CASE HISTORY NO. U1609 / U1640 FEB. / SEPT. 2009

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Kerry Horton
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1 NO. U1609 / U1640 FEB. / SEPT ESKOM Koeburg Nuclear Power Station Cape Town, South Africa UNITS: Generator Hydrogen Coolers (13) 108 finned tubes per cooler, Admiralty Brass 24mm OD x 1.2mm wall thickness End-step erosion caused by plastic inserts and high-flow erosion/corrosion at tube ends. Installation of 2,808 Shield/Seals, 200 mm long, into inlet and outlet tube ends. Material used was 70/30 CuNi, required due to the extent of erosion/corrosion of the Brass tubes.

2 NO. U-3057 MAY 2009 Lower Colorado River Authority TC Ferguson Power Plant Marble Falls, TX Turbine Surface Main Condenser Air Cooling Section Two Waterboxes with 391 tubes each, 304SS 1 O.D. x.035 w.t. x long Air Cooling section of both waterboxes suffering from advanced erosion/corrosion and related tube pluggage. LCRA cut a large enough hole in both waterboxes to enable CTI Technicians to install and hydraulically expand 782 Full Length Tube Liners manufactured from 316L SS material into all designated tubes in both waterboxes. All previously plugged tubes were returned to service enabling this section of the condenser to operate at full capacity. Resultant success of this installation has led plant engineers to consider installing Liners in the main body of this unit.

3 NO. U-3110 DECEMBER, 2009 Winnetka Electric Plant Village of Winnetka, IL Main Condenser 2,180 Admiralty Brass tubes 7/8 O.D. x 18 BWG x 15 long Severe full-length problems from both pitting and also ammonia grooving. The problem is compounded by a total lack of access to the condenser because of a recently installed Caterpillar Diesel Generator located only feet from the tubesheet. CTI was able to restore over 225 previously plugged tubes to full service by installing our Full Length Tube Liners through the crank-case of the large diesel generator. The flexibility of the thin-walled Brass Liners allowed for 100% of the targeted tubes to be restored. A re-tubing of the condenser would have been impossible without moving the generator.

4 NO. R-3019 APRIL, 2009 Chevron Performance Contractors Pascagoula Refinery Pascagoula, MS Overhead Condenser 220 tubes per unit, 8 units 1 O.D. x 14 BWG x 36 long finned SA-179 tubes Severe wall loss and full-length pitting on the tube ID s, resulting in an overage of plugged tubes. CTI installed over 270 Full Length Tube Liners constructed from Alloy C-276 material into failed tubes only, returning them to normal operating service. All work was performed in-situ at the elevated overhead exchangers. The tube ID s had been gritblasted and Eddy Current tested prior to our arrival and work was completed though inlet and outlet header box plug holes.

5 NO. R3223 DECEMBER 2009 ESSO (via Foure Lagadec Mediteranee OEM) Fos Sur Mer Refinery Fos Sur Mer, France E-2212 Fin-fan units (2) 243 tubes each, Carbon Steel 1 O.D. x 14 BWG x 30 long Integrity of existing bundles forced the plant to modify their design. The original tube wall thickness was reduced from 10 BWG to 14 BWG and included the addition of CTI Full Length Tube Liners with.028 wall thickness. CTI fitted 486 Full Length Tube Liners into new fin-fan units, made of Alloy C276 in order to increase reliability and extend the life of the Carbon Steel units. All work was performed through header box plug holes.

6 NO. R3074 DECEMBER 2009 ExxonMobil Baytown Refinery Baytown, TX WHB E-701 Claus D Boiler 475 tubes, SA178 Carbon Steel 2½ O.D. x.134 MW Sulfitic corrosion attacking the original Carbon Steel tubes at the inlet end resulting in premature failures and tube replacement. Installation of 475 CTI Shield/Seals manufactured from 316SS,.049 wall thickness x 36 in length. These Shields were hydraulically expanded into the new parent tubes the entire 36 and then mechanically expanded at both the tubesheet and exit end of the Shield. Ceramic tube ferrules, 10 in length were then installed inside the CTI Shields by a local contractor. This installation was critical path and completed in two back-toback 12 hour shifts.

7 NO. R3062 JUNE 2009 Flint Hills Resources Corpus Christi Refinery Corpus Christi, TX E03 10A Units A thru H fin-fan bundles 8 units with 233 tubes each (1864 total tubes) SA214 Carbon Steel 1 O.D. x.125 MW x 32 long Design Pressure: 45 psig Design Temperature: 350 F Eddy Current examination on 100% of the tubes revealed unexpected, excessive corrosion ranging from 25% to 75% tube wall loss. On an emergency basis, CTI was contracted to install 1864 Full Length Tube Liners manufactured from 316L material into all 8 bundles. Flint Hills engineers isolated two bundles at a time enabling CTI Technicians to remain at the site until all 8 bundles were completed. The repair was a resounding success and site Engineers posted a job review of the installation for access by all FHR personnel systemwide.

8 NO. R3099 AUGUST 2009 Singapore Refining Company Singapore Crude OH Fin-Fan Condensers (6) 178 tubes each, Carbon Steel 1½ O.D. x 12 BWG x 31 4 long Units have history of inlet-end erosion of Carbon Steel tubes. SRC elected to manufacture new tube bundles, then install CTI Shields into all inlet ends (1068) of the new tubes. Shields were 12 long with a wall thickness, made of 316SS. Based on the success of this installation, CTI returned to the same plant to install another 768 Shields in September `09, into newly retubed fin-fan units.

9 NO. I2104 JANUARY 2009 Shell Philippines Exploration (SPEX) Malampaya On Shore Gas Plant Batangas, Philippines E 211 Inlet Gas Heater 193 U tubes, A179 Carbon Steel 1 O.D. x 10 BWG x 11 2 straight leg Shell Side (St eam) Tube Side (Sour Gas) Operating Temperat ure 162º C 73º C Operating Pressure 3.5 barg 128 barg Severe external corrosion of bottom half of the unit, between the tubesheet and first support sheet. Additional damage was also detected up to the 4 th support sheet. Installation of CTI Shields made of 321SS, 10 6 long. Two wall thicknesses (.022 /.028 ) were supplied, using the heavier walled Shields into the more damaged tubes. All Shields were hydraulically expanded their full length followed by mechanical expansions. Plant removed/cut out existing division plate for unobstructed access to the tubesheet/tubes. (see photo) Upon completion of the job and a successful hydrotest, Shell s Sr. Maintenance Engineer said There will be no question about using the services of CTI again in the near future ( On Feb. 17, Shell awarded CTI a Purchase Order for the repair of another Gas Heater at Batangas)

11 NO. I JANUARY 2009 Qatar Electricity and Water Commission Ras Abu Fontas Distillation Plant Doha, Qatar UNITS: Multi-Stage Flash Evaporators (6) 14,406 tubes, Aluminum Brass 1-1/8 OD x.039 wt x 41 7 long Severe inlet-end erosion leading to tube leaks. Installation of 14,406 CTI Shields via hydroswage, 8 long made of 70/30 CuNi material. Due to the extent of erosion, collars were required on 15% of the tubes.

12 NO. I3089 JULY 2009 Celanese (Nanjing) Chemical Co. Nanjing, China HE 323 Vertical Acid Reboiler 812 tubes, Alloy C276 3/4 O.D. x.065 wall Thinning of outlet tube ends (hottest section) with up to 65% wall loss. Tubesheet/ligaments have active corrosion with tube to tubesheet welds corroded completely in some spots, weakening the joints and creating leaks. In an extremely critical situation, CTI fabricated within 48 hours over 800 tube end Shields,.028 wall thickness x 6 long, made of C276 material. Collars were also fabricated due to the extreme erosion/corrosion at the tube openings. Celanese expedited the air freight of material direct to Nanjing. CTI personnel hand carried all tools and equipment to China, arriving in Nanjing before a Purchase Order could even be issued. All Shields/Collars were installed via mechanical expansion into the outlettube ends and the unit then successfully hydrotested. CUSTOMER COMMENTS: I would like to extend my sincere thanks, on behalf of Celanese, to CTI for their understanding and timely support in this critical matter.you assisted us immensely in very prompt production of the inserts and timely shipment/packaging efforts which had to be worked through to ensure uninterrupted shipment into Nanjing. Thank you again for the valiant and supportive effort.

13 NO. I3012 MARCH 2009 Samsung Fine Chemicals Ulsan, Korea Flue Gas Heater EA tubes, 316SS 1 OD x 12 BWG x 15 long Inlet-end erosion/corrosion due to flue gas (SO3) CTI Korea installed 480 Shields,.028 wall thickness x 16 long, made of Alloy C276. Collars were required on all Shields due to extent of erosion in the tubesheet area.

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