Cold Water Intake Pipeline of Power Station at Prai, Pulau Pinang, Malaysia. Project: Cold Water Intake Pipeline Location: Prai Power Station at Prai, Pulau Pinang, Malaysia. Applicator Eastern Energy Services Sdn Bhd Date Of Application: July 2000 The Challenge: The internal of a 1.83m I.D., 500m length steel pipelines exhibits heavy barnacle and marine growth formation. The existing solvent type epoxy coating was completely exhausted. The barnacles had penetrated the epoxy coating to attach to the substrata (steel surface), thus causing heavy and pitted corrosion. Seawater enters the pipe and used as cooling water for the power plant thus causing it to corrode due to constant exposure to moisture and salt laden atmosphere. The original wall thickness of the pipe was reduced to almost 50% and replacement is inevitable. Recommended System: The recommendation was to cut/replace heavily corroded portions of the pipe, abrasive blast and apply epoxy coatings. This recommendation is quite expensive and Corro-Dur products were able to justify its use since it can rebuild the thickness on corroded and heavily pitted surfaces. The facility owner conducted trials with several products claiming tolerance to wet or damp surfaces before selecting the solvent free Corro-Dur products. Other features such as being environment friendly, 100% solid, high abrasion, greater abrasion resistance due to KEVLAR fibers, low water vapor permeability and chemical resistance are some of the plus factors why it was chosen among other protective coatings. The entire internal area was subjected to manual scraping/hi-pressure washing to remove thick barnacles and marine growth. Followed by abrasive air blasting to remove rust scales and other contaminants. Corro-Dur 561 was used to patch all pitch all pitted areas and smoothen corroded portions including weldments. Then Corro-Dur 258 was applied on the entire area and final coating with CeRam-Kote 99 at a total DFT of 700 to 1200 microns. This proved to be cheaper, high production rate and safe usage.