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Repair and maintenance solutions for the power industry

Belzona’s comprehensive range of cold curing, 2-part polymeric coatings, and repair composites have been used by the power industry for over 60 years. Our materials are engineered to withstand demanding operating conditions and offer exceptional continual wear resistance plus erosion and corrosion protection.

Whether your plant generates power by nuclear, fossil, or renewable means or your facility distributes energy to end-users, it is likely you will experience routine or unexpected maintenance challenges that result in increased operating costs. Belzona provides cost-effective solutions to such maintenance problems by minimizing downtime, labor, and equipment replacement costs, whilst increasing the efficiency of the plant and ensuring environmental compliance.

Repair and protection of fluid handling equipment

Aggressive erosion-corrosion of fluid handling equipment can lead to a reduction in the hydraulic efficiency of cooling water systems. Severely damaged pumps and tube sheets can be rebuilt and restored to their original profile and protected against the effects of erosion, corrosion, chemical attack, and deterioration using Belzona’s range of metal repair materials and coatings. Cold-curing materials, such as Belzona 1111 (Super Metal), can be used to repair cracked and holed pumps, providing outstanding chemical resistance.

The application of coatings, such as Belzona 1321 (Ceramic S-Metal) provides long-term erosion and corrosion resistance whilst Belzona 1341 (Supermetalglide) is proven to increase pump efficiency up to 7% on new equipment and up to 20% on refurbished equipment. High-performance polymeric coatings including Belzona 5811 (Immersion Grade) provide corrosion protection to equipment such as water boxes, end covers, and tube sheets.

Cavitation-resistant elastomers, such as Belzona 2141 (ACR-Fluid Elastomer), are ideal for lining turbine runners, wicket gates, and other fluid handling equipment. Resisting the impact of imploding cavitation bubbles, they help to reduce equipment degradation and subsequent running costs.

Abrasion resistant systems

Belzona polymeric coatings and metal repair composites can help to slow down the effects of erosion in solids handling and FGD systems, whilst resisting corrosion even in areas where chemicals and high temperatures are present. Our high build erosion resistant materials, such as Belzona 1311 (Ceramic R-Metal)Belzona 1811 (Ceramic Carbide), and Belzona 1812 (Ceramic Carbide FP), will restore eroded steelwork, whilst ceramic filled coatings such as Belzona 1321 (Ceramic S-Metal) can extend equipment life.

Pipework repair and protection

Thin-wall and through-wall defects caused by external corrosion can be repaired using a Belzona wrap system or a simple cold plate bonding technique. Cold-cure materials, such as Belzona 1111 (Super Metal), can be utilized to bond repair patches over damaged areas. For bonding over manually prepared, oil or water contaminated surfaces, Belzona 1212 provides a unique solution to repair damaged equipment.

Reinforced Belzona wraps are commonly used for the permanent repair of low-pressure, non-critical equipment. Belzona wraps can be applied in situ in a matter of hours.

Belzona SuperWrap II is an ISO and ASME compliant wrap repair solution, which is ideally suited for pressurized, weakened, or holed pipes. It can be easily applied in situ eliminating the need for traditional cut and weld hot work.

Belzona 3411 (Encapsulating Membrane) can be used to prevent flange corrosion by sealing the flanged connection from the environment. The system can be easily peeled back for inspection and resealed to reinstate protection.

Corrosion Under Insulation (CUI) can be repaired using surface-tolerant, heat-activated materials and further corrosion can be prevented by encapsulating the insulation with a microporous Belzona 3211 (Lagseal) system.

Linings for chemical containment areas, channels, and sumps:

With the ability to be applied by brush or by airless spray, areas such as chemical bunds, channels and sumps can be effectively lined ensuring long-term environmental protection. Belzona’s comprehensive range of polymeric coatings such as Belzona 4311 (Magma CR1) provides chemical resistance against a wide range of aggressive chemicals.

Transformer oil and SF6 leaks:

Environmental problems can occur as a result of deterioration of aging equipment resulting in leakage. Belzona 1161 (Super UW-Metal) has the unique attribute of bond strongly to oily and wet metal surfaces. Dependent on their location, even live leaks on pipework and other metallic equipment can be stemmed and sealed in situ using a Belzona leak sealing kit due to its high adhesion and cold curing capabilities.

These cold-applied materials eliminate hot work and have been designed to be easy and safe to use. They are resistant to a wide range of chemicals and provide excellent corrosion protection offering long-term solutions.

Our metal repair composites and polymeric coatings are suitable for other areas within the power industry including:

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