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Some might consider the relentless maintenance regime at a treatment plant in Kansas to be almost too pro-active. But the longevity and reliability of this site’s equipment speaks volumes for the way this wastewater facility is run; not to mention the multiple awards it has won.

At Gardner, just south west of Kansas City, Site Superintendent Scott Millholland is a firm believer in keeping the Kill Creek Water Resource Plant clean, fully serviced and at optimum efficiency – at all times.  Protecting the environment, waterways and his team are paramount.

Scott recently completed 25 years’ service (the past 12 as Site Superintendent), seeing in the Kill Creek facility when it was built in 2002 by Kruger as a Bio-Denitro-phased oxidation ditch technology plant. Also there since the plant first opened are two mixers made by Landia, which help keep everything in suspension in the ‘racetrack’ nitrification/denitrification set-up.

“These Landia mixers continue to keep everything moving and do a very good job for us,” said Scott. “We pull them up every Spring and Fall to pull off any rags and make sure there’s nothing on the magnetic plug rings – and after checking them over, put them right back into service. They’re an integral part of what we do here.”

In the corrosive world of wastewater treatment that Scott knows very well, his view on all that pro-active maintenance is partly summed up with the statement that ‘oil is cheap!

“We didn’t have to carry out any type of rebuild on the first Landia mixer until it had completed 14 years of service,” he said.

“We look after them properly, but they’re a strong, solid design and very easy to maintain. Equipment should always be maintained properly, but clearly, the mixers made by Landia are truly built to last. After our rotors have been on for an hour and a half, we run the mixers for 45 minutes. At just 13 amps, they are super-low on energy usage, especially when compared to blowers. We’ve just replaced 130-amp (125HP) blowers with new units that are just 50 amps, so it has been a very quick payback.”

Keeping 21-year-old mixers in tip-top condition is just one of the many reasons that Gardner has rightly been recognized as an outstanding wastewater treatment facility. Each of the 23 lift stations in and around Gardner are also checked every day to ensure that all of the wastewater is getting through properly. Serving a population that has leapt from 6,900 people (in 1998) to a figure approaching 25,000 today, Kill Creek has won the Kansas Water Environment Association (KWEA) Wastewater Treatment Plant of the year seven times, and in 2020, Scott Millholland received the William D. Hatfield Award for Wastewater Operator of the Year. The coveted title honors operators who have contributed positively to preserving and enhancing the water environment through their leadership, example, enthusiasm and hard work. Scott not only oversees the entire facility, leading and mentoring his team, but also still works as an operator and mechanic/engineer.

‘Never Compromise On Treatment Quality’

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“Building a better community today for future generations really inspires me,” added Scott, “and our team takes great pride in protecting the local environment and waterways. We haven’t had a permit violation for over two decades. The plant here was originally designed to serve a population of 25,000 with a processing capacity of 2.5 mgd. We’re currently running at about 2.3 mgd, with room to expand (because it is modularized) to 7.5 mgd without disrupting operations. Gardner is one of the fastest growing cities in the US; very much on the up with new jobs and an expanding economy, so it is very important that we keep at least one step ahead with our operations. We try to save money wherever we can, but never compromise on treatment quality.”

In addition to significant population growth, Kill Creek Water Resource Plant is also having to meet the new task of reducing phosphorous and nitrogen outputs to meet ever stricter discharge permits.

‘A Long Way On Its Journey’

“We’ve made some operational process adjustments to tackle this,” said Scott, “and will continue to keep on top of it. “Gardner has come a long way on its journey from lagoons, fixed film plant with trickling filter, rotating biological contactor, chlorine, package plant – and then full treatment plant. We used to do pretty much everything on an on-call basis, from checking the water and wastewater plants, water breaks, turning meters on and off, and anything and everything else that needed to be done. For new challenges such as reducing phosphorous and nitrogen, all of our equipment, no matter how new or old, including the mixers from Landia, will play their part.”

Hoist & Winch Ltd recently supplied a special tandem-lifting hoist system as part of improvements to Environment Agency flood defence assets at Taplow Weir on the Jubilee Relief Channel, an 11.6 km asset that reduces flood risk to 3,200 properties by diverting water from the River Thames when flows are high. The tandem hoist units lift 7 m long galvanised steel stop logs each weighing 2000 kg. These stop logs provide a temporary barrier to the Jubilee Relief Channel so that workers can perform maintenance on the hydraulically controlled sluice gates.

Working for a large water industry engineering contractor, Hoist & Winch designed the remote-controlled tandem-lifting system to bespoke Environment Agency requirements. In terms of operating concept, the tandem lifting hoist system raises and lowers the stop logs in a level position so they locate correctly in the guide rails without any misalignment.  At the heart of the system is a pair of Yale CPV 2500 kg swl (safe working load) single-fall, electric-powered chain hoists mounted in motor trolleys to provide fast and slow speed operation.

A Danfoss/Ikusi wireless remote control handset offers individual control of either hoist raise/lower motion for initial levelling of the load hooks prior to lifting operations. The wireless remote also provides dual tandem hoist control for the precise level positioning of the stop-log load during lifting and lowering.

In the event of power loss or activation of a raise/lower limit switch, special software ensures that the system fails safe and the load does not lift unevenly. As a point of note, mechanical linking of the hoist units ensures correct load-hook separation at all times, while both hoist units also feature audible and visual operating alarms.

From an electrical perspective, Hoist & Winch Ltd provided rugged, heavy-duty plug and socket connectors for ease of maintenance and installation. In addition, the company utilised a fully enclosed (outdoor specification) power-feed system to provide safe maximum hoist-hook coverage across the entire gantry. PVC covers provided added protection for the IP55 hoist enclosure and electrical control panels from outdoor weather conditions.

The criticality of the project and close proximity to water demanded closely monitored working practices, with very stringent planning of all activities and the provision of additional PPE, including life-preserver jackets. Site work was also subject to CDM regulations and required all site engineers to hold a valid CCNSG Safety Passport/CSCS competency certification.

Installation took place over a five-day period and involved a barge-mounted hydraulic crane. Testing of the complete system took place using a dynamic test load of 2.5t + 2.5t + 125% proof load. Additional repeated function tests involved the dynamic test load and actual stop-log load to prove system functionality and satisfy Environment Agency requirements. On completion, Hoist & Winch Ltd issued a LOLER Thorough Examination report and provided operator training for site personnel.

 “The project to install the special tandem-lifting hoist system supports the Environment Agency’s annual maintenance programme, which is essential to ensure its flood defence assets remain in good working order,” says Andy Allen, Director of Hoist & Winch Ltd. “This type of tandem-lifting system would prove ideal for many other applications, such as lifting steel blast doors used in explosive/hazardous environments or handling valuable or delicate long loads in the manufacturing sector. Essentially any task that demands very precise and failsafe level lifting.”

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

Investment in new wastewater treatment equipment has enabled a leading producer of cereals and cereal bars to overcome the challenges it was facing with a very problematical effluent.

Deeside Cereals had first introduced a new DAF unit (Dissolved Air Flotation) from Watermark (a division of WA Cooke Group) to separate suspended solids and for the thickening of sludge.

However, the FOG (Fats Oils and Greases) caused by ingredients such as chocolate, rape seed oil and lecithin (phospholipids) had at one point sent COD (Chemical Oxygen Demand) up to 78,000.

‘Very Strict Compliance Levels’

Karl Johnson, Safety, Heath & Environment Manager at Deeside Cereals, commented: “The DAF unit from Watermark has proved very successful, bringing COD down to 6,000 initially, but with very strict compliance levels to meet for Dŵr Cymru Welsh Water, we wanted to make further improvements to our treatment regime.”

He added: “Working closely with Watermark, we agreed that the introduction of a high-quality aeration system would be best. Based on their previous good experiences, Watermark recommended the AirJet from Landia. I’d read about how reliable and effective their equipment is for the long-term, so we decided to first take one on trial for our new 60m³ wastewater treatment tank.”

To suspend the solids from Deeside Cereals’ effluent, the Landia AirJet was soon put into operation. Comprising a 5.5kW Chopper Pump (invented by Landia in 1950) and a venturi nozzle, the low-energy AirJet can mix and aerate down to a water depth of approximately 7.5 metres, without the need for a compressed air supply.

Alistair Fielding from Watermark said: “It’s a simple set up; easy to install, and very effective.  Based on our preceding work with Landia, we had no hesitation in recommending them to Karl. We want our customers to benefit from equipment that not only provides the right solution, but also offers the best possible value in total cost of ownership.”

Watermark had previously teamed up with Landia to help introduce a mixing system to handle wastewater at an expanding organic poultry producer in South Wales. Here, the AirJet eliminated the need for compressors, bottom-mounted diffusers and advanced controls.

‘Very Challenging To Treat’

Karl Johnson from Deeside Cereals, continued: “When our sugary water used to become entrained, it was very challenging to treat and fulfil our compliance obligations . It took us a little while for the AirJet and the DAF to harmonise, with some minor adjustments required around the length of time to aerate the trade effluent. We’ve also found that it is easier to control the COD by only half filing our tank, but we always test it before discharge – and if needs be, can aerate the effluent a little longer until it is below our compliance threshold. The Landia pump needs nothing more from us than a quick visual inspection each day to check on oil. We’re now looking at setting up a service agreement for a twice-yearly maintenance check. The guys at Landia are very good to work with. Landia have provided excellent support at all times and the installation was very straightforward. The purchase was a judicious decision on our part and I would highly recommend Landia as a service provider. Air-Jet has paid for itself in less than 10 months.”

“Low-speed machines like our sewage sludge dryer are difficult to monitor with vibration measurement technology. With SONOTEC's ultrasonic technology, it was possible to detect roller bearing damage and assess its condition," says Tobby Brümmer, Head of Machinery Maintenance at PD Energy GmbH

Ultrasound is the technology for the first step in damage detection and has the advantage over other methods in that it can be used at all bearing speeds. Even with extremely low-speed bearings, damage can be detected at the earliest possible stage.

Focus on sewage sludge incineration

As a 100% subsidiary of PD energy GmbH, KSR sewage sludge recycling Bitterfeld-Wolfen GmbH operates a mono sewage sludge incineration plant in the Bitterfeld-Wolfen chemical park. The plant is designed for a rated thermal output of 19.9 MWth. Running more than 8,000 hours a year, the incinerator consumes up to 260,000 tons of dewatered sewage sludge from municipal sewage treatment plants. The thermal utilization of sewage sludge in mono-incineration plants will be an important disposal path in the future. With the construction of the plant, KSR sewage sludge recycling Bitterfeld-Wolfen GmbH is making a contribution to the phosphorus recovery that will be required in Germany starting in 2029. The finite resource is filtered out via various systems and fed back into the material cycle.

Slow-speed disc dryer

The core process in the treatment of sewage sludge is drying. Two disc dryers are used at the site for this purpose. The redundancy of the systems is important so that one dryer can always process sewage sludge. However, the system capacity is designed in such a way that both dryers are always running, if possible, in order to be able to achieve the appropriate utilization. Downtimes must be kept as short as possible, and if they are necessary, they should only affect one dryer at a time. "The availability of both disc dryers is extremely important to us," says Tobby Brümmer, Head of Machinery Maintenance at PD Energy GmbH. In the disc dryer, the material is slowly transported from one end to the other, reducing the residual moisture. Disks heated with steam form a large contact surface where indirect drying takes place. Scrapers ensure an even process and transport of the material. The rotor turns very slowly with only 7.5 revolutions per minute.

Roller bearing damage detected and evaluated

During the commissioning phase, noises were detected on a roller bearing on one of the two dryers, whereupon a vibration measurement was initiated. “The results of the vibration measurement were not useful for us. They showed no indication of damage to the examined roller bearing,” says Tobby Brümmer. After a short research it was clear that ultrasonic measurement technology could help. "We then contacted SONOTEC GmbH and asked for a measurement using ultrasonic technology," adds Tobby Brümmer.

During the on-site measurement, the damage could be narrowed down to the corresponding roller bearing. The measurement effect was clear and in comparison to the second dryer, a statement about the severity of the damage could be made on-site.

The subsequent evaluation by the application engineer from SONOTEC provided further insights. Tt could be confirmed that the damage to the roller bearing had to be severe and very advanced. Furthermore, the data analysis revealed that the outer ring must have been severely damaged and, in particular, that one race of the double-row bearing was more severely affected. “Such details are extremely important for us to be able to identify the causes as precisely as possible. This is the only way to take appropriate preventive measures to prevent the problem from reoccurring,” says Tobby Brümmer.

Solution for slow-movers: condition monitoring with ultrasound

The advantages of ultrasonic testing technology from SONOTEC are very apparent in this application. The broadband data evaluation enables an optimal adjustment to the conditions on site. In this way, characteristic values ​​can be calculated in the range from 20 kHz to 128 kHz. Frequency ranges with background noise can be suppressed with the adjustable filter function. The high sensitivity of the sensors enables early detection of roller bearing damage, making ultrasonic monitoring a very effective solution, especially for slow-running roller bearings. “We are excited about the statements that can be made with the help of the ultrasound data. Ultrasonic roller bearing monitoring will be an integral part of our maintenance measures for our slow-moving machines in the future,” explains Tobby Brümmer.

SONAPHONE: A modular approach with different apps and sensors

With the ultrasonic testing technology from SONOTEC, other applications in preventive maintenance can also be performed. The device makes it possible to locate and evaluate compressed air leaks, and steam traps can be tested and their condition evaluated. Both applications are moving more and more into the focus of many companies due to ever increasing energy costs. "We are also interested in the other possible applications of ultrasonic technology," says Tobby Brümmer.

With various apps and corresponding sensors, the ultrasonic testing device SONAPHONE can be easily adapted to the respective application. “This means that the investment in the testing equipment pays for itself very quickly. And the device is better utilized by using different departments. It is used between the regular routes on the disk dryers for other applications," says Tobby Brümmer.

Interview partner: PD energy GmbH, Tobby Brümmer, Head of maintenance for machine technology

Find more about SONOTEC here: https://www.sonotec.eu/en/

KSR sewage sludge recycling Bitterfeld-Wolfen GmbH (Source: PD Energy GmbH)

Data acquisition at the disc dryer (Source: SONOTEC GmbH)

Mapal has surpassed its fund target of £400,000 via Crowdcube, with 475 new investors choosing to inject over £467,000 into the business that has completed over 100 installations of its energy-saving, wastewater aeration solutions.

Due to the high demand, the deadline to invest was extended by 14 days as more and more parties expressed their interest in becoming part of the Mapal success story, which has seen projects delivered worldwide, including the UK, Australia, Israel, South Africa, and Chile - with critical acclaim.

Mapal’s Chairman/Director, Ilan Diamond, commented: “It is very encouraging to not only achieve our target, but beat it.  Investors can clearly see the major benefits and huge potential of our innovative systems that are 50-60% more efficient than traditional mechanical surface aeration.”

He added: “As well as providing general working capital, this new boost in funds will enable us to further develop our sales and marketing teams. We can also fund a pre-sale trial (rental) fleet and continue to develop our key research into ammonia removal in aerated lagoons.”

Diamond explained that while some aeration methods partly address higher than ever energy (and maintenance) costs of conventional surface treatment, they often require very specific conditions. This can prove price-prohibitive as a new-build, and requires the process to be shut down for upgrades, resulting in costly and potentially damaging downtime. In contrast, Mapal’s floating and retrievable fine-bubble aeration solutions, which do not need a levelled floor, can be installed and maintained while the plant is operating; without personnel having to enter the wastewater.

mapal-ge.com

this article can also be found in the issue below.

There has been considerable growth in the wind power industry over the past few years. However, further exponential growth of the industry is required in order to ensure that the net-zero by 2050 pathway (outlined in the Paris Agreement) is successfully reached.

Figure 1 - Maintaining the integrity of wind turbines with polymeric technology

In order to support this seismic growth, polymeric repair and protection technology has an important part to play. Designed to safeguard the integrity of wind turbine blade leading edges for the long term, this technology plays a critical role in supporting this burgeoning industry.

Wind Electricity Generation Needs to Grow Fourfold by 2030

According to the International Energy Association’s (IEA) Wind Electricity Tracking Report

(September 2022): “In 2021 wind electricity generation increased by a record 273 TWh (up 17%). This was 55% higher growth than that achieved in 2020 and was the highest among all renewable power technologies.”

While the industry has undoubtedly experienced impressive levels of growth in these years, according to the IEA, wind electricity generation needs to reach four times the record levels set in 2020 by 2030. The Report said: “Our pathway calls for scaling up solar and wind rapidly this decade, reaching annual additions of […] 390 GW of wind by 2030”.

Figure 2- Wind electricity generation needs to grow fourfold by 2030 (IEA. License: CC BY 4.0)

How is the Scale-Up of the Wind Industry Being Financed?

According to the IEA’s Report: “Policy support remains the principal driver of wind deployment in the majority of the world.” Indeed, over the past few years, several policies have been launched that are designed to drive forward the roll-out of renewables.

For example, in August 2022, the US brought in the Inflation Reduction Act (IRA) which includes $369 billion (US dollars) of investment, in the European Commission’s Green Deal Industrial Plan, $270 billion (US dollars) was pledged, and since the UK government’s Ten Point Plan was launched in November 2020, over £26 billion of government capital investment has been mobilised.

Safeguarding Expanding Fleets of Wind Turbines with Polymeric Technology

Given the critical role wind power plays in the transition to a net-zero future, as well as the significant amount of capital being invested into the renewables industry, the wind power sector is poised to experience considerable exponential growth in the upcoming decades. In order to support this growth, polymeric technology plays a significant role when it comes to maintaining the operational efficiency of the rapidly expanding fleets of wind turbines.

Polymeric systems such as the rebuild, blade filler material, Belzona 5711 and the cartridge-applied leading edge protection coating, Belzona 5721, are specially designed to repair damaged leading edges and protect them against rain erosion and impact damage for the long term.

In addition to the performance capabilities of these systems, maintenance engineers are investing in this technology due to the simple, in-situ application method and fast cure times the cold-curing systems facilitate. In turn, this helps to keep downtime to a minimum, and allows the turbine to be returned to service in the same day.

Belzona 5711 can be directly overcoated with Belzona 5721 in as little as 30 minutes at 20°C/68°F without the need for any additional surface preparation. At the same temperature, Belzona 5721 will be fully cured within five hours.

Below is a case study featuring the repair and protection of a wind turbine leading edge with Belzona 5711 and Belzona 5721.

Wind Turbine Blade Repaired and Protected

Belzona, a global designer and manufacturer of industrial protective coatings and repair composites, successfully addressed the wind turbine blade damage issue at Electricity Generating Authority of Thailand’s (EGAT) Khao Yai Thiang Windfarm in Thailand.

Figure 3 - Leading edge damaged by erosion

Leading Edge Erosion Damage

The windfarm features wind turbines with 40-metre-long (131.2 ft) blades. During routine inspections, evidence of damage measuring 300 cm x 14 cm x 2 mm (118 in x 5 in x 0.08 in) on the leading edge of one of the blades was discovered.
System Selection

Representatives from the 35-year-old Belzona Authorised Distributorship, Pan Mechanic Engineering, recommended the solvent-free, two-part repair paste, Belzona 5711, to reconstruct the damaged area on the blades, followed by the high-performance coating, Belzona 5721 , to overcoat the area.

Application Procedure

The application procedure involved surface preparation using an orbital sander, followed by the direct application of approximately 1.4 kg (3.1 lbs) of Belzona 5711 from a self-mixing cartridge onto the blade. The repair area was contoured using a piece of Belzona mixing board.

Figure 4 - Surface preparation using an orbital sander

Figure 5 - Self-mixing Belzona 5711 cartridge

After a two-hour curing period, a visual inspection was conducted to ensure the application's readiness for overcoating with approximately 3.5 kg (7.7 lbs) of Belzona 5721. Using a short-bristled brush, this system was then applied to the leading edge and left to cure. The blade was

back in service 24 hours later.

Figure 6 – Application of repair paste, Belzona 5711

Addressing the fast-rising cost of energy is rightly high on today’s agenda, so when four hefty 40HP rotors serving one’s aeration plant are also sitting at the top of your maintenance budget, finding a better means of mixing certainly concentrates the mind.

In Huntsville, Arkansas, the route to achieving optimum mixing of its oxidation ditches has been a marathon, not a sprint; but this meticulously operated wastewater treatment plant is now reaping the rewards of significantly reduced horsepower and reduced repair costs.

Managing oxygen levels at Huntsville has been a major, fluctuating challenge, especially with the wastewater taken in from a large-scale food manufacturer, nearby.

The 160HP (total) rotors had to run 24/7 in order to sufficiently mix and add oxygen to Huntsville’s WWTP aeration basin, but when the expanding food manufacturer upgraded its own treatment plant, the problematical rotors were creating far too much oxygen; contaminating the anaerobic and anoxic zones.

“We had to find a new, sub-surface means of mixing our oxidation ditch”, commented Bill Eoff, Wastewater Manager at Huntsville.

“And as we only have the one oxidation ditch”, he said, “this presented the extra challenge of finding mixers that could be installed without there being any interruption to our process”.

Bill and his Water Department Director, Sean Davis, had tried pulsing the rotors on timers, and had also been having to feed in chemicals at additional expense to balance out the process, so that the ratio of BOD to ammonia could be harmonized, but to no avail. So, they consulted with their local equipment representative, Instrument & Supply, who have been working with Huntsville for over 20 years.

“We believed that by far the best solution for the plant was to separate the aeration and mixing functions; and that included mixers made by Landia. This provided a subtle, but highly effective solution”, said Chris Enloe from Instrument & Supply.

“We were very confident of our recommendation; plus, the fact that no other mixer manufacturer could, or was prepared to install their mixers without draining down the tank, which was not an option at Huntsville”.

‘Sledgehammer!’

At first, to some, the installation of a mixer to a full and operating ditch might sound rudimentary, especially with what includes about twenty solid blows with a sledgehammer (!), but in keeping with Landia’s long-established designs, no-nonsense simplicity often proves best. Actually, there’s real precision in ensuring that the (pre-marked) guide spike is installed plumb; approximately half an inch into the base, with the mixer on the guide pipe set at nine inches above the base of what is typically an eight- or nine-feet deep ditch. Installation takes just two to two and half hours.

Chris Enloe added: “The team at the plant had to work without the benefit of grants or loans that come with a new design. Everything was funded piece by piece on cash reserves. This made the task all the more trying; for example, keeping the rotors until such times that a second blower could be purchased, in order to meet the state’s requirement for redundancy to be in place”.

‘Big win for the City’

Sean Davis, Huntsville’s Public Works Director, continued:

“The rotors were proving costly and time-consuming to maintain, especially the gearboxes, but although the changes we needed to make to meet our treatment needs took longer than we would have liked, it has already resulted in a 15% reduction in our energy costs alone. This is a big win for the city. In total, the 160HP of course used up a huge amount of resource. The blower is 100HP, but is only needed 25 per cent of the time – and the mixers at just nine HP each (36HP in total) are in comparison, extremely efficient and very effective indeed”.

Bill Eoff added: “Running 24/7, for over five years with no major issues, the Landia mixers have been a great investment. We pull them up every six months to change the oil and grease them – and that’s basically all the maintenance they need. We’re very happy with them. We know that there will inevitably we some wear and tear with shims and seals that over time need to be replaced, but overall, they are very easy to maintain. In five years, we’ve spent less than $3,000 on spares. This is a world of difference compared to the rotors, which no longer provide value.  As well as the help we’ve had from Instrument & Supply, Landia have been very supportive throughout, from start-up to supervising our first service – and much more with additional advice and training. They were and still are determined to help us succeed”.

‘Supports the greater Community’

Chris Enloe concluded: “Huntsville did not have the option to build a new plant, but with real determination they now have the tools to effectively operate the plant within permit – without breaking the bank. This supports the greater community by working together with its neighbors, including the food manufacturer, which is very important to the local economy. The result demonstrates just how good the Landia solution fits within the many constraints that are in Huntsville. Rightly so, the team at the wastewater treatment plant are very proud of their work”.

Introduction

Hydropower is a renewable energy source that has been harnessed for thousands of years. Today, it is one of the most important sources of electricity in the world, and its use is only expected to grow in the future. One of the key components of the hydropower industry is the use of epoxy coatings, which are used to protect the machinery and infrastructure used in hydropower operations. In this blog post, we will explore the role that epoxy coatings play in the hydropower industry and the benefits they provide.

Figure 1 Grand Coulee Dam in the United States

The Benefits of Epoxy Coatings in Hydropower Operations

Epoxy coatings are a popular choice for use in the hydropower industry because of the many benefits they provide. One of the primary benefits of epoxy coatings is their ability to protect machinery and infrastructure from corrosion. Corrosion is a major problem in hydropower operations because the equipment used is often exposed to water and other corrosive substances. Epoxy coatings provide a protective barrier that prevents corrosion from occurring, which helps to extend the life of the equipment and reduce maintenance costs.

Another benefit of epoxy coatings in hydropower operations is their ability to provide a smooth surface for water to flow over. This is particularly important in turbines, where a smooth surface is essential for optimal operation. The use of epoxy coatings can help to reduce friction and improve the efficiency of the turbine, which can lead to increased power generation and lower operating costs.

Finally, epoxy coatings are also resistant to high temperatures and can withstand exposure to UV radiation. This makes them an ideal choice for use in the harsh environments found in hydropower operations, where machinery and infrastructure are often exposed to extreme temperatures and intense sunlight.

Hydropower Industry Case Study

Belzona had the opportunity to improve the condition of a 60-year-old Kaplan hydropower unit that was showing signs of wear and was due for a full mechanical overhaul.

Operators at the Hydropower Plant grit blasted and cleansed the unit with solvent. Belzona 1111 (Super Metal) was used to smooth over the wear and cavitation in a full skim coat. Once cured, the Belzona 1111 (Super Metal) was sanded down to the required profile, and frost blasted. Two full coats of Belzona 1341 (Super Metal Glide) were applied. The coating can provide increased efficiency on new and refurbished equipment while also providing full corrosion and erosion protection while immersed.

Surviving 60 years with minimal wear is impressive. However, by using Belzona 1341 (Super Metal Glide), the unit can continue to operate for many more years, providing reliable service and cost savings over the long term. The use of this product can improve the unit's resistance to wear and tear and can also provide an additional layer of protection against environmental factors such as moisture and chemicals.

Figure 2 Hydropower unit during surface preparation for Belzona 1111 (Super Metal) application

The Future of Epoxy Coatings in the Hydropower Industry

As the demand for renewable energy sources continues to grow, so too does the necessity for hydropower. This is expected to drive an increase in the use of epoxy coatings in the hydropower industry, as more and more equipment is needed to meet the growing demand for electricity. In addition, advances in epoxy coating technology are likely to make them even more effective at protecting machinery and infrastructure from corrosion and other forms of damage.

One area of particular interest is the development of epoxy coatings that are more environmentally friendly. As the world becomes increasingly concerned about the impact of industrial processes on the environment, there is a growing demand for coatings that are engineered with plant-derived ingredients. The Belzona Research and Development Team are currently in the process of formulating products made from bio-based materials that are produced from sustainable plant-based feedstocks, rather than the traditional fossil-fuel based ingredients.

Conclusion

Epoxy coatings play a critical role in the hydropower industry, providing protection against corrosion, improving efficiency, and withstanding the harsh environments found in hydropower operations. As the demand for renewable energy continues to grow, the use of epoxy coatings in the hydropower industry is expected to increase, and advances in technology are likely to make them even more effective. By working together, the hydropower industry and coating manufacturers can help to develop coatings that are both effective and environmentally conscious, ensuring a sustainable future for the industry and for the planet.

Lubrication is one of the most important success factors for time and cost-efficient maintenance. It is critical for low-friction and therefore energy-efficient machine operation and can contribute to greater sustainability in production. Incorrect lubrication is one of the most frequent causes of rolling bearing damage and machine failure. 

Schaeffler’s new white paper entitled “Can lubrication be easy and sustainable?” focuses on lubrication systems and lubricants, highlighting what is important when it comes to lubrication. The aim is to help you lubricate your machines more sustainably and cost-effectively, simplify your maintenance processes and prevent machine downtime.

The white paper will help you to discover how modern lubrication technology can pay off for your business; how lubrication systems can make your processes easier and more environmentally-friendly; and what you should consider when changing lubricants.It includes basic knowledge, expert tipsand guidance, as well asnumerous practical examples from a range of industrial sectors.

Automatic lubrication systems

In many companies, it is still common practice to lubricate machines manually with a grease gun. Not only is this time-consuming and sometimes involves working in hazardous areas, it also entails risks such as over-lubrication or lubricant starvation, as well as the use of inadequate types of lubricant. Automatic lubrication systems can eliminate these risks and offer additional significant benefits.

Looking for the answers? The white paper answers four key questions surrounding modern lubrication:

Lubrication can be a curse or a blessing. Sometimes it’s just small details that make the difference between failure-prone production and smoothly running operations. The latter can often be achieved with fairly manageable investments, so take a look at the new white paper and see where your operations may benefit.

This article can also be found in the issue below.