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Power
Generation

  • Protect generation and revenue with Belzona's repair composites and protective coatings
  • Keeps turbines, pumps, condensers, fans, and cooling systems in service
  • Supports fossil, nuclear, and renewable generation while minimizing outage time
The Challenge

Power generation plants run hot, wet, and hard, and every hour offline is lost generation and revenue. Turbine components erode, condenser tubes and water boxes corrode, cooling-water pumps cavitate, and fans foul — and outage windows are short and tightly scheduled. Traditional welding and replacement rarely fit inside the outage, and hot work brings added risk in an energised facility.

Belzona Solutions for the Nuclear Power Industry Belzona Solutions for Geothermal Power

Across boilers, turbines, condensers, cooling systems, and balance-of-plant equipment, erosion, corrosion, and fouling steadily erode efficiency and reliability. The most critical repairs must be completed inside a planned outage, on equipment that cannot simply be sent out to a shop.

Belzona's cold-cure composites and coatings rebuild and protect generation equipment in situ, letting repairs be completed within outage windows without hot work. Rumford Industrial Group brings this capability, and the technical support to plan it, to power producers across five states.

Belzona Solutions for Power Generation
Repair and Protection of Fluid Handling Equipment
Pumps, tube sheets, water boxes, end covers, turbine runners, and wicket gates suffer erosion-corrosion and cavitation damage that reduces hydraulic efficiency, requiring metal repair materials, protective coatings, and cavitation-resistant elastomers that restore original profiles and boost efficiency.
Abrasion Resistant Systems
Solids handling and FGD systems suffer erosion and corrosion from abrasive materials and high temperatures, requiring high-build ceramic repair materials and ceramic-filled coatings that restore eroded steelwork and extend equipment life.
Pipework Repair & Protection
Thin-wall and through-wall pipe defects, corrosion under insulation, and flange corrosion threaten costly hot work and shutdowns, requiring cold-cure bonding, ISO/ASME-compliant wrap systems, and peelable flange protection that eliminate the need for cut-and-weld repairs.
Linings for Chemical Containment Areas, Channels & Sumps
Bunds, channels, and sumps face constant exposure to aggressive chemicals, requiring brush- or spray-applied polymeric coatings that provide long-term chemical resistance and environmental protection.
Transformer Oil and SF6 Leaks
Aging transformers and electrical equipment develop oil and gas leaks at joints that create environmental risk, requiring cold-curing materials that bond to oily and wet surfaces to seal even live leaks in situ without hot work.
Common Asset Areas
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Pumps
Pumps suffer cracking, holing, and erosion-corrosion from continuous fluid handling, requiring cold-curing metal repair materials and efficiency-enhancing coatings that restore original profiles and improve output by up to 20% on refurbished units. Learn More →
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Heat Exchangers
Tube sheets, water boxes, and end covers suffer erosion-corrosion that reduces hydraulic efficiency in cooling water systems, requiring high-performance polymeric coatings for long-term corrosion protection. Learn More →
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Valves, Pipes, & Fittings
Thin-wall and through-wall pipe defects from external corrosion and corrosion under insulation threaten costly shutdowns, requiring wrap systems, cold plate bonding, and heat-activated CUI repair materials that eliminate hot work. Learn More →
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Solids Handling Machinery
Solids handling and FGD systems, along with conveyor belts, suffer erosion and corrosion from abrasive materials and high temperatures, requiring high-build ceramic repair materials and flexible elastomer repairs. Learn More →
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Tanks & Chemical Containment
Chemical bunds, channels, sumps, and SF6 gas containment systems face constant chemical exposure and leak risk, requiring brush- or spray-applied polymeric coatings for long-term chemical resistance. Learn More →
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Mechanical Power Transmission
Shafts, keyways, turbine runners, and wicket gates wear from continuous operation and cavitation damage, requiring in-situ repair and cavitation-resistant elastomer linings that reduce degradation and running costs. Learn More →
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Engines & Casings
Casings and other mechanical elements wear from continuous operation, requiring in-situ metal repair composites that avoid costly disassembly and replacement. Learn More →
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Gaskets, Seals and Shims
Flanged connections and machinery requiring precise alignment suffer corrosion and misalignment, requiring peelable flange protection systems and chocking/grouting compounds for reliable sealing and anchorage. Learn More →
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Floors
Facility floors face wear and safety concerns, requiring floor screeds and slip-resistant grip systems for long-term protection in high-traffic areas. Learn More →
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Roofs
Facility roofs are prone to leaks and weather damage, requiring liquid-applied waterproof roofing membranes for long-term protection. Learn More →
View All Asset Areas →
Power Generation Equipment We Repair & Protect
Specific assets we service across the power generation industry.
Equipment We Service
  • Pumps
  • Tube sheets
  • Water boxes
  • End covers
  • Cooling water systems
  • Turbine runners
  • Wicket gates
  • Solids handling equipment
  • FGD systems
  • Conveyor belts
  • Pipework
  • Flanged connections
  • Chemical bunds
  • Channels
  • Sumps
  • SF6 gas containment systems
  • Transformers
  • Shafts
  • Keyways
  • Casings
  • Floor screeds
  • Roofing membranes
Proven Track Record
Impeller Wear Before
The Problem
Impeller Wear

Erosion and cavitation had eaten into the impeller vanes, dropping head and efficiency while pushing power draw up.

  • Replacement (Parts & Labor)$108,000
  • Lead Time16–24 Wks
  • Performance GainNone — Same As Before
Hover for Belzona repair →
Rebuilt & Coated In Situ After — Belzona
The Solution
Rebuilt & Coated In Situ

Lost metal rebuilt with Belzona composite and the hydrophobic surfaces coated smooth — done on site, with no new impeller to wait for.

  • Cost Savings$88,500
  • Time to CoatOne day per Impeller
  • Electricity ConsumptionReduced by 19.9%
Recent inspections show no measurable impeller wear to date
Read the full case history →