Bearing Supports: Power Facility, Italy.

The Challenge:

The failure of a Power Facilities critical turbine shaft bearing supports, driven by poor manufacturing and persistent oil leakages, the turbine shaft bearing supports presented a significant operational challenge. Because the high cost of replacement was prohibitive, moreover the original construction drawings were entirely missing, the client required a specialised, in-situ repair solution to restore structural integrity as fast as possible. Their primary objective was to find a cost-effective alternative that could permanently seal the leaks and stabilise the bearing supports without the need for a total component overhaul.

The Resimac Solution:

Within just ten days, the turbine shaft bearing supports were fully refurbished, using our rigorous surface preparation and multi-stage coating process. The Resimac team began with a deep clean and grit blasting to an SA 2½ standard with a 75-micron profile, followed by an initial application of Resimac 501 CRSG and a subsequent frost blasting once cured.
A second coat of 501 CRXL 90 was then applied and subjected to a four hour post cure at 90°C (194°F) using hot air inflation. This specific application was engineered to drastically increase thermal and chemical resistance, effectively solving the root cause of the initial bearing shaft failure.

Results & Benefits of Resimac Solutions?

Critical equipment previously destined for the scrap heap was fully restored to operational condition.
The entire refurbishment was completed in just ten working days, with the bearing supports back in service within fifteen.
Avoided the high cost of a full replacement including the redesign costs associated with manufacturing new units without original drawings.
Resimac 501 CRXL & 501 CRSG system significantly increased resistance to bearing overheating compared to the original design.
The new coating cycle has become the standard for high heat applications involving low performance lubricants.
Successfully resolved the root cause of persistent oil leaks and manufacturing flaws through advanced surface technology.

Industry: Power.
Location: Italy
Application: Bearing Supports.
Products: Resimac 501 CRSG & 501 CRXL.