Tank Bottom Replacement
Addressing Severe Through Wall Failure in a Condensate Storage Tank
The Power Generating facility faced significant challenges with a condensate storage tank resting on a badly corroded concrete pad. Despite a previously installed repair using a protective coating, the tank had still experienced multiple leaks. A large crack through the tank floor and the coating system was discovered during inspection. Rather than replacing the tank floor entirely, the plant engineer chose a CFES carbon fiber composite repair solution that was not only a more cost-effective solution but offered the benefit of returning the tank to service with-in a 1-week schedule verse several weeks:
Inspection and Preparation
The team conducted a detailed inspection and prepared the surface for repair:
Surface Preparation:
Grit blasted the steel substrate to SSPC SP-10 Near White Metal finish, achieving a 3+ mil angular profile.
Material Selection:
A high-strength, aerospace-grade bi-directional carbon fiber system was selected for its exceptional durability and stiffness.
A permeation-resistant epoxy novolac topcoat was chosen to prevent osmotic blistering and ensure long-term protection.
Innovative Repair Methods
The repair process involved:
Carbon Fiber Application:
A three-layer bi-directional carbon fiber system was applied to form a structurally independent composite floor capable of withstanding continuous service up to 250°F.
Epoxy Novolac Topcoat:
A chemical-resistant epoxy novolac topcoat was installed to prevent water permeation through the composite lining, protecting against future damage.
Key Outcomes
Restoring Structural Integrity: The carbon fiber composite provided a structurally independent tank bottom, restoring the tank’s integrity and extending its operational life.
Preventing Future Failures: The permeation-resistant topcoat protected against osmotic blistering, a common failure mechanism in ultra-pure water storage systems.
Cost-Effective Solution: MATEP avoided the expense and downtime of a full tank floor replacement by opting for a durable composite repair that ensured long-term, maintenance-free service life.
