Restoring ACW Pump Rubber Joint with Belzona Composite Repair System
The Challenge
A major power plant in India encountered a critical maintenance challenge with one of its ACW pipeline components. The rubber expansion joint at the discharge side of the ACW pump had deteriorated severely. Constant exposure to extreme heat and environmental conditions had caused the rubber joint to crack, tear, and degrade significantly. The joint had developed multiple leak points, posing a threat to the operational safety and efficiency of the cooling system.
Conventional Solution:
The traditional approach would be to replace the rubber joint entirely — a process that is time-consuming, costly, and would require extended shutdowns, negatively impacting plant productivity.
Why Belzona?
Considering the downtime and cost constraints involved in replacing the rubber joint, the client turned to a reliable alternative — Belzona’s cold-applied composite repair system. This offered a non-intrusive, fast, and long-lasting solution to restore the joint’s structural integrity without replacement.
The Belzona Solution
Surface Preparation:
The rubber joint was first cleaned thoroughly to remove dust, debris, and loose rubber fragments to ensure proper adhesion of Belzona products.
Products Used:
- Belzona 2911 – Applied as a conditioner to promote adhesion on the rubber substrate
- Belzona 9341 – Reinforcement tape used to strengthen the repair
- Belzona 2211 (MP Hi-Build Elastomer) – A flexible, high-performance elastomer used to rebuild and seal the damaged rubber surface
Application Process:
The system was applied in accordance with the guidelines from the Belzona System Leaflet. The repair was carried out on-site with minimal equipment and no hot work, ensuring the safety of personnel and avoiding unnecessary operational disruptions.
The Outcome
✅ Rapid Turnaround – Repair was completed in a fraction of the time needed for part replacement
✅ Cost-Effective – No need to source and install a new rubber joint
✅ Durable & Flexible – The restored joint can now withstand thermal stress and vibration
✅ Extended Service Life – Increased the lifespan of the equipment with a proven, reliable Belzona solution
Thanks to the quick response and robust performance of Belzona’s elastomeric repair system, the power plant was able to avoid equipment replacement, minimize downtime, and ensure the long-term reliability of its cooling system. This case stands as a strong example of how Belzona empowers industries with innovative and efficient cold repair solutions.