Condenser & Heat Exchanger

Restoration Systems

PresentedBy

Terry Quinn

Tube Ferrule Inserts - Shield/Seal™

Patented Process

Expanded tube ferrules, either:

· Mechanical

· Hydraulic

· Combination of both

Many alloys available

Large selection of tube alloys

Experience since 1976

· Over 3 million installations

These are typically used to combat velocity-induced corrosion at tube inlets

2

SUMMARY OP ACTIVITYCONDENSER REPAIR

1979 - 1988

Main EngineAir Coolers 34 $812,000 $367,200 $244,800

DIESEL AIR COOLER REPAIR

* RETUBED OEM REPLACEMENT COST COST SAVINGS

REFINERY CASE HISTORIES

J O B # CLIENT UNIT REPAIR

R PDVSA Services Various (1984 — 2008) Shields

R Exxon Co. USA Multiple Units Shields

G-1243 Aramco - Uthmaniyah Shell & Tube Heat Exchangers Liners

6-1479 Aramco - Yanbu Ref. Fin Fan Coolers Shields

6-1498 Aramco - Lubref Fin Fan Coolers Shields

R-1244 Aramco - Shell Fin Fan Coolers Shields

R-1509 Lyondell - Houston Ref. Vacuum Condenser Liners

R-1525 Chevron - Pascagoula Ref. Fin Fan Coolers Shields

R-1534/R-1617 BP - Cherry Point Fin Fan Coolers/Effluent Exchanger Liners

R-1550 Chevron Canada Overhead Steam Condenser Liners

R-1592 Exxon/Mobil Corp. Fin Fan Coolers Liners

R-2020 Aramco - Uthmaniyah Fin Fan Coolers Shields

R-2035 BP - Cherry Point Fractionator Condensers Liners

R-2516 Exxon Co. USA Debutanizer Reboilers Shields

R-2521 Tosco Refining Co. Air Compressor Intercoolers (2) Shields

R-4527 Exxon/Mobil Corp. Fin Fan Exchangers Shields

R-4541 BP Oil UK Ltd. Fin Fan Air Coolers Shields

R-5267 Sun Company, Inc. Unifiner Tube Bundles (2) Shields

R-5506 Citgo Petroleum Corp. Fin-Fan Coolers Shields

R-5626 Exxon-Mobil Fin-Fan Coolers Liners

R-5653 Valero Refining Co. Overhead Fin Fan Cooler Shields

R-6581 Hovensa L.L.C.— St. Croix Platform Condensers Shields

R-6595 Exxon Mobil - Baton Rouge Sulfer Condensers Shields

R-6605 Petrogal, S.A. Various Turbine Condensers Liners

R-7009 Mossgas Freon Condenser Shields

R-7573 Conoco Phillips Claus Boilers Shields

R-7588 Tonen General - Wakayam Ref. Fin Fan Coolers Liners

R-7596 Kellogg, Brown & Root Suction Gas Cooler Shields

R-7637 Exxon Mobil Refining Surface Condenser Liners

R-8098 Phillips Petroleum(U.K.)Ltd. Refrigerator Condenser Shields

R-8262 Aramco Lean Solution Air Coolers Shields

R-8265 Amerada Hess Reactor Effluent Condenser Shields

R-8501 Exxon Mobil Fin Fan Coolers Ferrules

R-8555 Shell Nederland Chemie BV Condenser Liners

R-8562 Tonen General Sekiyu K.K. Air Fin Coolers Shields

R-8617 AES Cayuga LLC GeneratorSet Coolers Liners

R-9148 ChevronChemical CrudeStyreneCondenser Shields

R-9199 Koch Refinery Inter/AfterCondenser Liners

R-9510 BP West Coast Products CrudeOverheadFinFanCondensers Liners

R-9540 Hovensa CDU 0/H Condenser Shields

R-------- Conoco Phillips (2006) Various Units Shields/Lim

R-9572 Flint Hills Resources — Joliet Vertical Process Heat Exchanger Shields

R-9602G-1455

ExxonMobil - Augusta Ref.

Saudi Aramco — Riyadh

FinFanCoolers

SteamGenerators

Liners

Shields

G-1433 Saud(Yanpet) Fin Fan Coolers Liners

(Hold down "Control" and click on any PP number to go directly to that Case History.)(Hold down "Control" and click on back to tc. to go return to the list.)

INDUSTRIAL CASE HISTORIES

JOB # CLIENT UNIT REPAIR

1-1542 BAPCO Multi-Stage Flash Evaporators Shields

1-1562 LG Chemical - Yeosu Plant Hiboil Column Vent Chiller Shields

1-1569 Methanex New Zealand Ltd. Steam Condenser Liners

1-1571 Arco Chemical Reboiler Shields

1-1576 Norske Skog Parenco Main Condenser Shields

1-1642 Linde, lnc./BOC Gases CO2 Gas Coolers Shields

1-2009 Dow Chemical Caustic Scrubber Shields

1-2012 Chemtrade Logistics Sulfuric Acid Heat Exchanger Shields

1-2519 Pfizer Inc. High Pressure Feedwater Heater Shields

1-2033 Arkema, Refrigeration Condensers Liners

1-3530 Vulcan Chemicals HCI Stripper Coolers Shields

1-3553 WEB — Aruba Aquachem No. 6 Distiller Shields

1-4534 Chevron Products Co. S.W.S.O.C. Shields

1-4539 E.I. duPont de Nemours &Co. Various Jet Condensers Shields

1-4620 Dow Chemicals — Benelux Vertical Caustic Heat Exchanger Shields

1-4633 Chevron Phillips Chemical Verticle Effluent Exchanger Shields

1-5645 Bayer Corporation Neutralization Condenser Shields

1-5557 Stora Enso North America Vertical Gas Process Exchanger Shields

1-6076 ICI Chemicals Analine Reboiler Shields

1-6588 United States Navy — Saipan Main Condensers Shields

1-6602 PCS Nitrogen Trinidad CO2 Stripper Ejector Steam Generator Shields

1-7563 Hitachi Zosen — Maizuru Waste Heat Boilers Shields

1-8014 ICI Chemicals Vertical Caustic Heat Exchanger Shields

1-8073 Zeneca (BASF) 1st Stage Concentrator (Vertical) Shields

1-8079 Pt. Aceh Asean Fertilizer Gas Reboiler Shields

1-8154 Kemira Ince, Ltd. Vertical Gas Heat Exchanger Shields

1-8179 PT Badak Fin-Fan Coolers Shields

1-8190 ICI Chemicals C-702 Vacuum Condenser Liners

1-8248 Boise Cascade—Cianbro Corp Black Liquor Condenser Shields

1-8253 Inland Paperboard Vertical Surface Steam Condenser Shields

1-8556 Tonen Chemical Corp. Surface Condenser Liners

1-9505 DuPont Dordrecht Formaldehyde Exchanger Shields

1-9568 Invista — Sabine River Works Cooler Condenser Liners

SHIELDINSTALLATIONSWASTE HEAT BOILERS/STEAM GENERATORS

Mandrel Diagram With Shield/Seal

Mandrel Shield/Seal''' Parent Tube/

Sleeving Process

Shield/Seals being loaded and hydraulicallyexpanded full length into Feedwater Heater tubes

Full-Length Tube Liners TM

• Patented process

• These are full-length, corrosion-resistantalloy liners

•

• Clean existing tubes• Install alloy liner• Hydraulically expand• Cut to length and flare ends

These can be installed on the ID of new carbon steel tubes or on the ID ofexisting carbon steel tubes, if old tubes not too damaged

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Condenser & Heat Exchanger Restoration

CASE HISTORYNO. R9510APRIL 2006

CLIENT: BP West Coast Products LLCCarson Refinery Carson,California

UNIT: #2 Crude Overhead Fin Fan Condensers (2)389 Finned tubes, Carbon Steel1" O.D. x 12 BWG (.109" MW) x 40' long

PROBLEM: Unacceptable mechanical integrity of Carbon Steeltubes due to corrosion.

SOLUTION: Installation of thin-walled (.028") Full Length TubeLiners™ manufactured from UNS N10276 (Alloy C-276).Liners were hydraulically expanded full length followed bymechanical roller expansion at each tubesheet into newCarbon Steel parent tubes. All work was performed thruheader plug holes.

Carson Refinery

#2 Crude Unit

Overhead Fin Fan Condenser Full

Length Hastelloy C-276 Liners

The Issues

Excessive corrosion in carbon steel crude unitOH fin fan condenser

One in-service failure plus additional shutdownsfor inspection to avoid loss of containment;unacceptable tube life

Undersized water wash

Unequal water wash distribution

Non-desaltable (phantom) chlorides

Chemical inhibition program cannot manage thiscorrosion issue

Sequence of Events

Isolate, steam out, remove old tubes

Retube both bundles 1" OD, 0.109 MW embedded

finned SA-179 tubes. Note: tube replacement isoptional assuming tubes can be adequately cleaned andhave reasonable integrity.

Hydrostatic test

Install liners 0.735" OD x 0.028" AW UNS N10276 WLD

ASME SS 626-03 Class III

Hydraulically expand to approx 7000 psi, end mill, ID cut

and roller expand.

Leak test plugs

Return to service

$$

CS Finned Tubes: $121,000 (optional step)

Labor: $100,000 (optional step)

732 Liners: $450,000

(tube liners were 0.028" AW; can be reduced to 0.020 MW resultingin a estimated 20% reduction in cost)

Labor: $100,000

Total Job: $800,000 (could be reduced to $500,000)

Solid Hastelloy 0.065 MW tubes: $1.04 MM

Hastelloy bundle Replacement (2): $1.2 MM

Does not include labor to install solid Hastelloy tubes or new bundleROM $50K/bundle

This innovation saved a full shift

Inlet Feed Chuck for Hydraulic Expansion of Liners to 7500 psi

Portable Hydraulic Liner Expansion Pump

Outlet Air Bleed Liner Expansion Chuck

Post Expansion of Liners shown extending through Header Box

ID Tube Cutter

BP Cherry Point Refinery (GEA Rainey- new build)

Finished Liner installation as viewed thru the header

hole