Intense corrosion poses a major challenge for power plants, impacting both old and new steel and reinforced concrete structures across the nation. This corrosive threat becomes particularly concerning when it affects critical infrastructure. Take, for instance, American Electric Power, which faced alarming corrosion within a year of installing a pollution scrubber at its Cardinal plant in Ohio. The scrubber, designed to last 25 years, began showing signs of deterioration sooner than expected. Similarly, the Electric Power Research Institute, funded by utility companies, has documented comparable corrosion issues nationwide. The ramifications are severe, ranging from possible plant shutdowns to exorbitant repair costs that could end up being passed onto consumers through higher electricity bills.

Power plant corrosion repair options vary in scale, cost, and complexity. Protective coatings act as barriers against water and chemical-induced corrosion in steel and reinforced concrete. However, when structural strengthening becomes necessary beyond just preventing corrosion, power plants look for swift, long-term solutions to avoid costly infrastructure replacements. This applies to all types of power plants, including geothermal facilities that use Earth's heat to generate electricity.

In one such geothermal power plant on the west coast, severe corrosion had severely damaged the primary clarifier, a vital component in the operation. The clarifier showed corrosion on its walls, upper tank ring, and dome. About 80% of the steel had deteriorated, greatly weakening the tank's structural integrity. The walls were exposed to temperatures nearing 140°F, worsening the corrosion problem. Several areas needed attention, including a wall patch, the connection between the tank's sidewall and dome roof, the dome roof itself, and a 36-inch diameter overflow pipe.

The repair process entailed sandblasting to eliminate the corroded layers of steel, followed by applying a high-modulus paste. CarbonSeal carbon fiber was then saturated and installed, topped off with a chemical-resistant coating to ensure lasting protection against future corrosion.

HJ3’s CarbonSeal repair system successfully achieved the required 20-psi hoop strengthening to the steel vessel during the planned maintenance downtime, saving considerable costs compared to replacing the clarifier unit entirely. Aggressive corrosion remains a persistent issue for power plants and their users, leading to millions in infrastructure replacement expenses. Fortunately, effective long-term solutions are available, such as HJ3’s CarbonSeal carbon fiber repair systems and robust chemical-resistant coatings. If your steel or reinforced concrete structure requires reinforcement, and you're interested in exploring HJ3’s CarbonSeal industrial repair systems, reach out to our project managers at [insert contact information].

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