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Econo Seal announced the completion of a 2,400 MW river intake for a local power plant. Project details are as follows:The Power Plant operates a warm water discharge pipe in the Missouri River at the intake structure in order to prevent ice buildup on trash racks and to warm water entering the condenser during cold weather. The pipe is approximately 165' in length, ranges in diameter from 6'-6" at the center to 4' at each end and is fed from the plant circ water system. After the original installation, the plant added a 24" discharge line on the upstream side of the warming line to push river debris off the trash racks. The piping has outlet holes on the bottom where warmed water is discharged into the river.
The Problem:
The pipe is typically fully immersed in the river but when river levels are low can be fully exposed. Over its service life, the pipe has suffered significant corrosion both externally and internally. While particularly bad at welds, the entire pipe had lost substantial wall thickness and many welded areas were corroded completely through. The largest gap was between the warming line and the discharge pipe, where 37" of steel was completely corroded away.
The plant planned to replace the pipe with either carbon or stainless steel in the same configuration and solicited bids for this work. In discussing unrelated work with Econo Seal, their team suggested the plant consider using carbon fiber in lieu of replacement. While there was interest in this approach, there were concerns about whether a carbon fiber solution was viable and, more importantly, whether it could be considered replacement and thus capitalized.
Econo Seal worked with plant engineering, operations, and accounting to develop a "full replacement value" carbon fiber solution that could be largely completed with the pipe fully immersed in the river and that was determined to be an "abandoned in place" replacement by accounting and thus a capital project. The carbon fiber option was less than 1/3 the cost of steel replacement and offered a five-week installation schedule vs. 2+ years for a replacement.
The Solution:
Working with their engineering partners, Econo Seal developed a carbon fiber design that used the remaining host pipe as a mold for a full replacement value carbon fiber pipe that was designed to take all internal and external loading of the original carbon steel pipe. This included transitioning from an internal replacement in the warm water pipe to an external replacement of the discharge line without relying on the remaining host pipe for any structural capacity.
Because of schedule and capital spending issues, the plant awarded the contract in late November and needed the project finished by December 31. Econo Seal completed design work in 5 days while mobilizing the site and began work in early December.
As the project progressed, temperature forecasts indicated river temperatures dipping below 36 degrees F, which presented the possibility of "trickle ice" forming in the river and blocking the intake, potentially shutting down all four units. Econo Seal was requested to accelerate the schedule and, despite working in below freezing temperatures for the duration of the project, completed the work eight days ahead of the original schedule - just before river temperatures dipped below 36 and the plant was forced to put the warming line back in service.
The Results:
Econo Seal, which specializes in Industrial Composites and Coatings, used a permeation-resistant topcoat. Advantages of the composite solution included a much shorter schedule, lower plant impact, lower cost, and the construction materials not being subject to corrosion, thus providing a longer life-cycle with little or no maintenance.
Despite the severe schedule, weather issues and multiple safety complications related to open water, confined space, use of accelerants and large-scale heaters, Econo Seal completed the entire work scope in four weeks with a perfect safety record and within budget.
Learn more about Econo Seal’s Industrial Tank Repairs and discover their Storage Tank Solutions at econo-seal.com.
About Econo Seal:
Econo Seal specializes in industrial coatings for any size company looking for a full-service provider. Their reputation for reliability has paved their way to success across the Midwest when customers are looking for storage tank repair and maintenance. Econo Seal’s certified specialist provides their customers with the quality and dependability they have grown to expect.
Contact Info:
Name: Rob Lawton
Email: Send Email
Organization: Econo Seal
Address: 11137 C South Towne Square St. Louis, MO 63123
Phone: 314-846-6657
Website: https://econo-seal.com
Release ID: 295796
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