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Condenser Corrosion Protection

32 year old tube sheets
32 year old tube sheets
Osmosis blisters scattered over the entire surface
Osmosis blisters scattered over the entire surface
Localised corrosion pitting and metal loss
Localised corrosion pitting and metal loss
Tube sheets refurbished using RP 500 Epoxy system
Tube sheets refurbished using RP 500 Epoxy system

OVERVIEW:    Chemcote were approached to refurbish the recirculated water condenser unit from 1981. Repairs were made to tubes that were leaking out onto the tube sheet and localised areas of metal loss that were affecting the tube sheet interface. 

INDUSTRY

HVAC, Power Generation, Oil & Gas,

ENVIRONMENT

Up to 60°C Recirculated Water

SUBSTRATE

Cast Iron

CHALLENGE

The condenser unit was manufactured in 1981 and installed shortly after. There was some metal loss in localised areas across the tube sheet and some of the tube to sheet interface was affected. It was also found that some tubes were leaking out onto the tube sheet.

SOLUTION

We recommended coating with RP 500, an epoxy coating utilising very robust ceramic technology. RP 500 provides a hard wearing, abrasion resistant impermeable barrier to provide long term protection in this environment.

SCOPE

Abrasive blast to AS1627.4, 75 µm nominal profile and removal of all existing coating

Application of RP 500 in one coat at 250 µm

Perform Wet Film Thickness test to ensure proper coverage

Pit fill to provide a smooth finish and coating continuity

Application of second coat of RP 500 at a total nominal thickness of 500 µm

Perform wet film thickness test to ensure proper coverage

PRODUCTS

Ceram-chem™ RP 500

OUTCOME

Chemcote was able to refurbish the tube sheets within the strict time frame given by the client. This application will provide at least 10 years of condenser corrosion protection.

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