Condenser Inlet Chamber Repair
Addressing Severe Leaks in a Critical Water Line
The New England based Generating Station faced persistent issues with leaks at the joint between the condenser inlet chamber and the pump housing. This critical component of the circulating water line suffered from severe corrosion, with up to an inch of concrete missing at the junction. Previous attempts using caulking materials provided only temporary solutions. PSEG sought a long-term fix to restore the integrity of this critical infrastructure.
Experience always overcomes challenges
This repair project presented unique challenges, including:
How can a durable seal be achieved in a moisture-laden, porous concrete substrate during a limited plant outage?
What materials can effectively rebuild and protect a severely degraded concrete structure to prevent future leaks and erosion?
Inspection and Preparation
The team prepared the surface for repair and ensured a proper seal:
Surface Preparation:
Grit blasted the concrete substrate to ICRI CSP-4 standards to remove contaminants and create a surface profile suitable for bonding.
Material Selection:
Ceramic Epoxy Repair Putty MT: Chosen for its moisture tolerance and ability to create a durable, immersion-grade seal.
100% Solids Immersion Grade Epoxy: Selected for its resistance to corrosion and erosion in immersion-grade environments.
Innovative Repair Methods
The repair process involved:
Sealing the Junction:
The Ceramic Epoxy Repair Putty MT was applied using a caulking gun to seal the joint between the pipe and the inlet chamber.
Concrete Rebuild:
A second layer of the repair putty was applied to rebuild the missing concrete and create a uniform substrate.
Surface Coating:
A scratch coat of the Ceramic Epoxy Repair Putty was applied to fill bug holes and smooth the surface.
Two coats of 100% Solids Immersion Grade Epoxy were applied to protect the substrate from future corrosion and erosion.
Key Outcomes
Eliminating Leaks: The repair completely sealed the junction, resolving all leaks and restoring the structural integrity of the inlet chamber.
Long-Term Protection: The 100% Solids Immersion Grade Epoxy lining provided a durable barrier, preventing further degradation of the concrete substrate.
Efficient Execution: The repair was completed within a tight plant outage window, ensuring minimal disruption to operations while delivering a long-term maintenance free solution.
