    Case Study #4: Sealing Large Influent Pumps – Split Seals Increased MTBF to 9+ Years

    Case Study #5: Chesterton 442C Cartridge Split Seals Switch Results in Easy Installations

    Conclusion:

    The water and wastewater industry faces numerous challenges, from ensuring safety and managing aging infrastructure to reducing energy consumption and maintenance costs. Advanced mechanical sealing solutions, particularly split seals, offer a practical and effective way to address these challenges. As the industry continues to evolve, the adoption of such innovative technologies will be crucial in achieving sustainable and reliable water and wastewater management.

     Do you have any questions about our Mechanical Seal Technology? Our Expert Desk is here to help. We are happy to assist you!

    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.

    *SpiralTrac® is a trademark of EnviroSeal Engineering Products Ltd.

  • Boosting Pump Performance and Increasing Pump Availability Using Chesterton® DualPac® 2212 Packing

    Boosting Pump Performance and Increasing Pump Availability Using Chesterton® DualPac® 2212 Packing

    There are numerous pumps in waterworks or sewage treatment plants in all industrial sectors. Pumps are involved wherever drinking water, process water and wastewater need to be moved; many of these pumps run continuously. No municipal or industrial water treatment plant can afford frequent, time-consuming pump shut-downs.

    Chesterton offers packing solutions for rotating equipment in a wide range of industries. However, in this article we would like to highlight the performance of our DualPac® 2212 pump packing. When used in combination with a SpiralTracTM Packing Device, these two products assist plants with reducing maintenance costs.

    Patented braiding technology of high-performance fibers – Chesterton DualPac 2212 Packing

    Conventional pump packing requires regular gland adjustment to control leakage.

    Chesterton 2212 DualPac Packing installed in Pump

    Using a patented braiding method, Chesterton combines resilient and wear-resistant para-aramid fibers and temperature-resistant meta-aramid fibers to create a unique braided packing material. The fibers are braided separately on each side of the packing so that the properties of these high-performance fibers are used individually for the shaft side and the stuffing box side. The orientation of this 2-color packing in the stuffing box can be varied according to requirements. For example, heat-resistant fibers with a low coefficient of friction are used on the shaft side. The high-strength, elastic fibers act on the outside and seal reliably even with changing gland pressure. The packing remains properly compressed against the shaft, helping to minimize gland adjustments, reduce leakage, and mitigate shaft scoring.

    Chesterton DualPac 2212 packing offers these performance functions:

    • Heat-resistant fibers help to minimize gland adjustments and prevent over-tightening
    • Higher stuffing box pressure capabilities
    • Superior sealing performance and extrusion resistance in one packing
    • Lower leak rates than conventional packings
    • User-friendly: easy to cut, install and maintain

    The results of these product features are fewer gland adjustments and reduced maintenance costs.

    Chesterton 2212 DualPac Packing - high performance mechanical packing

    SpiralTracTM Packing Device removes solid particles in the stuffing box

    We complement the performance of DualPac 2212 packing with SpiralTracTM technology to remove solids from the sealing environment helping to prevent shaft sleeve wear. With the use of a flow controller, the amount of flush water required can be reduced by 60% or more.

    Many pumped media contain solid particles. Examples are slurries, wastewater, river water, etc. The problem with solids is that they cause excessive shaft sleeve wear. The solids typically embed themselves in the rotating shaft sleeve and compression packing interface as they migrate through the stuffing box. This decreased the Mean Time Between Failure (MBTF) and increases maintenance costs.

    The SpiralTracTM device is very effective for minimizing the impact of solid particulates in the stuffing box. Utilizing a spiral-shaped groove design, the SpiralTracTM device applies a centrifugal force to the pump medium entering the stuffing box in combination with the clean water flush. The centrifugal force imparted on the pump medium and incoming flush serves to effectively remove the solid particles found in the pump medium by directing them to an exit groove.

    Conclusion

    The combination of DualPac 2212 packing and the SpiralTracTM device, also known as Chesterton® “SuperSets,” is an effective solution to significantly increase the packing service life and reduce pump maintenance costs.

    Do you have specific questions about DualPac 2212 packing and SpiralTracTM devices?

    We will gladly help you with any questions regarding these products, or other Chesterton products. Please ask our Expert Desk for further information.

    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.

    *SpiralTracTM is a trademark of EnviroSeal Engineering Products Ltd.

  • The Important Contribution of Lubricants in the Water and Wastewater Industry

    The Important Contribution of Lubricants in the Water and Wastewater Industry

    In the world of the water and wastewater industry, lubricants are a critical and essential component for the smooth operation of mechanical equipment. These often overlooked oils and greases play a crucial role in the reliability and efficiency of mechanical components in water and wastewater treatment plants. It is important to recognize that not all lubricants are the same and that significant benefits can be achieved using modern high-performance lubricants.

    But what exactly are the benefits of these high performance lubricants?

    • Reducing friction and wear
      In an environment where equipment operates continuously and are often exposed to extreme conditions, minimizing friction and associated wear is critical to equipment longevity. Lubricity and extreme pressure additives help the lubricant reduce friction and prevent wear between the moving parts. High performance lubrication effectively protects moving parts of bearings, chains, valves, motors, gearboxes, etc. which in turn extends equipment life and reduces the need for costly repairs.
    • Improving efficiency
      Efficiency is a key word in any industry, and water and wastewater treatment is no different. High performance modern lubricants with low coefficient of friction help bearings and conveyor chains work more efficiently as less energy is required for operation. This leads to direct cost savings through lower energy costs, while also helping to make plants more environmentally friendly by reducing energy consumption. Remember lowering friction also means reduced wear on the equipment.
    • Prevention of breakdowns and malfunctions
       High performance modern lubricants increase equipment lifetime reducing breakdown and downtime. This increases the operational reliability of the plant and the spend on unplanned maintenance and replacement parts. This is crucial, as breakdowns not only lead to additional costs, but also affect the operation of the entire processing plant.
    • Protection against corrosion and contamination
      In water and wastewater plants equipment is often exposed to water, moisture, chemicals and the environment. These conditions provide a challenge for the lubricants and can result in equipment corrosion, seizure, increased maintenance and replacement parts. Water resistance and corrosion resistant lubrication technology is important to insure equipment reliability. This helps prevent corrosion and seizing of equipment such as threaded assemblies(nuts and bolts). High-quality lubricants reduce the penetration of dirt particles into the mechanics and offer reliable water resistance and corrosion protection.

    Advanced lubricant technology from Chesterton: We offer targeted solutions for efficient cost reduction and performance optimization

    Chesterton carries an extensive range of industrial lubricants, cleaners, corrosion protection and specialized maintenance products that keep vital machinery running smoothly and efficiently.
    Our goal is to use the latest raw material technology with the ultimate goal of reducing our customers’ costs.
    By using modern raw materials, we manufacture industrial lubricants with excellent protective properties against corrosion, high and low temperatures, high-pressure loads, heavy abrasive wear and water washout.

    Benefits our customers have seen in their plants include:

    • Extending equipment service life
    • Reduction of premature failure
    • Improving the reliability of the systems
    • Optimizing the performance of the equipment
    • Cost reduction
    • Increased productivity
    Chesterton corrosion-inhibiting grease 617(E) HP Grease #2

    Whether its bearings, motors, agitators, gears, chains, mechanical assemblies – with our advanced modern lubricants and specialty chemical products you can increase the efficiency and lifetime of your equipment and reduce your maintenance and operating costs.

    617(E) - Chesterton's high-performance, corrosion-inhibiting grease

    For example, our high-performance, corrosion-inhibiting grease 617(E) HP Grease #2 is the ideal choice for demanding operating conditions. It maintains performance even at extreme pressures and very high or cold operating temperatures. Applications in water-rich environments are no problem, as this high-performance grease has excellent resistance to water washout.

    Continuous lubrication with Chesterton LubriCup

    The lubricators from Chesterton enable constant lubrication of bearings and chains. Filled with the appropriate Chesterton high-performance grease or oil, the various LubriCup systems provide a processor-controlled, precise delivery of lubricant to the point to be lubricated.

    Maintenance work is significantly reduced thanks to automatic lubrication. For areas that are difficult to access, the use of Chesterton LubriCup also means an increase in work safety, as the lubrication points can be safely accessed using a lubrication line.

    Chesterton Lubricups

    However, the most important aspect of using our LubriCups is that there is no risk of over- or under-lubrication. Under lubrication can mean the equipment runs dry reducing the lifetime. Over lubrication can result in excessive consumption of lubricants, making it uneconomical and causing lubricant dripping or leakage. These are scenarios that you can effectively avoid with our lubricant dispensers.

    Chesterton supports you with an experienced team of competent technicians to find the optimum lubricant solution for your specific requirements.

    If you have any questions about lubrication, please contact us via our Ask an Expert platform.
    We will gladly assist you with your operating challenges.

    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.