Case Studies Supporting a Titanium-Tubed Heat Exchanger Upgrade from Copper Nickel

Transcription

1 Case Studies Supporting a Titanium-Tubed Heat Exchanger Upgrade from Copper Nickel Principal Author Dennis J. Schumerth ASME Fellow & Principal - DBA Titanium Tubular Consultants 4811 East LaPalma Avenue Anaheim, CA USA Phone Cell schumert@aol.com dennisschumerth@gmail.com Web Site: TitaniumTubularConsultants.com Paper Sponsor: UNITI Titanium

2 Yellow Metals Low cost Availability Good heat transfer characteristics (HEI Baseline) Bacteriostatic properties Ease of fabrication Material C194 C443 C687 C706 C715 C722 Description Iron-Modified Copper (97.5Cu 2.5Fe) Admiralty Brass (71Cu 28Zn 1Sn - 0.6As) Aluminum Brass (77.5Cu 20.5Zn 3Al -.06As) 90/10 Copper Nickel. 70/30 Copper Nickel 85/15 Copper Nickel Material Spec (ASTM) Tube Condition Min Yield (ksi) Thermal Cond BTU/hr- o F Modulus 10 6 ksi Density Lb/in 3 Admiralty B111/543 S Al Brass B111/ Al Bronze B111/ CuNi 70/30 B111/ CuNi 90/10 B111/ Titanium B338 Gr

3 Yellow Metals Low cost Availability Good heat transfer characteristics (HEI Baseline) Bacteriostatic properties Ease of fabrication Limited domestic availability Volatile costs Issues connected with copper pick-up/discharge & toxicity Corrosion susceptibility issues due to changing water chemistry Alloy control Material C194 C443 C687 C706 C715 C722 Description Iron-Modified Copper (97.5Cu 2.5Fe) Admiralty Brass (71Cu 28Zn 1Sn - 0.6As) Aluminum Brass (77.5Cu 20.5Zn 3Al -.06As) 90/10 Copper Nickel. 70/30 Copper Nickel 85/15 Copper Nickel Material Spec (ASTM) Tube Condition Min Yield (ksi) Thermal Cond BTU/hr- o F Modulus 10 6 ksi Density Lb/in 3 Admiralty B111/543 S Al Brass B111/ Al Bronze B111/ CuNi 70/30 B111/ CuNi 90/10 B111/ Titanium B338 Gr

4 General Erosion Corrosion High Velocity Erosion Corrosive Activities (partial list) Associated with Yellow Metals Ammonia Attack MIC Manganese Chloride Attack Fatigue/Vibration SCC Galvanic Attack Sulphide Attack NSSS Denting Copper Pickup & Transport

5 Titanium Volatile/High Pricing Long Lead Time Fabrication Questions Installation Pedigree ASTM Grade Grades Grades Grades Palladium Aluminum Vanadium Moly Nickel Palladium Oxygen Spec (ASTM) UNS No. Alloy Type Tube Min Yield (ksi) Therm Cond BTU/Hr- 0 F Modulus 10 6 ksi Density Features Iron Hydrogen Ti Gr.1 B338 R50250 Alpha Clad & PHE Carbon Nitrogen Ti Gr 2 B338 R50400 Alpha Widely Used Best Property Combination Palladium Ruthenium Ti Gr.3 B338 R50550 Alpha Higher Strength Not Widely Used Molybdenum Nickel Ti Gr.7 B338 R52400 Pd Alpha Added Corrosion Resistance over Gr. 2 Aluminum Vanadium Ti Gr.9 B338 R56320 Alloy Lean Alpha/Beta Cold Formable Medium Strength Alloy Other, Each Other, Total Ti Gr.12 B338 R53400 Alloy Lean Alpha/Beta Added Corrosion Resistance over Gr. 2 Titanium Bal. Bal. Bal. Bal. Bal. Bal. Bal. Ti Gr.16 B338 R52402 Pd Alpha Added Corrosion Resistance over Gr. 2

6 Titanium Volatile/High Pricing Long Lead Time Fabrication Questions Installation Pedigree ASTM Grade Superior Corrosion Resistance/Immunity Ease of Fabrication Transition to Conventional Lead Times Titanium Industry Commitment to Invest/Expand Capability Grades Grades Grades Palladium Aluminum Vanadium Moly Nickel Palladium Oxygen Spec (ASTM) UNS No. Alloy Type Tube Min Yield (ksi) Therm Cond BTU/Hr- 0 F Modulus 10 6 ksi Density Features Iron Hydrogen Ti Gr.1 B338 R50250 Alpha Clad & PHE Carbon Nitrogen Ti Gr 2 B338 R50400 Alpha Widely Used Best Property Combination Palladium Ruthenium Ti Gr.3 B338 R50550 Alpha Higher Strength Not Widely Used Molybdenum Nickel Ti Gr.7 B338 R52400 Pd Alpha Added Corrosion Resistance over Gr. 2 Aluminum Vanadium Ti Gr.9 B338 R56320 Alloy Lean Alpha/Beta Cold Formable Medium Strength Alloy Other, Each Other, Total Ti Gr.12 B338 R53400 Alloy Lean Alpha/Beta Added Corrosion Resistance over Gr. 2 Titanium Bal. Bal. Bal. Bal. Bal. Bal. Bal. Ti Gr.16 B338 R52402 Pd Alpha Added Corrosion Resistance over Gr. 2

7 Case Studies Case Study One: Trans Canada - Ravenswood Station (6) Queens, NY Case Study Three: Southern Company Barry & Yates Newnan, GA Cooling Water Source: East River Original Tube Material: Al Brass & 70/30 Cu.Ni. Tubesheet Material: Muntz Metal o Material degradation symptoms Chloride Intrusion Pronounced leaks and entire tube failures Prior Excellent 12 Year Titanium Service Record Rejected 90/10 Material Option Solution: Retube Gr. 2 titanium Cooling Water Source: Cooling Tower (3-5 Cycles) Original Tube Material: Admiralty & 304SS Tubesheet Material: Muntz Metal or Equivalent o Material degradation symptoms Overall Unit Degradation Significant Tube Leaks Prior Multiple Unit Titanium Historical Service Record Rejected Admiralty, 304SS, AL29-4C, SeaCure Material Option Solution: Retube Gr. 2 titanium Case Study Two: Santee Cooper Winyah 1& 2 Charleston SC Cooling Water Source: Lake Original Tube Material: & CuNi Tubesheet Material: Aluminum Bronze o Material degradation symptoms Manganese Attack High Chloride Levels Presence of MIC Rejected Admiralty, 90/10 Cu.Ni., AL29-4C & Sea Cure Options Titanium Immunity to Manganese, MIC (12) and Chlorides Titanium Selected for Retube Case Study Four: Sea Water-Cooled Chillers World Markets Application: Sea Water Cooled Chillers Cooling Water Source: Polluted Sea Water or TSE Original Tube Material: Seamless Copper Tubesheet Material: Titanium Clad C. Steel o Material Requirements Polluted Sea Water Corrosion Resistance Galvanic Compatibility Integrity of the Bi-metallic press fit interface Rejected CuNi/Aluminum Bi-metallic Solution: Titanium/CuNi Bi-metallic

8 Case Studies Case Study Five: WE Energies Oak Creek Station, Milwaukee Area Case Study Seven: NRG Staten Island Plant Cooling Water Source: Lake Michigan Original Tube Material: Tubesheet Material: Muntz Metal/Equivalent o Material degradation symptoms Aggressive MIC Attack Escalating Tube Leak Percentage Prior Multiple Unit Titanium Service Record Rejected Admiralty, 304SS, AL29-4C, SeaCure Material Option Solution: Retube Gr. 2 titanium Cooling Water Source: Arthur Kill Original Brass Alloy Tubesheet Material: Brass Alloy o Material degradation symptoms o General, Localized and Pitting Corrosion o Boiler Tube Failures From Condenser Tube Leaks First Titanium Condenser Retube Case Study Six: PSE&G: Linden CCGT Cooling Water Source: Cooling Tower/TSE Original Tube Material: 316 SS Tubesheet Material: 316 SS o Material degradation symptoms TSE Tower Make-up MIC Attack Solution: Detube 316 SS - Retube Gr. 2 titanium Case Study Eight: EDF Cattenom Unit 4 (7) Cooling Water Source: Towers Original tube material Al Brass Tubesheet Material C. Steel o Material Degradation Symptoms o Localized tube wall lose o Pronounced leaks and entire tube failures Abrasion Vortex / Vena Contracta Tube End Erosion Steam Erosion SCC (Stress Corrosion Cracking) Ammonia Grooving - Corrosion from Hydrazine Scavenging

9 Case Study Nine: Delaware City Refinery (Shell, Texaco, Aramco Joint Venture) Case Studies Application: Refinery Process Heat Exchanges Cooling Water Source: Delaware River Original Tube Material: 70/30 Cu.Ni. Tubesheet Material: NRB o Material Requirements Eliminate High Chloride CW Level Corrosion Process-Side Rejected Replacement 70/30 and other alloys Solution: Titanium Retubes 140 Thru 1990 Zero Corrosion Failures No corrosion failures of the titanium APS Palo Verde Units 1,2 & 3 Make-up = 100% Treated Sewage Effluent The Nuclear Option Plant Tubesheet Material Replacement Tube Material Oyster Creek Al. Bronze Gr. 2 Titanium Turkey Point 3 Muntz Metal Gr. 2 Titanium Turkey Point 4 Muntz Metal Gr. 2 Titanium Pilgrim 1 Muntz Metal Gr. 2 Titanium Farley 1 Al. Bronze Gr. 2 Titanium St. Lucie 1 Al. Bronze Gr. 2 Titanium Surry Unit 2 Al. Bronze Gr. 2 Titanium Surry Unit 1 Al. Bronze Gr. 2 Titanium Farley Unit 2 Al. Bronze Gr. 2 Titanium Calvert Cliffs 2 Unknown Gr. 2 Titanium Pt. Lepreau Al Bronze Gr. 2 Titanium St. Lucie 2 Al. Bronze Gr. 2 Titanium San Onofre 2 Al. Bronze Gr. 2 Titanium Brunswick 1 Al. Bronze Gr. 2 Titanium San Onofre 3 Al. Bronze Gr. 2 Titanium Brunswick 2 Al. Bronze Gr. 2 Titanium Diablo Canyon 1 Muntz Metal Gr. 2 Titanium Maine Yankee Unknown Gr. 2 Titanium Indian Point 3 Unknown Gr. 2 APS Titanium Diablo Canyon 2 Muntz Metal Gr. Palo 2 Titanium Verde Palo Verde 1 Al Bonze Gr. Units 2 Titanium 1,2 & 3 Palo Verde 2 Al Bronze Gr. Make-up 2 Titanium = Palo Verde 3 Al Bronze Gr. 100% 2 Titanium Treated Fitzpatrick Muntz Metal Sewage Gr. 2 Titanium Effluent Millstone 3 Al. Bronze Gr. 2 Titanium Hope Creek 1 Hope Creek Gr. 2 Titanium Millstone 2 Unknown Gr. 2 Titanium Vogtle 1 Al. Bronze Gr. 2 Titanium Trojan Unknown Gr. 2 Titanium STP 1 & 2 Al. Bronze Gr. 2 Titanium Vogtle 2 Al Bronze Gr. 2 Titanium Hatch 2 Unknown Gr. 2 Titanium Hatch 1 Unknown Gr. 2 Titanium Comanche Peak 1 Unknown Gr. 2 Titanium Seabrook 1 Al. Bronze Gr. 2 Titanium Peach Bottom 2 Unknown Gr. 2 Titanium Fermi 2 C. Steel Gr. 2 Titanium Comanche Peak 2 Unknown Gr. 2 Titanium Peach Bottom 3 Unknown Gr. 2 Titanium Sequoyah Gr. 2 Titanium Sequoyah Gr. 2 Titanium San Onofre 1 Unknown Gr. 2 Titanium OPPG Calhoun Unknown Gr. 2 Titanium Shoreham 1 Muntz Metal Gr. 2 Titanium San Onofre 1 90/10 Cu. Ni. Gr. 2 Titanium

10 potential titanium issues (+ other special case issues)

11 Concluding Takeaways Yellow Metals

12 Concluding Takeaways - Titanium Superior Corrosion Resistance/Immunity

13 Concluding Takeaways - Titanium Superior Corrosion Resistance/Immunity Reduced Weight

14 Concluding Takeaways - Titanium Superior Corrosion Resistance/Immunity Reduced Weight Ease of Fabrication

15 Concluding Takeaways - Titanium Superior Corrosion Resistance/Immunity Reduced Weight Ease of Fabrication Conventional Lead Times

16 Concluding Takeaways - Titanium Superior Corrosion Resistance/Immunity Reduced Weight Ease of Fabrication Conventional Lead Times Expanded Industry Capacity

17 Concluding Takeaways - Titanium Superior Corrosion Resistance/Immunity Reduced Weight Ease of Fabrication Conventional Lead Times Expanded Industry Capacity Competitive Costing

18 Concluding Summary Use The Published Paper As A Reference

19 Concluding Summary Use The Published Paper As A Reference Yellow Metals The GOOD The BAD The UGLY

20 Concluding Summary Use The Published Paper As A Reference Yellow Metals The GOOD The BAD The UGLY Titanium Technical Advantages Commercial Stability Seamless Performance

21 Case Studies Supporting a Titanium-Tubed Heat Exchanger Upgrade from Copper Nickel Principal Author Dennis J. Schumerth ASME Fellow & Principal - DBA Titanium Tubular Consultants 4811 East LaPalma Avenue Anaheim, CA USA Phone Cell schumert@aol.com dennisschumerth@gmail.com Web Site: TitaniumTubularConsultants.com Paper Sponsor: UNITI Titanium