Comprehensive Rehabilitation of HPFF Electrical Feeder Systems
Innovating Solutions for Aging High-Pressure Systems
In Boston, a High-Pressure Fluid Filled (HPFF) Electrical Feeder Systems, showed signs of severe corrosion and wear. These aging yet irreplaceable systems required a hybrid repair strategy to address the diverse conditions encountered while maintaining operational integrity.
Experience always overcomes challenges
CFES addressed the repair needs by overcoming two critical challenges:
Implemented a hybrid repair strategy combining wax tape, epoxy coatings, and CFRP systems to match corrosion severity.
Ensured seamless integration across diverse system configurations, transitions, and pressure requirements.
Inspection and Preparation
Detailed inspections and meticulous preparations set the stage for a reliable repair:
Surface Preparation:
Removed loose debris, scale, and moisture to prepare for CFRP and wax taping application.
Grit-blasted heavily corroded areas to achieve a SSPC SP-10 near-white metal finish for CFRP termination points.
Material Selection:
Applied profiling mastic for contoured transitions and gaps.
Selected CFRP for severe corrosion zones and epoxy coatings for moderate corrosion areas. Ensured removal of debris and coatings and grit blasted to create a clean bonding surface.
Innovative Repair Methods
CFES employed a hybrid system tailored to the specific needs of HPFF systems:
Wax Tape Application:
Installed wax tapes for areas with mild to no corrosion, ensuring proper adhesion and sealing with overlaps and air bubble elimination.
CFRP System Installation:
Applied bidirectional CFRP over severe corrosion zones, adhering to prepared surfaces and existing materials.
Created clam-shell transitional wedges to address stress risers and ensure smooth transitions.
Protective Coatings:
Applied immersion-grade epoxy coatings for enhanced durability and corrosion resistance.
Key Outcomes
Extended System Life: The hybrid repair method reinforced feeder systems, delaying replacement needs.
Seamless Operation: Repairs were executed without disrupting service, maintaining reliability.
Cost Savings: By avoiding full system replacement, CFES delivered significant financial benefits.
Design Versatility: Solutions adapted to varying configurations and corrosion conditions
