Wastewater pump overhaul improves equipment performance

KETO was approached to perform a scheduled 15-year overhaul of an 1100x1000 TKL wastewater pump. The pump had been taken offline due to excessive bearing vibration. The client requested that during the overhaul, Chesterton split mechanical seals be installed, replacing the existing gland packed sealing arrangement. During service, the wastewater pump runs at 2500L/s at 59m head with a trimmed impeller and is capable of 2800L/s at 59m head when fitted with a full-size impeller. The pump is driven by a 2800kW gearbox reduction 6.6kV motor.

CHALLENGE

The wastewater pump was removed from service and transported to our KETO facility in Perth, Australia. With the pump weighing in at 13 tonnes and taking up a footprint of 2.6m x 2.1m by 2.8m tall, it is one of the largest pumps overhauled at our Perth facility. During the strip and access, it was identified that significant erosion to the casing and impeller had occurred during the 15 years of service. The shaft, shaft sleeves, and gland areas were examined, and it was determined that engineering would be required in order to fit 180mm mechanical seals. Due to the age and relative rarity of the pump, all parts required were to be reverse engineered.

INDUSTRY / APPLICATION

Wastewater
- Treated effluent
LOCATION

Western Australia
CUSTOMER BENEFITS
- Improved efficiency and performance
- OEM quality
- Extending the life of equipment

SOLUTION

Shaft damage was repaired by metal spraying and machining.
Eroded parts were repaired using CHESTERTON ARC 855 coating.
New shaft sleeves, bearings, mechanical seal adapter plates, and studs were manufactured.
The seal area was re-engineered to suit 180mm split mechanical seals. Care was taken to ensure mechanical seals could be easily replaced in-situ in the future. To achieve this, modifications were made to the casing and bearing housings.
The pump was reassembled and statically hydrotested at our KETO facility in Perth.
All new and repaired parts were manufactured to reverse engineered / re-engineered drawings generated by KETO.