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Resimac Solutions: Part 2 – Repair of Rotating Components in Hydropower Applications

Resimac Solutions: Part 2 - Repair of Rotating Components in Hydropower Applications
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Resimac Solutions: Part 2 – Repair of Rotating Components in Hydropower Applications

July 25, 2024
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In our previous blog post, we discussed the protection of stationary components in hydropower systems against erosion and corrosion. Today, in the second part of our two-part series, we focus on the repair and protection of rotating components, such as wicket gates, Kaplan blades, Francis runners, and runner hubs. These components are critical to the efficient operation of hydropower turbines but are often subjected to severe cavitation and corrosion. Through detailed case studies, we will explore how Resimac’s advanced repair materials can restore and protect these vital parts. 

Cavitation and corrosion are significant challenges for rotating components in hydropower systems.

Cavitation and corrosion are significant challenges for rotating components in hydropower systems. Cavitation occurs when vapor bubbles form in the liquid flow, leading to implosive force that erodes the material surface. Corrosion, on the other hand, results from chemical reactions between metal surfaces and water or other environmental elements, causing gradual degradation. Both processes can severely damage turbine components, reducing their efficiency and lifespan. 

To illustrate the practical applications and benefits of Resimac products in hydropower systems

To illustrate the practical applications and benefits of Resimac products in hydropower systems, let’s dive into three specific case examples where these advanced coatings and repair solutions have made a significant impact: 

Case #1 – Kaplan Turbine Blades – Cavitation Repair

Cavitation Repair
  • Situation: During routine maintenance of a Chinese hydro-power station, heavy cavitation damage was recorded on the Kaplan turbine blades, particularly on the leading edges and the root of the blade near the hub connections. 
  • Solution: Prepare the substrate and rebuild with Resimetal 101 Metal Repair Paste. Protect with Resichem 209 EIP PU. 
  • Application Details: Blades abrasive grit blasted to SA2.5 with a 75-micron angular profile. Cavitation damaged sections rebuilt with 101 Paste using a plastic applicator. After a 4-hour cure, repaired sections machined to a flush finish. Following an overnight cure, blades fully coated with two applications of 209 EIP PU, applied by brush to a nominal total dry film thickness of 750 microns. 

Case #2 – Kaplan Turbine Blades – Corrosion & Wear Repair

Kaplan Turbine Blades-Corrosion & Wear Repair
  • Situation: Leading edges of turbine blades showing signs of corrosion and wear damage. 
  • Solution: Replace lost steelwork and protect with 203 Superflow Ceramic Fluid. 
  • Application Details: Blades abrasive blast cleaned to SA2.5 with a 75-micron profile. Pitted sections rebuilt with 201 Ceramic Repair Paste. Blades coated by brush with 203 Superflow Ceramic Fluid, applied in two coats to a nominal total dry film thickness of 500 microns. 

Case #3 – Francis Runners and Kaplan Runner Hubs – Pitting Repair

Kaplan Turbine Blades
  • Situation: Internal turbine components, including Francis runners and runner hubs, suffering from pitting and requiring refurbishment. 
  • Solution: Prepare the surface and fill pitted sections with Resimetal 203 Superflow. Protect with additional coating. 
  • Application Details: Steel substrate abrasive blast cleaned to SA2.5 with a 75-micron profile. Pitted sections filled with 203 Superflow using a plastic applicator. Once cured, 203 Superflow applied by brush to the entire steel substrate in two coats to a nominal total dry film thickness of 500 microns. 

Using Resimac’s protective coatings and repair solutions offers numerous benefits for hydropower customers: 

Enhanced Durability
Extends the lifespan of components by protecting against erosion and corrosion.
Cost Efficiency
Reduces maintenance costs and operational downtime by minimizing the frequency of repairs and replacements.
Improved Performance
Maintains the efficiency and reliability of hydropower systems by ensuring the integrity of critical components.

Repairing rotating components in hydropower systems is essential for maintaining operational efficiency and extending the lifespan of critical equipment. Resimac’s advanced repair materials provide effective solutions for addressing cavitation and corrosion damage, ensuring that these components remain in excellent condition. 

ask an expert from Millstream engineering

For expert assistance in selecting the right Resimac grade for your specific application, contact Millstream Engineering today. Our team is ready to help you enhance the durability, cost-efficiency, and performance of your hydropower systems. 

technical assistance contact millstream engineering

Stay tuned for future blog posts, where we will dig deeper into the technical specifications and benefits of Resimac’s wide range of product grades. We will share detailed case studies, application-specific examples, and comprehensive content that highlights how our innovative solutions can address your unique operational challenges. 

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