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Condenser Water Box

OVERVIEW:    This power generation client has approached Chemcote to protect multiple condenser water box units.

The Chem-tect system has regularly been applied to the Mild Steel water boxes, tube sheets, and copper alloy combinations to prevent deterioration from sea water corrosion.

INDUSTRY

ENVIRONMENT

60-80°C, sea water

SUBSTRATE

Mild Steel water boxes & mild steel tube sheet with a copper alloy combination tube

CHALLENGE

Tube sheets were corroded due to a galvanic reaction between dissimilar metals. These were treated on site by scaffolding and encapsulation to prevent dust in the station. A two week outage allowed time for removal of the condenser water box units from site, fabrication repairs to corroded areas and machining of rebates prior to deliver to our workshop. There was a large amount of work to be completed within a tight time frame.

SOLUTION

These units were treated on site by scaffolding and encapsulation to prevent dust in the station. Work was carried out around the clock during the two-week outage to remove the condenser water box units from site, carry out fabrication repairs to corroded areas and machine of rebates to get them back into service by the deadline.

SCOPE

Work commenced on a round the clock basis due to the required deadline

Abrasive Blast to AS 1627

Application of primer to all surfaces

Pitfill all corroded areas and reinforce using composite materials i.e. fibreglass

Application of RB 332 in 3 coats

Carry out QA to ensure coating longevity

Application of RC 500 to prevent marine growth

OUTCOME

This client has become one of our regular customers particularly for its cooling water systems. Chemcote has now conducted numerous jobs for this client, including multiple condenser water box units. During a routine inspection, it was noted that another unit with the same coating showed no signs of deterioration.

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