High-Pressure Electrical Feeder Repair

Ensuring Reliability of High-Voltage Systems

During routine inspections, critical high-pressure fluid-filled electrical feeders in Boston were found to be below the minimum wall allowance, jeopardizing their operational reliability. Immediate intervention was necessary to restore their integrity while ensuring uninterrupted service during repairs.

Experience always overcomes challenges

CFES addressed the repair needs by overcoming two critical challenges:

1. Repairs had to meet rigorous safety standards for high-pressure systems.

2. Work was performed while the units remained online, requiring precise execution.

Inspection and Preparation

CFES implemented a comprehensive approach to inspection and preparation:

• Damage Assessment: 

  • Identified sections of feeders with wall thickness below the acceptable threshold.

• Surface Preparation:

  • Grit blast cleaned and prepped feeder surfaces for repair.

  • Ensured removal of debris and coatings to create a clean bonding surface.

Innovative Repair Methods

Advanced materials and techniques were employed to ensure reliable and durable repairs:

• CFRP System Application:

  • CFES Style 1266 Carbon Fiber Fabric along with CFES HP Saturant was utilized with an anti-corrosion wraps were applied to reinforce the feeders, providing structural integrity and corrosion resistance.

  • The CFES CFRP refurbishment system was rated up to 1,000 psi and installed in accordance with ASME PCC-2 standards.

• Terminal Sealing:

  • Terminal ends were sealed with specialized tape to ensure containment.

  • An immersion-grade epoxy topcoat was applied to protect the repair area from environmental and operational wear.

Key Outcomes

Restored Integrity: The feeders’ wall thickness was restored, ensuring safe operation under high pressure.

Continuous Operations: Repairs were executed without disrupting service, maintaining system reliability.

Cost Savings: The innovative CFRP system eliminated the need for costly and time-consuming barrel replacements.

Enhanced Durability: The repair provided long-term resilience, Long-term protection was achieved through the anti-corrosion wrap and the CFES S-epoxy topcoat.