Fixing Leaking Pipes at Duke Energy Facilities to Prevent Coal Ash Contamination
The recent coal ash spill from a Duke Energy facility, which polluted over 70 miles of the Dan River with 40,000 tons of toxic coal ash, has raised serious concerns about the integrity of the company’s infrastructure. In response, Duke Energy is now conducting urgent inspections and developing repair plans across all 14 of its facilities, including both active and decommissioned sites. While initial assessments suggest that most systems are functioning as intended, several leaks have already been found in riser pipes and pipelines throughout the facilities.
The Eden facility, responsible for the major spill, isn’t the only one facing issues. The Weatherspoon Steam Electric Power Plant, though retired in 2011 and demolished in 2013, still has a 54-acre coal ash pond with a cracked riser pipe still in use. This steel-lined concrete riser is designed to draw clean water from the surface when water levels rise, allowing heavier sediments and ash to settle below. Although experts believe a large-scale leak like the one in Eden is unlikely at Weatherspoon, the crack still poses a risk of ash-laden water leaking into nearby rivers and tributaries. Coal ash contains dangerous substances such as mercury, lead, arsenic, and chromium, making any leakage a serious environmental threat.
Duke Energy has until July 20 to submit a detailed repair plan. If they fail to do so, they could face daily fines of up to $500. The crack in the Weatherspoon riser was discovered through a camera inspection, leading to further engineering evaluations to determine the best course of action. A similar issue was found at another plant, the Cape Fear Steam Electric Plant, where shifting earth caused a 40-foot crack in a coal ash dam. Although this issue has since been resolved, the Weatherspoon plant’s riser remains unaddressed.
Power plants like Duke Energy rely on complex water circulation systems to cool steam after it passes through turbines. These systems include critical components like riser pipes, which can corrode over time and eventually develop cracks or leaks. Corrosion is a common issue in these environments, especially when exposed to acidic or mineral-rich water.
In a case involving a power plant in the southwestern U.S., corroded riser pipes had developed significant cracks and were leaking. To address this, HJ3 used the CarbonSealâ„¢ system to reinforce the damaged sections. The process began with excavating the pipes and removing their concrete casings. The exposed steel was then cleaned to near-white metal standards and primed. Next, a high-modulus carbon-based paste was applied, followed by saturated CarbonSeal fabric. A protective topcoat was added to ensure durability against abrasion and UV exposure. Steel sleeves were installed at the base of the repair area, and new concrete casings were placed around the repaired sections. The client also requested aesthetic improvements, so the repaired risers were painted to match the surrounding structures.
Overall, all 22 steel risers were successfully reinforced within a tight timeframe. By repairing rather than replacing the pipes, the client saved an estimated $1 million per day that would have been lost due to plant downtime. Additionally, the project prevented the loss of over 127,000 gallons of water and 17,000 kWh of energy. It also reduced CO2 emissions by 3 tons and cut down on 2.5 tons of construction waste going to landfills.
If you're dealing with rusted or leaking riser pipes and want to explore effective repair solutions, consider reaching out to HJ3 for more information on their CarbonSealâ„¢ system. Their approach not only saves money but also helps protect the environment and extend the life of critical infrastructure.
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