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Iron Pulley Refurbishments

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An independent remote mining operations client in Western Australia enlisted CPS Pulley Division for refurbished pulley services. Two pulleys were sent down from site and upon completion of a detailed assessment the CPS team identified several components to be refurbished and replaced due to signs of damage and excessive wear. Providing a cost effective solution when compared to purchasing new pulleys, the two fully refurbished pulleys were supplied back to the client.

The Challenge

CPS’S Strip and Assessment report showed a detailed evaluation of the condition of each pulley component. Based on the report, the lagging, bearing housing, bearings, adapter sleeve, lubrication, lock assembly, L.A. bore, and shaft needed replacements while the shell/end disc and auxiliary needed refurbishments.

The lagging showed signs of damage and irregular wear patterns while the components of the bearing assembly exhibited significant damage. In addition, replacements for the bearings were required due to the loose components and excessive fretting corrosion. The locking element bolts were worn and unable to be removed, requiring replacements as well. Moreover, the shaft showed significant corrosion at the locking element journals and seal journals.

A detailed cost comparison for the refurbishment service compared with providing new pulleys was presented to the client and the decision was made to proceed with the refurbishment service.

The Solution

The CPS team proceeded with the refurbishment and replacement work for each component according to the results of the assessment and in-line with the client specifications. Both pulley shells were found to still be viable, therefore refurbishment work was performed. The scope of the project also included replacement of the shafts, locks, bearings, and housings, machining, non-destructive testing (NDT) of shaft and shell. The shaft was then installed to the pulley, and locking assemblies were supplied and installed. The refurbished shell and end discs were sandblasted, undercoated, and painted.

Natural Plain Rubber cold-vulcanised lagging installed to meet the client specifications. For transport requirements a purpose built frame was manufactured and supplied for each pulley with a focus on providing support of the new bearings to elliminate brinelling damage.
CPS Pulley’s refurbishment services include complete stripping down and cleaning of parts, a refurbishment vitality report, third-party NDT of shaft and shell, re-machining, re-lagging, and reassembly of the pulley with new locking elements, bearings, and assemblies—restoring each pulley to pristine condition.

 CPS Refurbished pulleys are fully engineered and supplied from our local facility, delivering our customers value and confidence.