Project Overview
A power generation facility located in Victoria, Australia required specialised flexible rubber boots to seal and protect PIB duct connections between transformer equipment and rigid ducting. These connections demanded a flexible insulating barrier capable of accommodating movement, preventing moisture ingress, and maintaining electrical isolation in a harsh operating environment.
The geometry of each PIB connection varied slightly due to installation tolerances and duct alignment, meaning standard off-the-shelf components were not suitable. A fully customised fabricated rubber solution was required to ensure proper fit, sealing performance, and long-term reliability.
The Challenge
Varying PIB duct angles and alignment created complex sealing requirements between transformer and bus duct connections.
Connections between PIB ducting and transformers are exposed to a combination of mechanical movement, environmental exposure, and electrical insulation requirements. Without an appropriate flexible sealing solution, rigid interfaces can allow moisture ingress, contamination, and vibration transfer that may compromise equipment integrity and insulation performance.
The project was further complicated by the fact that each duct entered the transformer enclosure at a slightly different angle. This meant every boot required unique dimensions and geometry to achieve correct fitment and avoid installation stress or sealing gaps. The absence of suitable standard components increased the risk of extended downtime and installation delays.
Solution: Custom Fabricated Bromo-Butyl Rubber Boot
To address these challenges, Reglin supplied custom fabricated PIB boots manufactured from Butyline, a high-performance bromo-butyl rubber lining compound. The material was selected due to its excellent electrical insulating properties, extremely low permeability, and ability to remain flexible while providing a reliable environmental seal.
Each boot was individually designed and fabricated to suit the specific duct angle and dimensional requirements of the installation. The flexibility of the material allowed the boots to accommodate thermal movement and vibration while maintaining a consistent seal between PIB ducting and transformer connections.
Reglin coordinated the fabrication and supply to meet the project timeframe, ensuring the components were delivered quickly and ready for installation without modification.
Why Butyline Bromo-Butyl Rubber Was Selected for the Application
Butyline provided the combination of performance characteristics required for electrical infrastructure sealing applications. Its excellent moisture and gas impermeability helped prevent condensation and contamination within the PIB system, while its electrical insulation properties supported safe operation around high-voltage equipment. The material’s flexibility allowed it to conform to irregular geometries and accommodate movement without cracking or losing sealing performance. In addition, strong resistance to ozone, weathering, and environmental exposure ensured long service life in the power station environment.
Result
The fabricated boots were installed successfully across all PIB connections, with each component fitting precisely. The flexibility of the material simplified installation and eliminated stress at the connection points, while providing a reliable protective barrier against moisture and contamination.
The custom solution delivered immediate sealing performance and long-term confidence in the integrity of the PIB transformer interfaces, demonstrating the value of engineered fabricated rubber components where standard products cannot achieve the required fit or performance.
Reglin Capability in Custom Fabricated Rubber Components
This project highlights Reglin’s ability to deliver engineered fabricated rubber solutions for specialised infrastructure applications. By combining material selection expertise with custom fabrication capability, Reglin supports projects requiring flexible sealing, electrical insulation, and protection where installation conditions are unique and standard components are not viable