INDUSTRIAL CASE HISTORIES
JOB # CLIENT UNIT REPAIR
I-1542 BAPCO Multi-Stage Flash Evaporators Shields
I-1562 LG Chemical - Yeosu Plant Hiboil Column Vent Chiller Shields
I-1569 Methanex New Zealand Ltd. Steam Condenser Liners
I-1571 Arco Chemical Reboiler Shields
I-1576 Norske Skog Parenco Main Condenser Shields
I-1642 Linde, Inc./BOC Gases CO2 Gas Coolers Shields
I-2009 Dow Chemical Caustic Scrubber Shields
I-2012 Chemtrade Logistics Sulfuric Acid Heat Exchanger Shields
I-2519 Pfizer Inc. High Pressure Feedwater Heater Shields
I-2033 Arkema, Inc. Refrigeration Condensers Liners
I-3530 Vulcan Chemicals HCI Stripper Coolers Shields
I-3553 WEB – Aruba Aquachem No. 6 Distiller Shields
I-4534 Chevron Products Co. S.W.S.O.C. Shields
I-4539 E.I. duPont de Nemours &Co. Various Jet Condensers Shields
I-4620 Dow Chemicals – Benelux Vertical Caustic Heat Exchanger Shields
I-4633 Chevron Phillips Chemical Verticle Effluent Exchanger Shields
I-5645 Bayer Corporation Neutralization Condenser Shields
I-5557 Stora Enso North America Vertical Gas Process Exchanger Shields
I-6076 ICI Chemicals Analine Reboiler Shields
I-6588 United States Navy – Saipan Main Condensers Shields
I-6602 PCS Nitrogen Trinidad CO2 Stripper Ejector Steam Generator Shields
I-7563 Hitachi Zosen – Maizuru Waste Heat Boilers Shields
I-8014 ICI Chemicals Vertical Caustic Heat Exchanger Shields
I-8073 Zeneca (BASF) 1st Stage Concentrator (Vertical) Shields
I-8079 Pt. Aceh Asean Fertilizer Gas Reboiler Shields
I-8154 Kemira Ince, Ltd. Vertical Gas Heat Exchanger Shields
I-8179 PT Badak Fin-Fan Coolers Shields
I-8190 ICI Chemicals C-702 Vacuum Condenser Liners
I-8248 Boise Cascade–Cianbro Corp Black Liquor Condenser Shields
I-8253 Inland Paperboard Vertical Surface Steam Condenser Shields
I-8556 Tonen Chemical Corp. Surface Condenser Liners
I-9505 DuPont Dordrecht Formaldehyde Exchanger Shields
I-9568 Invista – Sabine River Works Cooler Condenser Liners
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CASE HISTORY
NO. I-1542
JUNE `08 / MARCH `09
CLIENT: BAPCO
Desalination Plant
Bahrain
UNIT: Multi Stage Flash Evaporators (2)
Titanium Grade 2 tubes, 756 per unit
¾” O.D. x 22 BWG x 69’ long
PROBLEM: Collapsing of inlet and outlet tube ends due to High
Pressure water jetting.
SOLUTION: Tube ends had to be opened using tapered rods. A total of
3,024 CTI Shields made of Grade 2 Titanium, .020” wall x
12” long installed via hybrid expansion into all inlet and
outlet tube ends.
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CASE HISTORY
NO. I-1562
AUGUST 2007
CLIENT: LG Chemical
Yeosu Plant
Yeosu City, South Korea
UNIT: Hiboil Column Vent Chiller
300 Tubes, Alloy C-276
¾” O.D. x 18 BWG x 3 meters long
PROBLEM: Inlet-end erosion/corrosion due to EDC.
SOLUTION: Installation of 300 CTI Shields into the inlet tube ends,
performed by CTI Korea. Shields were made of Alloy C-276,
150mm / 6” long and mechanically expanded at each end.
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CASE HISTORY
NO. I-1569
NOVEMBER 2007
CLIENT: Methanex New Zealand Ltd.
Waitara, Taranaki New Zealand
UNIT: E-202 Steam Condenser
564 tubes, Admiralty Brass material
¾” O.D. x 18 BWG x 18’10” long
PROBLEM: Full-length tube I.D. pitting resulting in poor reliability.
SOLUTION: Installation of CTI Full Length Liners™ into all condenser
tubes. Liners were made of Admiralty Brass material with a
0.028” wall thickness.
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CASE HISTORY
NO. I-1571
JULY, 1998
CLIENT: Arco Chemical
Channelview, Texas
UNIT: Reboiler
1" O.D. x 16 BWG U-tubes
Type 304 Stainless Steel
PROBLEM: Stress corrosion cracking due to
over-rolling of existing tubes, located
immediately beyond 7" tubesheet
SOLUTION: Installation of 1276 CTI Shield/Seals
into inlet and outlet tube ends. Shields
were fabricated from Type 316L Stainless
Steel, .022" wall thickness x 10" long.
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CASE HISTORY
NO. I-1576
OCTOBER 2007
CLIENT: Norske Skog Parenco Paper Mill
Renkum, Holland
UNIT: Main Condenser - Stork
6,010 Tubes, Aluminum Brass
22mm O.D. x 1mm wall x 4300mm long
PROBLEM: Tube erosion and cracking of inlet and outlet tube ends
(reverse flow condenser). Depth of erosion extends to
150mm / 6”. Cracking is evident just beyond 30mm
tubesheet. Previous attempts to repair tubes by epoxy
coating failed.
SOLUTION: Installation of 12,020 CTI Shields into inlet and outlet tube
ends. This was preceeded by the removal of tube plugs and
epoxy coating. Shields were made of 70/30 CuNi, 200mm/
8” long and were mechanically expanded at each end.
*See Before/After Photos Below
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BEFORE
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AFTER
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CASE HISTORY
NO. I-1642
FEBRUARY 2008
CLIENT: Linde, Inc. / BOC Gases
Beaumont CO2 Plant
Beaumont, TX
UNIT: CO2 Gas Coolers (3)
240 Tubes/Unit, Carbon Steel
1¼” O.D. x 18 BWG x 40’ long
PROBLEM: Stress Corrosion Cracking attacking tubes from O.D. to I.D. in
the first 3’ from inlet tubesheet.
SOLUTION: Installation of 720 CTI Shield/Seals constructed from
Duplex 2205 material, using CTI’s hybrid expansion
method. Shields were sized (4’ long x .028” wall) and
material was chosen to combat and seal existing tube
corrosion issues.
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CASE HISTORY
NO. I-2009
SEPTEMBER, 1989
CLIENT: Dow Chemical
FT. Saskatchewan
Canada
UNIT: Caustic Scrubber
1660 tubes, Nickel 200
2” O.D. x 16 BWG x 20’ long
PROBLEM: Corrosion/pitting in first 6”- 8” of the tube I.D.’s
SOLUTION: Installation of 1660 CTI Shield/Seals, fabricated
from Nickel 200, 0.062” wall thickness, in lengths
of 12” and 16”. Hybrid expansion was achieved
by hydraulically expanding the full length of the
Shield followed by mechanical expansion of the
first and last inch.
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CASE HISTORY
NO. I-2012
APRIL 2008
CLIENT: Chemtrade Logistics
Beaumont Plant
Beaumont, TX
UNIT: E-1A Sulfuric Acid Heat Exchanger
2,347 tubes, 304H material
2” O.D. x 11 BWG x 20’ long
Shell Side Tube Side
Operating Temp 932ºF 1116ºF
PROBLEM: Excessive inlet-end erosion resulting in hundreds of tubes
severing 360 degrees at top inlet tubesheet.
SOLUTION: Installation of 2,000 CTI Shield/Seals and collar pieces
constructed from 304SS – 14” long x .049” wall. Shield and
collar assembly was roller expanded at both the tubesheet and
Shield exit end. Service Life Extension enabled plant to
operate unit until replacement bundle could be manufactured.
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CASE HISTORY
NO. I-2519
MARCH, 1999
CLIENT: Pfizer Inc.
Groton, CT
UNIT: HP Feedwater Heater
322 tubes, 90/10 CuNi
3/4” O.D. x 16 BWG x 16’ long
Shell Side Tube Side
Design Pressures: 175 psi 1,000 psi
Design Temperatures: 450° F 400° F
PROBLEM: Tube O.D. damage from vibration at first
support sheet, 31” depth.
SOLUTION: Installation of 36” long Shield/Seals via hybrid
expansion. Shields were manufactured from
70/30 CuNi. Also installed 24 stabilizer rods.
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CASE HISTORY
NO. I-2033
APRIL 2008
CLIENT: Arkema, Inc.
Beaumont Plant
Beaumont, TX
UNITS: E-207 A&B Refrigeration Condensers (2)
202 Tubes Each, Carbon Steel SA179
1” O.D. x .109” MW x 38’ long
PROBLEM: Eddy Current Testing showed excessive erosion/corrosion
attacking tube I.D.’s, resulting in greater than 40% wall loss in
139 tubes.
SOLUTION: Installation of 139 thin-walled (.020”) CTI Full Length Tube
Liners™ manufactured from 304 SS. Liners were hydraulically
expanded full length followed by mechanical roller expansion
at both tubesheets through header plug holes. The first
installation was completed less than 4 weeks from initial
contact from the customer.
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CASE HISTORY
NO. I-3530
APRIL, 2000
CLIENT: Vulcan Chemicals
Wichita, Kansas
UNITS: HCI (Hydrochloric Acid) Stripper Coolers
1) EX33070 2) EX33071
248 tubes, Ni 200 590 tubes, Monel
1" O.D. x 14 BWG 1" O.D. x 14 BWG
PROBLEM: Inlet end erosion and tube-to-tubesheet joint leaks.
SOLUTION: Installation of CTI Shield/Seals (with collars)
mechanically expanded into three areas of the existing
tubes - 2 within the tubesheet and one at the deep end of
the Shield.
1) EX33070 - Shields fabricated from Ni-200 material,
0.020" wall thickness x 8" long.
2) EX33071 - Shields fabricated from Alloy 400 (Monel),
0.028" wall thickness x 8" long.
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CASE HISTORY
NO. I-3553
SEPTEMBER 2000
CLIENT: WEB - ARUBA
Aruba, N.A.
UNIT: Aquachem No. 6 Distiller
2202 tubes, 90/10 CuNi
5/8” O.D. x .036” min. wall
PROBLEM: Crevice corrosion of the inlet tube ends
due to under-rolling of parent tubes.
SOLUTION: Installation of 2202 CTI Shields made of
AL-6XN material into all inlet tube ends.
Shields were 6” long x 0.020” wall thickness
and mechanically expanded at each end. The
expansion at the tubesheet area was performed
so as to tighten the tube-to-tubesheet joints.
More than half of the plugged tubes were returned
to service and as of September, 2003 - three years
after installation - the unit had no reported failures.
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CASE HISTORY
NO. I-4534
APRIL, 2001
CLIENT: Chevron Products Co.
Salt Lake Refinery
Salt Lake City, Utah
UNITS: Sour Water Stripper Overhead Condenser
223 finned tubes, Carbon Steel
1½” O.D. x 12 BWG x 30' long
PROBLEM: Erosion / Corrosion for first four feet of inlet tube ends
due to ammonium disulfides.
SOLUTION: Installation of CTI Shield/Seals, made from 2205 Duplex
Stainless Steel. Shields were 5 feet long with 0.035" wall
thickness installed through header box holes and
mechanically roller expanded into the existing tubes.
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CASE HISTORY
NO I-4539
APRIL, 2001
CLIENT: E.I Dupont de Nemours and Co.
Victoria Plant
Victoria, Texas
UNIT: Concentrating Still Jet Condenser
Semi-Refined Filter Jet Condenser
Crude Crystallizer Primary Jet Condenser
Crude Crystallizer Secondary Jet Condenser
PROBLEM: Tubes suffering from Stress Corrosion Cracking.
SOLUTION: Installation of CTI Shield/Seals, Grade 2 Titanium,
0.022”/0.028” wall thickness x 12” long. Shields were
mechanically expanded for the first and last inch.
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CASE HISTORY
NO I-4620
SEPTEMBER, 2001
CLIENT: Dow Chemicals - Benelux
Terneuzen, Holland
UNIT: Vertical Caustic Heat Exchanger
296 Tubes, Inconel 600
32mm OD X 3.56mm wall thickness
PROBLEM: Eddy Current Testing revealed severe wall thinning
in all tubes, with 73 tubes identified as having problems
up to depths of 28”.
SOLUTION: Installed via mechanical expansion 296 CTI Shield/Seals
made of Alloy 600. Seventy Three (73) Shields were 31”
long in order to completely by-pass the depth of the existing
tube damage. The balance of the Shields were ten inches long.
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CASE HISTORY
NO. I-4633
SEPTEMBER, 2001
CLIENT: Chevron Phillips Chemical Company
St. James Facility,
St. James, LA
UNIT: TT 4202 Vertical Effluent Exchanger
4,185 tubes, 304H Stainless Steel
1½” O.D. x 16 BWG x 16’5” long
Shell Side Tube Side
Design Pressure 40 psi 25 psi
Design Temperature 1150º 1200º
PROBLEM: Intergranular corrosion for first 6”- 8” of tube O.D.'s
SOLUTION: Installation of 4,085 CTI Shield/Seals, 0.035" wall thickness x 12”long
made of 304H Stainless Steel. Shields were expanded hydraulically for
the full 12” then mechanically roller expanded for their first and last
inch.
*HI-LITE: CTI received a Purchase Order from Chevron Chemical on
Wednesday, Sept. 5. Material (and tooling) was secured,
air freighted to the CTI facility for manufacturing and air
freighted to the jobsite on Monday, September 10. CTI
crews mobilized to the jobsite on Sept 10, performed
mandatory safety training on Sept. 11. Work commenced
on an around-the-clock basis on Sept. 12 at 7:00 a.m. in
order to complete the job by 7:00 a.m., Sept. 15.
Attached is the response from our customer.
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CASE HISTORY
NO. I-5645
NOVEMBER 2002
CLIENT: Bayer Corporation
New Martinsville, WV
UNIT: Neutralization Condenser
147 tubes, Carbon Steel
1” O.D. x 14 BWG min. wall
PROBLEM: Inlet-end erosion/corrosion.
SOLUTION: Installation of 147 Shields, AL-6X Stainless Steel
material, 4” long. In an emergency situation, CTI
manufactured and shipped the Shields less than 24 hours
after receiving Purchase Order.
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CASE HISTORY
NO. I-5557
APRIL 2002
CLIENT: Stora Enso North America
Wisconsin Rapids Pulp Mill
Wisconsin Rapids, WI
UNIT: Vertical Gas Process Exchanger
258 tubes, 317SS
¾” O.D. x 18 BWG x 12’ long
Shell Side Tube Side
Operating Temp 850 Deg. F 850 Deg. F
Operating Press. 60 Psig. 60 Psig.
PROBLEM: Acidic build-up at inlet tube ends causing severe
erosion/corrosion and pitting 2-to-3 inches from
tubesheet.
SOLUTION: Installation of 258 CTI Shield/Seals constructed from
Alloy C-276 material using CTI’s hybrid expansion method.
Shields were sized (6” long X .020” wall) and material
was chosen to combat and seal existing tube corrosion issues.
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CASE HISTORY
NO. I-6076
JUNE, 1994
CLIENT: ICI Chemicals
Wilton Site
Middlesbrough, England
UNIT: Aniline Re-boiler (Vertical)
4,800 tubes, Carbon Steel SA214
1” O.D. x 14BWG x 10’ long
Design Pressures: Shell Side 300 PSI
Tube Side 45 PSI
Design Temperatures: Shell Side 440° F
Tube Side 420° F
PROBLEM: IRIS testing revealed tube I.D. corrosion and severe pitting in
first 18” of tubes. Only 20% (approximately 1,000) of the
tubes affected. New bundle scheduled for installation
within ten (10) months.
SOLUTION: Installation of 1,000 CTI Shield/Seals. Shields were 24” long
x .020” wall thickness made of Type 316 Stainless Steel.
Installed and mechanically expanded at tubesheet and discharge
end.
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CASE HISTORY
NO. C-6588
OCTOBER 2003
CLIENT: United States Navy
USS Saipan (LHA-2)
Norfolk Naval Shipyard
UNITS: No.’s 1 + 2 Main Condensers
13,074 tubes, Admiralty Brass
5/8” O.D. x 18 BWG
Condensers fitted with CTI Shields,
8”-10” long with epoxy coating on inlet
tubesheets.
PROBLEM: No problem. U.S. Navy wanted to ensure
reliability without having to retube condensers.
Preventive maintenance.
SOLUTION: Removal of existing inlet tubesheet coating,
removal of existing CTI Shields. Re-installed
new, 12” long CTI Shields made of 70/30 CuNi.
Epoxy coating applied to inlet tubesheets.
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CASE HISTORY
NO. I-6602
AUGUST 2003
CLIENT: PCS Nitrogen Trinidad
Pt. Lisas, Trinidad, W.I.
UNIT: CO2 Stripper Ejector Steam Generator
1,884 tubes, Type 304SS
¾” O.D. x 16 BWG x 24’ long
PROBLEM: Stress Corrosion Cracking (SCC) occurring just behind
4” tubesheet.
SOLUTION: As the ENTIRE plant was shutdown due to the failure of
this exchanger, CTI was required to respond on an
emergency basis. Within 6 days from receipt of Purchase
Order, CTI manufactured and installed 1,813 Shields
with two (2) technicians working on an around-the-clock
basis. Shields were manufactured from AL-6XN stock
material and mechanically installed into the inlet tube
ends. Unit was immediately pressure tested, put into
service and the plant returned to full production. All
unplugged, leaking tubes were recovered.
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CASE HISTORY
NO. I-7563
JULY 2004
CLIENT: Hitachi Zosen
Maizuru Works
Maizuru City, Kyoto, Japan
UNIT: Two (2) Waste Heat Boilers (New)
Per Unit: 926 tubes
2” O.D. x .180” min. wall
Carbon Steel A213 T11
Tube Side Shell Side
Operating Temperature 1922ºF 550ºF
Operating Pressures 407 PSI 1043 PSI
PROBLEM: Haldor Topsoe, a world leader in the design and construction of
vessels and heat exchangers, designed these units for the largest
methanol plant in the world (Qatar Gas being the end user).
Hitachi was selected as the manufacturer of the boilers and the
installation took place in Hitachi’s workshop in Maizuru City.
Due to the severe process, Haldor Topsoe expected problems on
the inlet ends of the tubes.
SOLUTION: CTI Shields were integrated into the design of the new Waste
Heat Boilers, using Alloy 601 material. The Shields had a
0.040” wall thickness and were 16” in length. Once installed
into the tubes, Shields were hydraulically expanded for their
full length using pressures of 15,000 - 16,000 psi. A
mechanical roller expansion then took place for the first and last
inch of the Shields.
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CASE HISTORY
NO. I-8014
JUNE, 1996
CLIENT: ICI Chemicals
Wilton Site
Middlesbrough, England
UNIT: Vertical Caustic Heat Exchanger
1,658 tubes, Alloy Nickel 200
35 mm O.D. x 1.6 mm wall x 8150 mm long
PROBLEM: NDT testing (IRIS) revealed severe erosion/corrosion in
first 4” of inlet (bottom) tube ends.
SOLUTION: Inlet tube ends were wire brushed clean. Collars required
due to severe tube erosion at tubesheet area. Installed
Shield/Seals (Nickel 200, 8” long x .026” wall thickness)
with collars,then mechanically expanded at
tubesheet and discharge end.
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CASE HISTORY
NO. I-8073
JULY, 1996
CLIENT: Zeneca (BASF)
Ellesmere Port, England
UNIT: 1st Stage Concentrator (Vertical)
27 tubes, Alloy Nickel 200 - Low Carbon
33.4 mm O.D. x 2.77 mm wall x 21’ long
Design Pressures: Shell Side 262 PSI
Tube Side 37 PSI
Design Temperatures: Shell Side 608° F
Tube Side 572° F
PROBLEM: Unit suffering inlet end erosion/corrosion due to
caustics.
SOLUTION: Installation of CTI Shield/Seals made of alloy Nickel 200,
6” long x .028” wall thickness, mechanically expanded at
the tubesheet and discharge end restored the damaged
tubes.
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CASE HISTORY
NO. S-8079
MARCH, 1996
CLIENT: Pt. Aceh Asean Fertilizer
Lhokseumawe, Indonesia
UNIT: Gas Reboiler
3/4” O.D. x 16 BWG, Type 304 Stainless Steel U-Bend tubes
Design Pressures: Shell Side 75 PSI
Tube Side 410 PSI
Design Temperatures: Shell Side 284° F
Tube Side 320° F
PROBLEM: Crevice corrosion of tubes at inside face of tubesheet -
1 1/2” depth. Unit also suffering from erosion of tube
O.D.’s from re-boiling of benfield solution. The damage
to the tube O.D.’s extended to the depth of the second
baffle plate (54”).
SOLUTION: Plugs were removed from 511 tubes followed by the installation
of
CTI Shield/Seals, 60” long x .020” wall thickness, made of
Type 316L Stainless Steel. An additional 572 Shields were
installed
into tubes condemned by eddy current examination. All
previously plugged tubes were returned to circulation.
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CASE HISTORY
NO. F-8154
SEPTEMBER, 1996
CLIENT: Kemira Ince, Ltd
Ince, England
UNIT: Vertical Gas Heat Exchanger H2311
1,019 tubes, Type 304L Stainless Steel
¾” O.D. x 14 BWG x 20’ long
PROBLEM: Failure of inlet (bottom) tube ends due to re-evaporation
of nitric acid. Tube leaks occurring through welds at
tube-to-tubesheet joints. Heavy corrosion in first 6” of
tubes with up to 80% tube wall loss beneath corrosion.
SOLUTION: Inlet tube I.D.’s were cleaned with custom tapered reamers
to remove existing scale. Because of the severity of tube
wall loss, collars were required. Installed Shield/Seals
(Type 304L Stainless Steel, 8” long x .024” wall thickness)
and collars, then mechanically expanded at tube-sheet and
discharge end.
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CASE HISTORY
NO. S-8179
SEPTEMBER 1996
CLIENT: PT. Badak Natural Gas Liquification Company
Kalimantan, Indonesia
UNIT: Fin-Fan Coolers - 24 units
264 tubes each, 6,336 Total, Carbon Steel SA214
1” O.D. x 12 BWG Finned tubes
Header box welded to tubesheet
PROBLEM: Unit experiencing leaks from inlet end erosion.
SOLUTION: Tube ends were trimmed flush to tube sheet. Tube I.D.’s
were reamed to remove existing scale, Shield/Seals installed
(Type 316 Stainless Steel, .020” wall x 6” long), hydroexpanded
full length and mechanically expanded at the tubesheet and
discharge end. All work was performed through header box
plug holes.
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CASE HISTORY
NO. F-8190
JANUARY, 1997
CLIENT: ICI Chemicals
Billingham, England
UNIT: C-702 Vacuum Condenser
¾” O.D. x 18 BWG tubes, 90/10 CuNi
PROBLEM: Wall loss ranging from 10 - 80% on tube O.D.’s, due to
baffle plate fretting and/or vibration. IRIS inspection
revealed most problems were full length but only affected
the upper tube rows.
SOLUTION: Installation of 150 CTI Full Length Tube Liners made of
70/30 CuNi into the top rows of the unit. During the
installation, ICI engineers realized the success of the repair
and asked for 100 more “liners”. Unfortunately, material
could not be secured in the shut down time frame.
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CASE HISTORY
NO. I-8248
NOVEMBER 1996
CLIENT: Boise Cascade – Cianbro Corp.
Rumford Mill
Rumford, ME
UNIT: Unit 2 Black Liquor Condenser
Vertical Heat Exchanger
670 tubes, 304SS
2” O.D. x 18 BWG
PROBLEM: Multiple tube leaks caused by (SCC) Stress Corrosion Cracking
at the inlet tube ends resulting in severe process fouling.
SOLUTION: Installation of 655 CTI Shield/Seals constructed from
304 SS. Shield/Seals 12” long x .020” wall thickness
were installed via mechanical expansion. CTI recovered
over 50 tubes that had been previously plugged and returned the
unit to reliable service.
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CASE HISTORY
NO. I-8253
DECEMBER, 1996
CLIENT: Inland Paperboard & Packaging
Orange, Texas Plant
UNIT: Vertical Surface Steam Condenser
1 ½” O.D. x 18 BWG Stainless Steel Type 304
PROBLEM: Tubes were being plugged because of stress corrosion cracking
damage behind the upper tubesheet. Cause of damage was
attributed
to vibration due to lack of support sheets along the tube length.
SOLUTION: CTI installed 1,500 Type 304 Stainless Steel Shield/Seals,
8” in length x .035” wall to eliminate leaking due to cracking
of the tubes. The Shield/Seals were roller expanded at the
tubesheet and at the discharge end.
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CASE HISTORY
NO. I-8556
APRIL/JUNE 2005
CLIENT: Tonen Chemical Corporation
Kawasaki Plant
Kawasaki City, Japan
UNIT: E-104 Surface Condenser
5,980 Tubes, Aluminum Brass
19mm O.D. x 1.65/1.80mm wall x 6,150mm long
PROBLEM: Tube corrosion due to ammonia attack.
Overage of plugged tubes causing poor performance of the
condenser. Due to the critical condition, client could
not wait for next maintenance period for retubing and looked
for the best solution for the operation with savings of cost &
time.
SOLUTION: Working in conjunction with CTI’s local partner Moritani, a
total
of 463 Full Length Tube Liners™ were installed into
condemned/
plugged tubes. Liners were fabricated from 70/30 CuNi
material
with a 0.020” / 0.5mm wall thickness. Due to short outage
durations,
job was performed in two (2) mobilizations, both working on an
around-the-clock basis.
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CASE HISTORY
NO. I-9505
JANUARY 2006
CLIENT: DuPont Dordrecht
Dordrecht, Holland
UNIT: Formaldehyde Exchanger (produces Nitric Acid)
939 tubes, 904L Stainless Steel
3/4” O.D. x 16 BWG x 18 ft. long
Tubes are recessed and welded to inside face of
904L tubesheet
PROBLEM: Leaks being caused by faulty tube-to-tubesheet welds.
SOLUTION: On an urgent basis, CTI/Furmanite – Holland installed
939 CTI Shields made of AL-6XN Stainless Steel
material. Shield flares were sized in order to slide thru
the tubesheet holes and seat against the recessed tube.
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CASE HISTORY
NO. I-9568
JULY 2006
CLIENT: Invista
Sabine River Works
Orange, TX
UNIT: No. E-107 Cooler Condenser
2596 Tubes, Type 304/310L SS
1” O.D. x 14 BWG AW x 23’ long
Tube Side Shell Side
Operating Temperatures 36º C 50º C
Operating Pressures 90 psi 67 psi
PROBLEM: Microbiological attack (MIC) resulting in through wall
penetrations, causing emergency shutdowns and
related loss of production.
SOLUTION: Installation of 2432 Full Length Tube Liners™ made of
304 Stainless Steel. Full hydraulic expansion was
achieved at 4000 psi. (Welded tube plugs and
obstructions prohibited the installation of 64 Liners). A
total of 327 of the 341 previously plugged tubes were
returned to service. Adjustments in water chemistry are
planned to prevent future MIC attack.
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