KHIA headerKnow-How in Action

VOL XXVII, NO 64, ELITE

Belzona® Repairs Broken Hydro Electric Turbine Runner

 
 

Industry:

Power (POWR)

 
 

Application:

Centrifugal Pumps (CEP)

 
 

Customer Location:

Hydro Electric Plant, USA

 
 

Application Date:

May, 2007

 
 

Application Situation:

Wicket gate came loose and fell into turbine breaking three blades on runner.

 
 

Problem:

Loss of balance and horsepower.

 
 

Products:

Belzona® 1311 (Ceramic R-Metal)
Belzona® 1321 (Ceramic S-Metal)
Belzona® 1341 (Supermetalglide)

 

Substrate:

Cast steel

 
 

Application Method:

Application was carried out in accordance with the Belzona Know-How System Leaflets CEP-1 & CEP-3. Expanded metal was tack welded in place before rebuilding with Belzona® 1311. Complete runner was coated with Belzona® 1311 and Belzona® 1341 was applied on top to improve fluid flow efficiency.

 
 

Belzona Facts:

The efficiency gain was so profound, that the customer was able to reduce the water setting from 70% to 62% without changing the power output from the runner, maintaining the 500 kW output. Using less water, the water behind the dam lasts longer, keeps the turbine running longer, resulting in increased revenue across a year. Belzona solution cost 9.2% of the conventional replacement by repairing the turbine instead of tearing it down and sending it out to be repaired. While the conventional repair would take 10 weeks of downtime, Belzona refurbishment took 2 weeks. The customer´s payback period on this repair was 3 months. Three years later and the turbines still have good horsepower with the runner blades still intact.

 
 

Photographs Description

Broken runner blade Expanded metal tack welded Blades rebuilt with Belzona® 1311 Completed application after coating runner

 
Case study pic one

 

 
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 Case study pic four

 

 
 
For more information about Belzona visit: www.belzona.com