Case Studies
FITT Resources Keeps Sydney Water Pumping
Challenge
Issue
Sydney Water provides water and wastewater services to the Sydney metropolitan, Illawarra, and Blue Mountains regions with an operational area of approximately 13,000km2. The network comprises water and wastewater treatment facilities, distribution/collection, and stormwater assets. In July 2020, Sydney Water launched its new infrastructure and delivery model – P4S: Partnering for Success. This program would simplify procurement, optimise value, and deliver $4 billion of construction works and services between 2020 and 2030. Water and wastewater specialists FITT Resources successfully tendered to undertake work in three main areas: the repair and overhaul of submersible, centrifugal, and positive displacement pumping units.
St Mary’s Sewage Pump Station – Vertical split pump units, Chesterton 442 Split Seal and overhaul including ARC Industrial Coatings.
Solution
Recommendation
Pump repair and overhaul using Chesterton® seals and packing
The scope meant FITT Resources would work on pumps from various manufacturers, all needing repair, maintenance and overhaul depending on the age, condition, location, and equipment use. Since their last overhaul in 2015, two tunnel pumps have started leaking excess glands due to shaft wear and packing degradation. As part of the ‘stop-gap’ solution, they were re-packed with Chesterton DualPac® 2211 1″ section in a bull ring configuration at the bottom and sealing ring configuration on the top. This packing upgrade has been very successful in terms of the ongoing gland operation.
Main outfall pump packed gland upgrade to Chesterton 2211 DualPac®.
Outfall pump gland being re-packed with 1″ square Chesterton DualPac®.
Chesterton 442 Split Mechanical Seal Program
FITT Resources was also tasked with upgrading and maintaining existing raw sewage pumps using Chesterton 442 Split Mechanical Seals. These pumps had been initially fitted with packing and then later cartridge seals. However, the decision was made to replace these with split mechanical seals. The seal set-up utilises either an API Plan 11 or 13, with close clearance or EnviroSeal SpiralTrac™ gland bushes. Additional benefits of the 442 mechanical split seals include protection and security for seal faces during installation, less heat under extreme pressure, and a compact gland design.
Chesterton 442 Split Mechanical seal.
Vertical Sewage pump upgraded during overhaul with Chesterton 442 split seal, EnviroSeal SpiralTrac™ and Chesterton ARC ceramic coating.
Potable Water pump overhauled with Chesterton ARC ceramic coating and 1810 cartridge seals.
Chesterton ARC Industrial Coatings
All sewage units were rebuilt and reclaimed using a Chesterton ARC industrial coating, which was chosen to ensure that reclaimed casings and impellers are in the best possible condition to provide prolonged operational life in harsh pumping environments. Chesterton ARC coatings also offer protection against erosion and corrosion attacks, making it an ideal solution for potable water and sewage pumps.
Vertical Sewage pump unit overhauled with hardened 420SS casing & impeller rings combined with ARC ceramic coating, reducing erosion wear.
Pump casing repair and coating process showing machined wear ring locations and ARC ceramic coating applied.
Pump casing repair and coating process showing machined wear ring locations and ARC ceramic coating applied.
Results
Using Chesterton’s range led to an increase in efficiency, extended equipment life, and reduced downtime. The partnership between FITT Resources and Chesterton continues to be an important and fruitful one, with both companies constantly looking for ways to improve and innovate to increase plant operating life and reduce the cost of ownership.
About Us
Chesterton® is a world leader in helping process industry companies and manufacturers improve the reliability and efficiency of their rotating, stationary, and fluid power equipment platforms. We are known across a wide range of industries for our award-winning pump and valve sealing solutions, applications expertise, equipment maintenance and wear-prevention products, and knowledgeable hands-on local service. Chesterton product range includes mechanical seals, packing and gaskets, industrial lubricants and coatings.
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