About Project
The Circulating Water System (CWS) had one primary purpose: remove waste heat from the turbine exhaust steam by supplying large quantities of Hudson River water through the main condenser. The Three Piping System Trains of the CWS had lost approximately 80% of the original thickness of their internal protective coating. And the remaining 20% coating was not functional due to its extensive deterioration (primarily due to 40+ years of service, corrosion and high flow fluid) which contributed to various localized and complete thru wall perforations on the steel piping. Furthermore, the leaks generated loss of Cooling Capability to Condenser and Turbine Vacuum Efficiency; and the leaking high water cavitation flows created sink holes under Turbine Building.
Each pipeline carried 140,000 GPM (530,000 Liters / Minute), and the pressure was 35 Psi (0.24 MPa). The Indian Point NPP unit was rated for about 1,020 Megawatt-Hour of electricity.
Services Provided
Provided Project Integrator, Project Management, Construction Management, Engineering Consulting including Inspections.
Engineered Scope of Work Activities Summary:
- Surface Preparation: Abrasive & High Pressure Water
- Application of Engineered Composite FRP System: Warren Epoxy and Robust Fiberglass Fabric
- Quality Control Testing
Result
Final Engineered Composite FRP System Solution Conclusions (i.e. Warren Epoxy and Fiberglass Fiber):
The rapid cure composite system provided cost effective quality repairs, minimum piping system down time of one 8-hour shift to perform composite repair, and with no safety issues. These types of nuclear power plants typically suffer financial losses of over 1 million dollars per day when they have a shutdown. Therefore, the project had no room for error. Project Team’s swift execution of this turnkey Mission Critical Project was a total success. Furthermore, after 5 years of systems operation, the client informed MADERO that the successful repairs were in excellent condition.
