Maintaining a Power Plant with Humidity Control
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This document discusses corrosion in power plants and how maintaining proper humidity levels is important for preventing equipment damage and ensuring worker safety. Corrosion costs the US power industry over $23 billion annually and can account for up to 54% of total production costs. It causes 50-75% of downtime when pipes and boilers fail. The harsh and humid conditions inside power plants also pose heat risks to workers. Proper humidity control strategies like dehumidification can save 25-30% on corrosion-related costs and boost power output by 25-60%. Temporary humidity control is also crucial when power plants are shut down to prevent equipment damage from things like freezing or high humidity.
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Maintaining a Power Plant with Humidity Control
- 1. Copyright 2016 © POLYGON Infographic designed by Mad Fish Digital Power plant components are especially susceptible to corrosion, so removing moisture from the environment is critical. Costs of Corrosion 54% Corrosion-related repairs can account for up to of total production costs. Corrosion causes as much as 50-75% of a power plant’s downtime. When pipes and boilers fail, they pose a safety hazard to employees. 2007: A corroded boiler explodes, killing three New England plant workers. The harsh conditions inside a power plant can threaten equipment and employees alike. Environmental control solutions protect both - minimizing maintenance costs as well as safety risks. Maintaining a Power Plant with Humidity Control When power plants are shut down for hours, weeks, or even months at a time, environmental control becomes crucial in preserving equipment. Temporary dehumidification solutions can be implemented to keep the plant in working order while not being used. Boiler Tube Failure 1. Boiler Tube Failure 37% of power plants routinely fail to protect the boiler during layups. 2. Turbine Pitting or Cracking 6%Only protect the turbine. 50% of those who develop heat stroke die even with medical attention Types of Corrosion Increased downtime Heat Illness Risk Factors High temperature and humidity Indoor exposure to radiant heat Limited air movement Physical exertion Heavy personal protective clothing & equipment Worker Comfort Working in hot, poorly ventilated spaces takes its toll on employees at a power plant. Environmental control is critical for their safety. Preventing Corrosion Danger Zone 80°F When indoor temperatures reach without sufficient ventilation Work output decreases 40-50% Don’t Sweat it 98.6°F The body attempts to maintain a constant internal temperature of at all times Sweat evaporation—the mechanism the human body uses—stops entirely when relative humidity reaches 90% Heat Stroke Heat stroke causes at least 300 U.S. deaths per year —more than the combined deaths caused by: Hurricanes Lightning Tornadoes Floods Earthquakes Ideal Conditions OSHA recommends maintaining an indoor climate of: 68-76ºF20-60% humidity 25-50 cubic ft. of airflow Corrosion costs the U.S. power industry more than $23 billion per year in: Generators: Turbines: Oil-fired boilers: 35% Maintain humidity levels of or lower. Dehumidify air that passes through turbines to reduce relative humidity. 20%Dry the air to relative humidity after shutting down a boiler. How Environmental Control Helps - Corrosion prevention strategies can save 25-30% of corrosion related costs. A controlled environment boosts power output by at least 25%—and up to 60% in some climates. 30% up to 60% up to Humidity Control Strategies SOURCES: www.cdc.gov - www.ccohs.ca - ohsonline.com - www.polygongroup.com - www.eaas-journal.org - www.nationalboard.org www.powermag.com - www.insights.globalspec.com - www.ipautah.com 98.6 Top Layup Hazards Localized heat sources prevent water from freezing within pipes. Layups can be hard on a power plant. Temporary climate control solutions help protect against: Freezing Water High Humidity Temperature Changes Controlling relative humidity shields against corrosion damage. Dehumidification helps mitigate changes in ambient temperature. Layup Benefits 23billion 1 2 3 Oxide: Galvanic: When metal is exposed to water and its chemical composition changes When two dissimilar metals make contact and the electrical reaction accelerates corrosion When environmental factors wear away a surface’s protective coating Erosion: