Hydropower stations operate in some of the most demanding service conditions. High-velocity water flow, cavitation, continuous immersion, erosion, corrosion and mechanical wear all contribute to equipment deterioration and reduced efficiency.
Belzona’s industrial coatings and composite systems are engineered to repair, protect and improve assets in this challenging environment. These solutions help to:
- Restore damaged components to their original dimensions
- Improve hydraulic efficiency
- Protect against erosion, corrosion and cavitation
- Reduce downtime and replacement costs
- Extend asset life and minimise landfill waste
Below are typical hydropower applications where Belzona systems provide durable, long-lasting performance.
Solutions for Hydropower Stations
Wicket Gates
The Problem:
Wicket gate blades are frequently exposed to erosion, corrosion and cavitation. Over time, material loss reduces hydraulic efficiency and can impair flow regulation.
The Solution:
Belzona 1000 Series repair composites can be used to rebuild damaged surfaces and restore original profiles. These systems also provide durable erosion and corrosion protection.
Where enhanced abrasion and cavitation resistance is required, Belzona 2000 Series elastomers can be applied to protect against high-impact and turbulent flow conditions.
Penstocks
The Problem:
Penstocks and spiral casings are subject to internal and external corrosion. Wear can also occur at pipe supports due to galvanic corrosion and vibration.
The Solution:
Belzona 1000 Series composite systems can be used to rebuild corroded areas and restore original geometry without hot work or substrate distortion. These cold-applied materials ensure high adhesion and can be used to bond pipe supports while eliminating metal-to-metal contact to prevent future corrosion.
Belzona 5000 Series industrial coatings provide long-term internal and external corrosion protection for metallic surfaces.
Inlet Valves
The Problem:
Inlet valves experience erosion, corrosion and mechanical wear. Damage may include loss of diameter on valve shafts and degradation of the valve body, disc and sealing areas.
The Solution:
Belzona 1000 Series composites can be used to rebuild valve shafts and restore original dimensions.
Belzona 2000 Series elastomers can be applied where elasticity, high abrasion resistance and tear resistance are required, particularly on sealing and high-wear areas.
Hydraulic Ball Valves
The Problem:
Hydraulic ball valves play a critical role in flow control and are continuously exposed to erosion, abrasion and chemical attack. Surface degradation can reduce performance and operational reliability.
The Solution:
Belzona 1000 Series paste-grade systems can be used to rebuild worn or damaged areas, restoring original dimensions while providing high mechanical strength and durability. Following restoration, a Belzona 1000 Series protective coating can be applied to provide long-term resistance to erosion-corrosion and flow-induced wear.
Pump Bearing Pedestal Flanges
The Problem:
Pump bearing pedestals in hydropower stations provide structural support and alignment. Damaged flange faces can lead to misalignment, vibration and premature equipment failure.
The Solution:
Belzona 1000 Series repair composites can be used to rebuild flange faces and restore original geometry. A protective coating from the same range can then be applied to safeguard against erosion and corrosion, ensuring structural stability and extended service life.
Turbines
The Problem:
Hydropower turbines are vulnerable to cavitation, erosion, impact damage and corrosion across runners, buckets, housings and nozzle heads. These effects reduce efficiency and increase maintenance demands.
The Solution:
Belzona 1000 Series paste- and fluid-grade materials can be used to rebuild and protect turbine components, improving surface finish and hydraulic performance.
Belzona 2000 Series elastomers provide high cavitation resistance and are well suited for confined spaces.
Belzona 5000 Series coatings deliver internal and external corrosion protection for metallic turbine surfaces.
Medium-Voltage Switchgears & High-Voltage Switchgears
The Problem:
Failure of sealants between bolted flanges can result in SF₆ gas leakage, reducing insulation performance and increasing environmental impact.
The Solution:
Belzona SF6-FIX is designed to seal sulphur hexafluoride (SF₆) leaks in switchgear systems. The solution can be applied online, without specialist tools, and can reduce leaks to undetectable levels.
Dam Spillways & Stilling Basins
The Problem:
Concrete structures are exposed to water ingress, freeze–thaw cycles, erosion, cracking and spalling. Bearing surfaces and high-wear zones are particularly vulnerable.
The Solution:
Belzona 1000 and 4000 Series systems can be used to repair damaged concrete and restore structural integrity. These materials provide durable, fast-curing repairs, particularly in high-wear areas such as baffle blocks and spillway surfaces.
Heat Exchangers
The Problem:
Heat exchangers regulate temperature in turbines and auxiliary systems. Over time, galvanic corrosion, erosion, and general degradation can reduce efficiency and increase the risk of leakage.
The Solution:
Belzona 1000 and 5000 Series systems can be used to restore damaged tube sheets and protect against further chemical and corrosion attack. These coatings provide long-term protection while maintaining operational efficiency.
Facilities Maintenance
The Problem:
Hydropower stations can experience damaged or weathered concrete, slip hazards on flooring, and deterioration of roofs and structural elements. These assets may also be exposed to chemicals and corrosion, accelerating degradation and increasing safety risks.
The Solution:
Belzona 3000 Series flexible membranes for the water- and weatherproofing of roofs and roofing elements. Belzona 4000 Series repair materials provide safety grip and slip resistance in the facility. Belzona 5000 Series environmental barriers for weather, corrosion and chemical protection of floors and structures.
Frequently Asked Questions
What are the advantages of composite repair over welding in hydropower stations?
Composite repair offers key advantages over welding in hydropower stations, particularly in reducing downtime and safety risks. Because epoxy repair composites are cold-applied, they eliminate the need for hot work permits and avoid heat distortion or residual stress in components such as turbines, penstocks and wicket gates.
What solutions are available to repair damaged concrete in hydro plants?
Dam structures and spillways affected by water ingress, freeze–thaw cycles or cracking can be restored using composite systems such as Belzona 4111 (Magma-Quartz). These materials allow operators to repair damaged concrete in baffle blocks, stilling basins and high-wear zones quickly and durably. For more information, please read the blog post: Top 5 Epoxy Concrete Repair Applications
Where can I buy repair composites and protective coatings for hydropower stations?
Belzona provides a full range of repair composites and protective coatings for hydropower stations. For more information, and to receive specifications tailored to your exact maintenance needs, please contact your local Belzona representative using this link: https://www.belzona.com/en/about/disfinder.aspx
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Contact Your Local Distributor to Learn More About Belzona Solutions for Hydropower
Chloe Hirst is the Senior Copywriter at Belzona Limited and is based in Harrogate, England. She gained a Bachelor’s Degree (with Hons.) in Media and Communications (specialising in Journalism) at Goldsmiths College, University of London. Chloe regularly writes case studies and thought leadership content featuring a variety of different industries, with a special focus on the renewables sector. In both 2023 and 2024, she won the Best Manufacturing Content Creation Specialist (UK) Award as part of Acquisition International’s Influential Businesswoman Awards.
