Restore cutwater profiles

Problem: The cutwater is directly exposed to impingement or entrainment from the pumped fluid. Rapid metal losses can be experienced. Mechanical damage can also occur if extraneous solids enter the pump. This leads to severe loss of efficiency.

Belzona Solution: Eroded cutwaters can be completely reconstructed using specialized techniques depending on the pump design and the degree of metal loss. Belzona repairs can be carried out on all metal substrates without the application of heat. Belzona provides outstanding resistance to future erosion/corrosion, without inducing bi-metallic corrosion.

Rebuild erosion-corrosion damage

Problem: The increased turbulence caused by pitting on the internal surfaces of a pump results in rapidly increasing erosion rates and a significant loss in pumping efficiency due to increased friction.

Belzona Solution: Belzona rebuilding grade materials are first used to restore the original profiles, then coating grades of Belzona are applied to all surfaces to prevent reoccurrence of the problem. Original profiles are rapidly restored without any risk of distortion or heat damage. Application of the coating will maintain or often times increase the original efficiency of the pump by providing a tough erosion/corrosion and chemical resistant surface.

Repair holed and cracked casings

Problem: Whether caused by severe localized erosion or mechanical impact, a holed or cracked casing will allow loss of fluid and environmental contamination. If neglected, loss of structural integrity leading to complete failure will occur.

Belzona Solution: In combination with mechanical reinforcement, Belzona products are used to stop leaks, restore structural integrity, and protect against future erosion damage. Both emergency and permanent repairs can be affected as required. Risk of distortion is eliminated since no heat is applied. Belzona poses no environmental risk, and is suitable for application in flammable areas.

Repair flow straighteners

Problem: Flow straighteners protrude directly into the main flow passages and are susceptible to mechanical impact damage and erosion/corrosion accelerated by solids entrainment. In severe situations, cavitation of the trailing edges can occur. All these factors will lead to increased turbulence and a loss of efficiency.

Belzona Solution: Belzona has a range of application techniques which can be used in conjunction with mechanical strengthening to rebuild, re-profile and protect eroded and damaged flow straighteners. The resultant surface will be more resistant to erosion/corrosion than the parent metal.

Reform end covers & protect wear plates

Problem: Solid particles entrained in the pumping fluid leads to rapid erosion of water ring seal areas of end covers and wear plates. Proper clearance is critical to pump performance, and the rate of erosion rapidly accelerates as clearances widen.

Belzona Solution: Using simple templates and forming techniques, Belzona systems can be used to accurately rebuild the profiles, precisely restoring the critical clearances. Belzona products possess outstanding erosion and chemical resistance properties. Application does not require heat, and offers a cost-effective alternative to conventional parts replacement.

Reduce friction losses to increase efficiency

• Protect against erosion and chemical attack.

Problem: As the internal surface of the casing of the pump becomes more damaged due to erosion-corrosion, the friction between the liquid and the surface increases, resulting in a drop in performance, and hence ,efficiency. This means that the pump now needs more power to push the same amount of liquid through the pump.

Belzona Solution: Belzona offers a range of coatings which, when applied to the internal surfaces of pumps either, enhance the efficiency by reducing the friction losses, as in the case of Belzona 1341 (Supermetalglide), or maintain the existing efficiency for a longer operating period, by delaying the onset of the erosion-corrosion damage.

Restore impeller wear ring clearances

Problem: Correct wear ring clearances are critical to the efficiency of a pump. Due to wear, or more commonly bi-metallic corrosion, leakage occurs at this point, leading to significant loss in efficiency.

Belzona Solution: Using simple forming or machining techniques, the wear ring can be relocated securely with accurate restoration of clearances. Belzona will act as an electrical insulator for the components, eliminating bi-metallic corrosion. This eliminates the most common cause of leakage in this area. Forming techniques can reduce the amount of close tolerance machining required.

Rebuild vane profiles

Problem: Impeller vanes are carefully profiled to obtain maximum efficiency from the pump. However, they are exposed to severe impingement and entrainment damage, and also to mechanical damage should foreign objects enter the pump.

Belzona Solution: Using a combination of Belzona systems, Belzona will accurately restore lost profiles and provide greater erosion-corrosion resistance than the original material. Belzona techniques can rapidly rebuild even the most severely damaged profiles without inducing stress or creating problems of bi-metallic corrosion.

Protect against erosion and chemical attack

Problem: Pumps handling or immersed in chemically-corrosive and/or abrasive solutions suffer from severe erosion-corrosion that can be accelerated by the effects of turbulence. Damage to both the interior and exterior surfaces of the casing will result in an increase in maintenance downtime. If neglected, this can lead to catastrophic failure.

Belzona Solution: The entire surface is restored to the original profile using the appropriate Belzona system. Future damage is inhibited by applying a Belzona abrasion- or chemical resistant-coating. Belzona systems provide long-term protection even under the most severe conditions and are suited to all types of substrate materials.

Re-align bushes

• Reseat spider bearing.

Problem: The support framework of rubber spider bearings can suffer damage from many directions. Very often, the outer ring is used as a seal face between the separate stages and in such a case can be damaged due to crevice corrosion. A further, quite common problem is distortion of the frame due to impact, heat damage or incorrect assembly.

Belzona Solution: New seal faces can be created using the appropriate Belzona 1000 Series Metallic Polymers which when cured, can be machine to the appropriate dimensions thus eliminating any distortion and preventing further crevice corrosion.

Reform gland housings

• Recast bearing seats.
• Reform wear ring locations.

Problem: Whether caused by seizure or corrosion, which is sometimes further accelerated by bi-metallic factors, the bearing and packing seats become seriously eroded. This leads to leakage, vibration, and in the most severe cases mechanical damage.

Belzona Solution: The original profiles are restored, either by over-building and machining back, or through simple forming techniques. This allows for the installation of new bearings and packings. Seats rebuilt with Belzona products are highly erosion and corrosion resistant, and completely insulated from bi-metallic corrosion. Application is rapid with no possibility of casing distortion.

Recast water lubricated bearings

Problem: Rubber spider bearings can suffer damage from many directions; when dry running occurs under normal stop/start conditions, when the lubricating pump fluid contains a percentage of particulate matter, or when vibration or misalignment of the shaft causes wear.

Belzona Solution: New replacement bearings are created using the appropriate Belzona 2000 Series Elastomers and a simply-constructed former. Bearings of any size can be cast, eliminating the need for inventories of spare parts. Belzona Elastomers exhibit outstanding abrasion resistance, and are ideal for the creation of obsolete or out-of-stock bearings.

Rebuild vane profiles

Problem: Vanes are carefully designed for maximum efficiency. However, severe impingement and entrainment damage will result in the loss of this efficiency. Mechanical damage may also occur if foreign objects enter the pump.

Belzona Solution: Lost profiles are accurately restored to the original design using a variety of techniques depending on the degree of damage. Repairs affected with Belzona will offer greater resistance to impingement and entrainment damage. Belzona techniques are suitable for rebuilding even the most severely worn profiles, and are affected quickly without inducing stress or bi-metallic factors.

Reform casing spigots

Problem: Particles entrained in the pumping fluid can lead to rapid erosion of seal areas of pump casing spigots, end cover spigots and wear plates. Proper clearance is critical to pump performance, and the rate of erosion rapidly accelerates as clearances widen.

Belzona Solution: Using simple templates and forming techniques, Belzona systems can be used to accurately rebuild the profiles, precisely restoring the critical clearances. Belzona products possess outstanding erosion and chemical resistance properties. These types of applications do not require heat, and offer a cost effective alternative to conventional parts replacement.

Repair casing wear ring locations

Problem: Correct wear ring clearances are critical to the efficiency of a pump. Due to wear, or more commonly, bi-metallic corrosion, leakage occurs at this point, leading to significant loss in efficiency.

Belzona Solution: Using simple forming or machining techniques, the wear ring can be relocated securely with accurate restoration of clearances. Belzona will act as an electrical insulator for the components, eliminating bi-metallic corrosion. This eliminates the most common cause of leakage in this area. Forming techniques can reduce the amount of close tolerance machining required.

Protect from erosion and chemical attack

Problem: Pumps handling or immersed in chemically corrosive and/or abrasive solutions suffer from severe erosion/corrosion that can be accelerated by the effects of turbulence. Damage to both the interior and exterior surfaces of the casing will result in an increase in maintenance downtime. If neglected, this can lead to catastrophic failure.

Belzona Solution: The entire surface is restored to the original profile using the appropriate Belzona system. Future damage is inhibited by applying a Belzona abrasion or chemical resistant coating. Belzona systems provide long-term protection even under the most severe conditions, and are suited to all types of substrate materials.

Repair cracked and holed casings

Problem: Whether caused by severe localized erosion or mechanical impact, a holed or cracked casing will allow loss of fluid and environmental contamination. If neglected, loss of structural integrity leading to complete failure will occur.

Belzona Solution: In combination with mechanical reinforcement, Belzona products are used to stop leaks, restore structural integrity, and protect against future erosion damage. Both emergency and permanent repairs can be affected as required. Risk of distortion is eliminated since no heat is applied. Belzona poses no environmental risk, and is suitable for application in flammable areas.

• Rebuild suction bowl profiles.
• Reduce friction losses to increase efficiency.

Rebuild and protect rotors

Problem: Although liquid ring vacuum pumps should operate with clean filtered water, contamination by chemicals or solid particles can occur, leading to severe damage to the rotors. If neglected, this can result in the loss of efficiency.

Belzona Solution: Belzona systems are used to rebuild damaged metals. Accurate tolerances are restored with machinable grade products. Erosion-corrosion and chemically resistant coatings are applied to protect to the rotor and prevent recurrence of the problem. Belzona provides outstanding long-term erosion-corrosion and chemical resistance.

Restore pump cone clearances

Problem: The clearance between the cone and rotor is critical to the efficient operation of the pump. Damage can occur due to wear, erosion-corrosion, or abrasion from the rotor due to bearing failure.

Belzona Solution: Vacuum pump cones are accurately rebuilt back to the original profiles using Belzona machinable-grade systems. The resulting surface is highly resistant to corrosion, chemical attack and abrasion by solids entrainment in the water ring seal. Cones rebuilt with Belzona products can often outlast original equipment. Spare part inventories are reduced and delays caused by non-availability of parts are avoided.

Reform end covers

Problem: Solids entrainment in the liquid ring caused by carry over of solid particles leads to severe erosion of the end covers. This erosion accelerates as the clearances increase.

Belzona Solution: Abrasion resistant Belzona systems are used to accurately restore lost profiles with the aid of simply constructed formers or templates. The lack of heat in the Belzona application eliminates any risk of distortion to the detailed castings. Resultant surfaces have excellent resistance to chemicals and abrasion, thus extending the life of the end cover and eliminating the need for expensive replacement.

Repair and protect casings

Problem: Vacuum pumps handling corrosive and abrasive solutions suffer from severe erosion/corrosion that can be accelerated by the effects of turbulence. Damage to the interior surface of the casing will result in loss of efficiency. If neglected, this can lead to catastrophic failure.

Belzona Solution: The entire interior surface is restored to the original profile using the appropriate Belzona system. Future damage is inhibited by applying a Belzona abrasion or chemical resistant coating. Belzona systems provide long-term protection even under the most severe conditions, and are suited to all types of substrate materials.

Repair and protect valve plates

Problem: Proper valve plate clearances are critical to efficient pump operation. Carry over of chemicals and solid particles can cause severe erosion to the surface of the valve plate.

Belzona Solution: The valve plate is rebuilt and machined back to size using Belzona machinable-grade systems. Alternatively, simple forming techniques and the abrasion resistant Belzona systems can be used to restore the required profiles with minimal machining. Belzona products are ideally suited for reclamation of unavailable or obsolete parts.

Repair and protect pitted line shafts

Problem: Line shafts - long shafts connecting pumps to motors - are usually operated in immersed or semi-immersed conditions, and are therefore subject to damage by corrosion and chemical attack. Worn and damaged shafts are conventionally repaired using a hot process (welding/machining or hot metal spray/machining). Obviously, these processes if not carefully controlled will cause residual damage to the shaft. They also require the disassembly of the machine, incurring unnecessary cost and downtime.

Belzona Solution: Belzona 1000 Series Metallic Polymers provide cold-curing repair solutions, which can often be carried out in-situ, thus saving the downtime and lost production costs incurred with traditional approaches.

Rebuild shaft sleeve/bearing locations

Problem: Bearing locations and particularly sleeved bearing locations are subjected to damage from crevice corrosion, and wear when bearings slip on the shaft, following damage sustained by excessive heat or vibration. Worn and damaged shafts are conventionally repaired using a hot process (welding/machining or hot metal spray/machining). Obviously, these processes if not carefully controlled will cause residual damage to the shaft. They also require the disassembly of the machine, incurring unnecessary cost and downtime.

Belzona Solution: Belzona 1000 Series Metallic Polymers provide cold-curing repair solutions, which can often be carried out in situ thus limiting the downtime and lost production costs that can be incurred.