A UK wind farm in was faced with major problems in some of their 27 offshore turbines. Each turbine has between one and three hangoff flanges, most of which are not gas tight. Changes in tide lead to dangerous gases seeping from the seabed and into the chambers. A temporary sealant had been applied but could not effectively seal the leaks and a permanent solution was required.

When choosing a repair material, the site manager had to bear in mind restricted access affecting surface preparation as well as high humidity, eliminating the potential use of polyurethanes. After careful consideration, they settled on the use of a Belzona surface-tolerant leak sealing system. Belzona Technosol, Belzona’s UK application division, was signed on to carry out the repairs with the application completed in the first quarter of 2014.

Charlie Farrant Belzona’s Application Technician, who travelled offshore to complete the job, described the repair process: “First we removed the temporary sealant, wire brushed and degreased the surface. We then packed the joints, cap bolts and nuts with a Belzona composite, also covering the edges to fully encapsulate the flange. Two coats of the coating grade material were applied onto flange tops and bottoms to ensure lasting protection and to eliminate any risk of leaks.”

After more than a year in service, the repair is performing well with no reported leaks or damage to the flanges. The use of a surface-tolerant composite and coating ensured that the repair could be carried out quickly regardless of surface moisture or contamination as these materials bond exceptionally well to oily or greasy surfaces and even underwater.   

About Belzona:

• Established in 1952, Belzona has pioneered innovative polymer technology that has revolutionized industrial repair and maintenance procedures.

• Belzona is a leading company in the design and manufacture of polymer repair composites and industrial protective coatings for the repair, protection and improvement of machinery, equipment, buildings and structures. 

• At Harrogate, the full Belzona product range is manufactured to stringent quality and environmental control guidelines complying with the requirements of ISO 9001:2008 and ISO 14001:2004.

• Belzona has over 140 Distributors in more than 120 countries ensuring not only the availability of Belzona materials, but also specification support, project management, application and supervision services. Distributorships and their teams are supported by Belzona Corporate offices in Europe, North America and Asia.

For more information about Belzona products and systems visit www.belzona.com