In 1975, three engineers, all experienced in power plant operation, had become convinced that the astronomical cost of condenser repairs by full retubing was, in many cases, wasteful and unnecessary.
Each of them - Gil Boyd, Chief Application Engineer of Allegheny Ludlum Steel, Carl Keuster - Superintendent of United Illuminating's New Haven Harbor Steam Plant (consistently rated in the top five most efficient oil fired units in the U.S.A.), and Cliff Tallman, Consultant to Martin Marietta and a former District Manager for Babcock and Wilcox, felt that there was a better way.
With borrowed and rented instruments and tools, condenser tubes were inspected and measured, along with water chemistry analysis and metallurgical evaluation of various tube alloys.
From this it was confirmed that over 85% of condenser tube failures take place at less than 6” from tube inlets and that a condition known as “inlet end erosion/corrosion” was the cause.
Also, a cost comparison analysis revealed that a 100% restoration of these locally damaged condenser tubes could be accomplished for 10-15% of the cost of retubing; Not a band-aid repair but a fully restored exchanger that will have years of additional service.
1976 was devoted to writing specifications, testing and developing sources of supply.
Initially, tests at several utility stations were little more than window dressing. At that time companies were only curious to learn of CTI’s techniques that could really stop “erosion/corrosion” and restore leaking and/or plugged tubes to normal operation.
However, in 1977, the first full scale installation was accomplished at Con Edison’s Indian Point Nuclear Station - 72,000 inlet end Shield/Seals ™ , 12” long made of AL6X. A big enough job to either get CTI off to a rosy business start or stamp it out and get several of Con Edison’s executives fired.
Ten years later after numerous successful installations throughout the world, CTI returned to Indian Point and installed 72,000 Shields in the outlet tube ends of those same units.
Eventually, Shield/Seals ™ were installed throughout the entire Con Ed system. Along with this, increased engineering and sales efforts resulted in a growing number of installations in utilities throughout the U.S.A. The following year, in 1978, ENEL, the national electric utility industry in Italy, began a CTI program of installations. This was followed by jobs in Western Europe, the Persian Gulf, South America and the Far East.
In the ensuing years, Cliff Tallman took over as sole owner/operator of CTI Industries, which had grown from a small office in Gil Boyd’s Wallingford home to its present offices and shop facilities in Connecticut, California, England, and the Middle East.
Also in 1978, the commercial marine market was identified and targeted. Achieving success in this area, the United States Navy was the next natural market to develop. As a result of several proven repair techniques, CTI was awarded an exclusive U.S. Navy contract in 1988. That required the opening of an office in Norfolk, Virginia, the hub of the Eastern fleet. Subsequently, due to government cutbacks in military defense spending, the contract was canceled, although CTI still remains an integral part of the U.S. Navy maintenance program.
Because of the success in Norfolk and the eastern seaboard, it was decided to extend our Navy and Marine expertise to the West Coast. With an office and service center in Carlsbad, California, CTI was able to effectively cover shipyards, utility stations, refineries and other industrial sites from San Diego to Seattle.
In January of 1995, CTI established an office/service center in Dubai, United Arab Emirates. CTI had at various times been very active in this part of the world, but realized, that without a local presence, it would be difficult to maintain the success to which it had grown accustomed. This also made Africa more accessible and opened doors in that area as well.
In September of 1999, CTI opened a sales office in Kendal, England in order to capitalize on the large European sector. CTI has taken advantage of this by extending our restoration services into the Far East.
The success of CTI can be attributed to our continuing efforts in developing cost effective solutions for the servicing and repair of condensers and heat exchangers, our strategic placement of CTI owned and operated offices and service centers and last, but certainly not least, the people who make up CTI Industries. Because of all this, we have developed into a worldwide condenser and heat exchanger restoration company continuing to offer … “New Solutions to Old Problems.” |
