The Challenge

Every point of lost efficiency is lost revenue, and the outage windows to recover it are infrequent and precious. Hydropower assets face constant erosion, cavitation, and corrosion from high-velocity water, often carrying silt and debris — turbine runners pit and lose profile, wear rings open up, and gates and penstocks corrode and leak. Repairs must last and be completed in the window available.

Turbine runners and wear rings, guide vanes, draft tubes, penstocks, gates, and trash racks suffer cavitation damage, silt erosion, and corrosion. Even small losses in surface profile and finish reduce hydraulic efficiency and generation output.

Belzona ceramic-filled composites and coatings rebuild eroded and cavitated components and restore smooth, efficient water-facing surfaces — proven to recover efficiency and extend intervals between overhauls. Rumford Industrial Group applies them in situ during planned outages.

Belzona Solutions for Hydropower

Erosion & Corrosion Protection for Fluid Handling Equipment

Penstocks, spiral casings, wicket gates, stay vanes, turbines, and concrete surfaces suffer solid particle entrainment, erosion, and corrosion that degrade equipment and surrounding infrastructure, requiring cold-applied metal rebuilding materials and non-porous concrete repair composites that restore original profiles without distorting the substrate.

Cavitation Protection for Fluid Handling Equipment

Turbine runners and wicket gates suffer degradation from imploding cavitation bubbles, requiring a durable, flexible polyurethane coating that creates a long-term barrier between fluid and metal, combined with hydrophobic epoxy coatings for added corrosion and erosion resistance.

Pipework Repair and Protection

Pipework suffers internal and external corrosion and erosion, along with live leaks and loss of structural integrity, requiring solutions applicable across a wide range of pressures and temperatures, often on live pipework without shutdown.

Transformer Oil, SF6 Leaks & Electrical Equipment Protection

Aging transformers develop oil and SF6 gas leaks, and ceramic insulators suffer damage, requiring materials that permanently seal leaks and restore insulators in situ.

Building & Structural Maintenance

Facility floors, walls, and roofs face hazards, moisture ingress, and weather damage, while HVAC systems suffer wear and corrosion, requiring epoxy floor coatings, breathable waterproof wall coatings, watertight roof membranes, and protective HVAC coatings and repair composites.

Common Asset Areas

Valves, Pipes, & Fittings

Penstocks and pipework suffer internal and external corrosion and erosion, plus live leaks and loss of structural integrity, requiring solutions applicable across a wide range of pressures and temperatures, often on live pipework. Learn More →

Mechanical Power Transmission

Wicket gates, stay vanes, and turbine runners suffer cavitation, erosion, and corrosion from continuous fluid exposure, requiring flexible polyurethane coatings and metal rebuilding materials that resist cavitation bubble impact and restore original profiles. Learn More →

Engines & Casings

Spiral casings suffer erosion from solid particle entrainment, requiring cold-applied metal rebuilding materials that restore original profiles without distorting the substrate. Learn More →

Tanks & Chemical Containment

Transformers develop SF6 gas leaks, requiring permanent in-situ sealing materials that eliminate the need for hot work. Learn More →

Walls

Facility walls suffer moisture ingress, requiring breathable, self-cleaning, waterproof coatings that maintain long-term appearance and protection. Learn More →

Roofs

Facility roofs suffer leaks across varied contours and roofing materials, requiring breathable, watertight membranes that stay sealed long-term. Learn More →

Floors

Facility floors face wear and safety hazards, requiring epoxy coatings that provide lasting protection and reduce hazards. Learn More →

Fans, Blowers, & Compressors

HVAC systems suffer wear and corrosion, requiring epoxy coatings and repair composites that restore and protect equipment. Learn More →

View All Asset Areas →

Hydropower Equipment We Repair & Protect

Equipment We Service

Francis turbines
Kaplan turbines
Turbine runners
Turbine runner vanes
Turbine blades
Guide vanes
Stay vanes
Wicket gates
Draft tubes
Draft tube cones
Draft tube walls
Spiral casings
Penstocks
Bearings
Shafts
Gears
Valves
End covers
Generators
Upper reservoirs
Lower reservoirs
Underground powerhouse structures
Transformers
Ceramic insulators
SF6 gas containment systems
Facility floors
Facility walls
Roof membranes
HVAC systems

Proven Track Record

Case Histories

In-depth case histories coming soon

In the meantime, visit Belzona’s official KHIA library for over 7,000 real case studies from around the world.

Explore the KHIA Library →