Aggressive Corrosion Repair for Power Plants

Combating Aggressive Corrosion in Power Plants: Affordable and Effective Solutions

Corrosion is a growing concern in power plants, affecting both older and newer steel and reinforced concrete structures across the country. This issue poses a serious threat to infrastructure, especially when it comes to critical systems that keep power generation running smoothly. For example, American Electric Power faced severe corrosion just one year after installing a pollution scrubber at its Cardinal plant in Ohio—a system expected to last 25 years. The Electric Power Research Institute, supported by utility companies, has also documented similar corrosion problems nationwide. The results can be costly, ranging from unexpected plant shutdowns to expensive repairs that are ultimately passed on to consumers through higher electricity bills.

There are various methods available for repairing corrosion in power plants, each with different sizes, costs, and levels of complexity. Protective coatings are often used as a first line of defense against water and chemical damage. However, when structural reinforcement is needed beyond basic corrosion protection, power plants require fast, durable solutions to avoid the high cost of replacing entire components. This applies to all types of power plants, including geothermal facilities, which use the Earth's heat to generate electricity.

Take, for instance, a geothermal power plant on the West Coast, where aggressive corrosion had severely damaged the primary clarifier—a key part of the process. The structure showed signs of corrosion on its sidewalls, upper tank ring, and dome. Approximately 80% of the steel had been compromised, significantly weakening the tank’s integrity. Temperatures around 140°F on the sidewalls worsened the situation. Several areas required repair, including wall patches, the connection between the sidewall and dome roof, the dome itself, and a 36-inch overflow pipe.

The repair process involved abrasive blasting to remove the corroded layers, followed by the application of a high-modulus paste. CarbonSeal carbon fiber was then saturated and installed, and a chemical-resistant top coat was applied to ensure long-term protection against future corrosion.

HJ3’s CarbonSeal system successfully restored the necessary 20-psi hoop strength to the steel vessel during a scheduled shutdown, offering significant cost savings compared to replacing the entire clarifier unit. While aggressive corrosion affects not only power plants but also their customers, leading to millions in replacement costs, there are effective, long-term solutions available. HJ3’s CarbonSeal carbon fiber repair systems and durable chemical-resistant coatings provide reliable options for reinforcing steel or reinforced concrete structures. If you have a structure in need of repair and want to learn more about HJ3’s industrial solutions, contact our project managers today.

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