In an era of constrained resources and rising costs, utilities are shifting to reliability-centred and predictive maintenance models, emphasising technologies that extend asset life, reduce manual intervention, and minimise invasive maintenance.
This is where engineering design is playing a more strategic role. Global sealing specialist Chesterton is focusing on solutions that directly address the operational pressures facing utilities.
“The notion of doing more with less is widespread across the water and wastewater industry,” said Jorge Mellado, Chesterton’s Sales and Business Development Manager – ANZ.
“Less resources and engineering capacity means organisations don’t have the manpower to take a step back and rethink their maintenance strategies. That’s when they turn to suppliers like us to fill the gap and be the experts they can rely on.”
A key piece of equipment for industries seeking to reduce downtime, simplify maintenance, and enhance sealing reliability is Chesterton’s split mechanical seals.
“Unlike traditional seals, which often require full pump disassembly for installation or replacement, split seals are designed to be installed in place. This eliminates the need to remove large rotating equipment, significantly reducing labour hours and downtime while also lowering the safety risks associated with dismantling heavy assets,” Mellado said.
Interventions that once required extended outages and multiple personnel can now be completed faster and with fewer resources, changing maintenance economics. Maintaining pumps without dismantling them provides utilities managing critical infrastructure an operational advantage.
According to Chesterton, split seals also improve reliability in demanding wastewater applications by reducing leakage and accommodating shaft movement and misalignment. This not only protects equipment from damage but also helps utilities meet environmental and compliance obligations by minimising the risk of fluid loss.
The efficiency gains from improved sealing technology are complemented by advances in asset protection. Many utilities are dealing with ageing pumps that have experienced years of erosion, corrosion and declining performance. Rather than replacing these assets outright, there is growing interest in restoring and protecting them to extend their operational life.
Protective coatings have emerged as a practical solution in this space.
“Chesterton’s ARC industrial coatings are designed to rebuild worn surfaces and provide a barrier against further damage, particularly in aggressive wastewater environments,” said Mellado.
By restoring internal pump surfaces to a smoother profile, they can improve hydraulic efficiency, reducing energy consumption and operating costs. At the same time, extending the life of existing equipment reduces capital expenditure and supports broader sustainability objectives by minimising waste and resource use.
These concepts are being applied through large-scale programs such as Sydney Water’s Partnering for Success (P4S) delivery model, launched in 2020, which represents a shift in how major works are procured and delivered.
Designed to simplify procurement and optimise value across the supply chain, the program is set to deliver approximately $4 billion in construction works and services between 2020 and 2030. A core objective of P4S is to foster closer collaboration between the utility and its delivery partners, encouraging innovation and more efficient outcomes over the long term.
Within this framework, FITT Resources, a distributor of Chesterton sealing products, has played a role in supporting maintenance and reliability improvements across Sydney Water’s asset base.
“FITT Resources has been involved in the repair and overhaul of various pump types, including submersible, centrifugal and positive displacement units. A key focus has been upgrading sealing systems to improve performance and reduce maintenance demands,” Mellado said.
“In several applications, legacy packing and traditional sealing arrangements were replaced with split mechanical seals, enabling faster installation and significantly reducing the need for pump disassembly.”
This approach has helped minimise downtime and labour requirements while improving overall reliability.
“ARC industrial coatings have also been applied to restore pump components and protect them from ongoing wear. The combination of improved sealing and surface protection has enhanced efficiency, extended equipment life and a reduction in total cost of ownership,” said Mellado.
The work undertaken through the P4S program also highlights the importance of adaptability in maintenance strategies. Water utilities operate a diverse range of assets under varying conditions, meaning that no single solution is universally applicable. The ability to draw on a suite of technologies, from advanced packing systems to split seals and protective coatings, allows operators to tailor their approach to specific challenges. This flexibility is particularly valuable in a resource-constrained environment, where optimising each intervention is critical.
“Chesterton is the only company that manufactures packing systems, split seals and protective coatings. Together, these technologies address the three biggest pain points in pump maintenance: downtime, safety, and efficiency,” said Mellado.
“By adopting smarter sealing and coating solutions, utilities can return pumps to service faster, minimise exposure to hazards, cut water and energy waste as well as extend asset life and defer costly replacements.”
For more information, visit chesterton.com
This article appears in the May/June 2026 edition of Utility. Subscribe HERE.
