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Case Study: Refurbishment & Repair of Power Plant Condenser Unit Deformed by Corrosion

A cast iron face deformed by corrosion in a power station condenser unit undergoes repair and refurbishment using Sylmasta Ceramic Supergrade Abrasion Resistant Epoxy Paste

Putting a new face on it – the cast iron face of a turbine cooler condenser unit deformed by corrosion undergoes repair and refurbishment

Replacing a turbine cooler condenser unit because of a cast iron face deformed by heavy corrosion was not a cost-effective solution for a power plant in Puerto Rico, so they instead turned to Sylmasta for a repair and refurbishment method.

Case Study Data


Site
Electrical Power Plant
Location
Puerto Rico
Repair Type
Metal repair & corrosion resistance
Defect
Turbine cooler condenser unit deformed by corrosion

Products Used


Ceramic Supergrade
Epoxy paste used to rebuild the deformed cast iron face via the creation of a new corrosion and abrasion resistant surface

Case Study PDF


Case Study Details


The condenser was part of the turbine cooler at the electrical power plant operated by the Puerto Rico Power Authority. It was used to condense steam back into water and had been in operation for approximately 20 years.

There were two components of the condenser. The tubes were made from bronze and the face was made from cast iron. Having been exposed to steam and water for over two decades, the cast iron face had become heavily corroded and deformed.

Replacing the condenser would have been an extremely costly exercise compared to the value of the turbine cooler as a whole, which itself would need replacing within the next 5 to 10 years.

Parts were no longer made for this particular type of condenser because of its age, and so a replacement face would have had to be specially fabricated and then shipped to Puerto Rico.

Rather than install an expensive new condenser with a lifespan of 20 years for a turbine that would have to be condemned long before that, the Power Authority instead sought a way of keeping the condenser in operation until such time as the whole turbine needed replacing.

Sylmasta recommended the use of Ceramic Supergrade Abrasion Resistant Epoxy Paste for the repair and refurbishment of the condenser, to rebuild the deformed face and offer protection from future corrosion and wear.

Ceramic Supergrade is filled with silicone carbide for ultimate surface hardness and an extremely smooth finish. It is applied to worn or damaged surfaces to rebuild, or to new equipment to protect parts from abrasion, corrosion and chemical attack.

Before the application began, the condenser was cleaned as best it could be, with traces of rust and grime removed. Rods were inserted into every tube hole in the face, covering them so that they did not become inadvertently filled with epoxy paste.

Ceramic Supergrade Epoxy Paste used to rebuild the cast iron face of a condenser unit damaged by heavy corrosion in a repair and refurbishment application
Ceramic Supergrade built a new, ultra-smooth layer with high corrosion and abrasion resistance over the original deformed cast iron face

Ceramic Supergrade was then applied to the face around these rods. The epoxy paste filled in imperfections in the cast iron as it was built up to create a new, waterproof, surface on top of the original deformed face with high resistance to abrasion and corrosion.

The 60 minute work time of Ceramic Supergrade allowed large quantities of the paste to be mixed and applied carefully without the threat of premature curing.

A full cure was achieved in 24 hours, after which the condenser could be returned to the turbine and the system put back into operation following a successful epoxy paste rebuild. The high-wear resistance of Ceramic Supergrade would keep the condenser in service for many more years.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Heavily Damaged Metal Machinery Repair Saves a Puerto Rico Ball Mill $60 million

A repair carried out to machinery in a Ball Mill which helped to save a company around $60 million

Having a Ball – The metal machinery repair which saved a Ball Mill in Puerto Rico $60 million in lost revenue

A three week lead time on replacing heavily damaged metal machinery at a Ball Mill in Puerto Rico looked set to cost a company $60 million in lost revenue – until Sylmasta Ceramic Supergrade carried out a repair in under 24 hours

Case Study Data


Site
Ball Mill
Location
Puerto Rico
Repair Type
Metal Repair
Defect
Heavily damaged metal machine part

Products Used


Ceramic Supergrade
Ceramic Supergrade epoxy paste filled in the significant crack in the metal machine for a hard wearing surface repair

Case Study PDF


Case Study Review


Ball Mills are used for mixing a wide variety of materials together by grinding particles down in size, often with the aim of turning them into powders.

A rotating shell is filled with balls or beads alongside the materials which are to be turned into powder. As the shell rotates, the balls and beads drop from near the top and impact on the materials towards the bottom, which grinds them down.

The process is hard wearing and the balls and beads have to be regularly replaced as a result. Whilst this maintenance work was being carried out, a part had been forced, causing significant damage to a metal part.

Metal machinery in a Ball Mill in Puerto Rico suffering from a heavy crack after being accidentally damaged during maintenance work
The cracked metal part in the machinery which required repair

It was not until a few days after the maintenance work had been completed that the Ball Mill noticed there was a problem. Water which ran between the liner and the outer wall of the machine was now leaking into the tank through a visible crack.

The cost of a replacement part was $200,000 with a three week delivery time from Germany. A specialist installer would also have to be flown over to Puerto Rico to fit the new part.

More pressing a concern for the Ball Mill was that daily production was worth $4 million. A three week wait would therefore have cost the Mill approaching $60 million in lost revenue.

Rather than replace the part, the Mill instead sought out a means to carry out a repair to the metal machinery. Sylmasta recommended the use of Ceramic Supergrade, a two-part epoxy paste designed to repair heavy damage to industrial machinery including silos, chutes, pumps, impeller blades, valves, fan blades, metals castings and tanks.

Sylmasta Ceramic Supergrade epoxy paste used to repair heavy damage to metal machinery at a Ball Mill
Ceramic Supergrade applied to the damaged machinery

The ease with which Ceramic Supergrade can be applied enabled the Ball Mill to carry out the repair themselves. Prior to application, the surface of the metal machinery undergoing repair was prepared by roughening it up. The epoxy paste was then spread over and pushed into the crack with a trowel, filling in the damage before it hardened.

Ceramic Supergrade is reinforced with silicon carbide for ultimate surface hardness, offers excellent protection against future wear and corrosion, and is moisture tolerant which would prevent any water leaking into the shell.

Repair to a metal machine part using Sylmasta Ceramic Supergrade epoxy paste saved a Ball Mill $60 million in lost production
The completed repair saved the Ball Mill $60 million in lost revenue

The repair was carried out whilst the Ball Mill was shut for business on a Sunday. Ceramic Supergrade has a full cure time of 24 hours. By the time the site reopened for business on Monday, the Ball Mill was able to operate at full capacity with tens of millions of dollars saved.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com