When Sponge-Jet distributor SIM (Specialised Industrial Maintenance) arrived at a major power station in Perth, Australia, they found that the condensers had serious corrosion and coating deterioration. Deep inside the system, years of exposure to steam, heat, and chemical residues had taken their toll, causing the original coatings to fail. Although it couldn’t be seen from the outside, it was threatening the integrity of critical infrastructure.
With the plant scheduled for a six-week shutdown, the maintenance team took this opportunity to remove foulant/coatings and corrosion from the condenser, with the goal of extending the units' 
service life. However, it wasn’t a straightforward maintenance job.
The work was to take place within the condenser shell, as well as on the four corresponding lids. Only the interior shell surfaces were to be blasted, with the tube sheets themselves protected behind containment. The crew would be working inside tight, confined spaces, and maneuvering within the enclosed spaces with limited visibility.
Since the work was being performed both in confined spaces and near sensitive equipment, the facility needed a solution that would not allow the equipment to become exposed to dust, debris, or rebounding abrasives.
Due to project constraints, ordinary abrasive blasting methods, such as slag, were quickly ruled out. If these had been used, not only would they have caused lower visibility for the workers due to dust generation, but containment and air handling would have been more extensive to protect from damage to nearby sensitive equipment. Failure to control emissions could have created expensive delays for the plant coming back online.
Needing precision, control, and visibility, the team ultimately chose Sponge-Jet technology. Blasting with Sponge Media™ offered a low-dust, low-rebound solution well-suited for working in confined spaces. It allowed operators to maintain clear visibility while blasting, keeping workers safe during the process. Sponge Media could also be recycled onsite, reducing waste.
Further, ventilation had to be carefully managed. Instead of erecting containment surrounding the condenser and using an air handling system, they used exhaust fans with dust socks attached to the manholes, which provided ample protection from the low dust generation associated with the Sponge-Jet blasting process.
The condensers were then blasted to achieve an average surface profile of 75 microns (3 mils), with a cleanliness level of NACE No.2 / SSPC-SP-10, Near-White Metal Blast Cleaning. Any loose material and coatings were removed, and areas showing major pitting damage were repaired. Following the preparation, the condensers shells were coated with two applications of CeramAlloy™ CL+AC, a two-component, 100% solids, liquid polymer composite coating, which were applied at an average thickness of 300 microns (12 mils) per coat.
Ultimately, after blasting with Sponge Media, the condensers were left with a clean, properly profiled surface that allowed for new coatings to adhere correctly, ensuring long-term protection of these assets. With control, safety, and precision as the top priorities for this project, Sponge-Jet technology was the best solution.
