condenser repair, steam condenser repair, tube sleeve, tube repair, heat exchanger repair, condenser, sleeving, tube sleeving, tube liner, full length tube liner, tube insert, ferrule, tube ferrule, feedwater heater, feedwater heater repair, CTI Industries

FEEDWATER HEATERS

CTI’s sleeving of feedwater heater tubes is typically performed via “hybrid” expansion – hydraulic expansion for the full length of the Shields followed by mechanical expansions at each end.

This process will allow the feedwater heater to operate efficiently for years. The Shields will not only protect damaged tubes from future failure, but will also recover plugged tubes to active circulation.

A partial list of feedwater heater repairs to date:

Company	Existing Tubes	CTI Shields
Plant	Problems	Quantity / Material
Date		Length
Colorado Springs	70/30 CuNi tubes suffering	464 Shields
*Martin Drake	SCC at inside face of 4½”	70/30 CuNi
July 1997	tubesheet	8” long
Florida Power & Light	Monel tubes suffering SCC at	2,566 Shields
*Port Everglades	inside face of 13” tubesheet	70/30 CuNi
March 1998		18” long
Baltimore Gas & Electric	304ss tubes suffering SCC up	718 Shields
C.P. Crane	to the 77” depth from the	316Lss
March 1998	outlet tube ends	87” long
Tampa Electric	Fretting of 304ss tubes at	238 Shields
*Big Bend	baffles in the desuperheating	316ss
April 1998	zone due to vibration	43” / 74” lengths
Florida Power & Light	Monel tubes suffering SCC near	500 Shields
*Sanford	drains cooler end plate	70/30 CuNi
November 1998		48” long
Pfizer, Inc	90/10 CuNi tubes damaged	322 Shields
Groton, CT	from vibration at 1^st support	70/30 CuNi
March 1999	sheet, 31” from tubesheet face	36” long
Tennessee Valley Authority	Monel tubes suffering SCC at	1,590 Shields
*Allen	inside face of 13” tubesheet	304ss
September 1999		15” long
Southern Energy – California	304ss suffering failures in the	927 Shields
Contra Costa	desuperheating section, 96”	316Lss
October 1999	from tubesheet face	110” long
Keyspan Corp.	Admiralty Brass tubes suffering	242 Shields
Northport	wall loss in sub-cooling zone,	70/30 CuNi
May 2001	13½ Feet from tubesheet face	14 feet long
Electrabel (Belgium)	Carbon steel suffering pitting	3,944 Shields
Doel Nuclear	and corrosion up to 8” depth	316ss
June 2001	from tubesheet face	12” long
*+South Texas Project Nuclear	304ss suffering intergranular	1,950 Shields
Wadsworth, TX	attack and SCC up to 20”	316ss
October 2001	depth from tubesheet face	22” / 13” lengths
Pacific Gas & Electric	Admiralty Brass tubes suffering from	72 Shields
Humboldt Bay	condensate corrosion	304ss
April 2002		56” long
Reliant Energy	304ss suffering SCC up to	396 Shields
Portland	5 feet from tubesheet face	316ss
April 2002		72” long
Enel (Italy)	Preventative maintenance.	370 Shields
Bastardo	To be installed in conjunction	316ss
July 2002	with OEM in Milan, Italy	6” long
Pennsylvania P+L	304ss suffering SCC up to	1253 Shields
Martins Creek	5 feet from tubesheet face	316ss
October 2002		56” / 60” lengths
Con Edison	Monel tubes suffering from SCC in	500 Shields
Waterside	tubesheet area	90/10 CuNi
November 2002		9” long
Reliant Energy/Texas Genco	304ss suffering SCC at	1,333 Shields
Webster	Inside face of 11¾” tubesheet	AL-6XNss
January 2003		16” long
Enel (Italy)	Preventative Maintenance	4,680 Shields
N/A	To be installed in conjunction with	321ss
July 2003	OEM in Milan, Italy	6” long
Mirant	304ss suffering from	927 Shields
Contra Costa	Chloride-induced SCC	316ss
December 2004	from tubesheet face	144” long
Eskom (So. Africa)	439ss suffering	1,088 Shields
Camden	from pitting corrosion	316ss
September 2005		14” long
Mirant	304ss suffering from	700 Shields
Pittsburg	Chloride Pitting	316Lss
December 2005		8 feet long
Detroit Edison	Cracking of 304 SS tubes	894 Shields
St. Clair	throughout the 12 ft.	Alloy 800
September 2006	desuperheating zone (LP)	13 feet long
Xcel Energy	Two (2) units with	1595 Shields
*Black Dog	304SS tubes suffering from	317 SS
March 2007	Stress Corrosion Cracking	67 inches long
Eskom (So. Africa) Komati March 2007	IBW related problems to ferritic SS tubes	6,000 Shields 316ss 28” long
TransCanada Ravenswood December 2008	ECT revealed 304Nss tubes suffering defects in the desuperheating zone, up to 11 feet downstream	325 Shields 316Lss 11’6” long
Ameren Labadie May 2009	Admiralty Brass tubes suffering from erosion / failures up to the 4th baffle plate	557 Shields 90/10 CuNi 12’6” long
Western Farmers Hugo May 2010	Admiralty Brass tubes suffering from erosion/ failures at various depths	250 Shields Admiralty Brass 6 ft. / 10 ft. long
NRG (Australia) Gladstone March 2011	OD corrosion / ammonia grooving of Admiralty Brass tubes	815 Shields 70/30 CuNi 13 feet long

* Denotes additional HP feedwater heaters were “Shielded” at a later date based on the success of the initial installation.

+ Denotes portion of these Shields installed “downstream”.

NOTES:

CTI’s initial test installation, performed for Florida Power & Light in 1997 resulted in CTI winning FP & L’s 1997 Presidents Cup award for “Best New Technology”.

In most cases, units with plugged tubes had existing plugs removed and Shields installed, resulting in tubes being returned to active circulation.
- Technical papers have been written by Con Edison, Florida Power & Light, Baltimore Gas & Electric, Colorado Springs, TVA, Detroit Edison and Ameren for presentations at various EPRI and FOMIS conferences nationwide.

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CTI Industries, Inc. is a service company that specializes in steam condenser repair and heat exchanger repair. Our tube repair technique using the unique CTI Shield/Seal™ is the most widely used and cost-effective system in the world. CTI services the electric utility, refinery, chemical, petro-chemical, commercial marine, U.S. Navy, paper mill, fertilizer, desalination and other industries in over 50 countries throughout the world.

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CTI Industries,Inc.
283 Indian River Rd | Orange,CT 06477
Phone: 203-795-0070 | 1-800-446-0060 (USA)
Fax: 203-795-7061
ctius@cti-ind.com