Client Challenge:
A dual-purpose plant on the Arabian Peninsula, producing over 264 million gallons of fresh water per day and 1,200 MW of electricity, needed to restore a corroded dump condenser with minimal cost and operational disruption. The condenser’s CuNi tubes had suffered under-deposit corrosion, pitting, and mechanical plugging, reducing condenser duty by 10%.
Curran’s Solution:
Curran recommended a two-pronged restoration approach:
- Advanced Coatings – Curran 1000T epoxy coating repaired pitted tubes and mitigated new corrosion. A water-based nanocomposite “release” topcoat was applied at 15–20 microns for hydrophobic performance. The total dry film thickness averaged 75 microns, providing robust protection with negligible impact on heat transfer.
- Optional Alloy Liners – Full-length C276 alloy liners could be hydraulically expanded in plugged tubes to restore flow and corrosion resistance. While site constraints prevented their use in this project, the method remains a proven alternative for future maintenance.
Step-by-Step Execution:
- Tube Prep & Cleaning: Residual channel water was removed; severely fouled tubes were hydro-lanced. IDs were grit-blasted to NACE 1 white metal standard, verified via borescope inspection.
- Coating Application: Curran crews applied 1000T coating across approximately 1,700 tubes (~13 miles of tube ID), followed by the thin-film release topcoat.
- Inspection & Documentation: Coating application was inspected with video probes; thickness readings confirmed 75.2 microns average DFT.
Project Outcome:
- The condenser now operates within thermal duty specifications.
- Corrosion has been mitigated, and tube release properties improved.
- Thin-film coating maintains heat transfer efficiency while reducing fouling risk.
Why It Matters:
Curran’s approach demonstrates cost-effective, high-quality condenser restoration without extended outages or major mechanical work. Thin-film coatings, paired with optional alloy liners, provide long-term reliability for critical water and power infrastructure.
Contact Curran International:
For consultation on condenser restoration and coating solutions, contact Jason Kolman: jkolman@curranintl.com | 281.339.9993
Catch Curran This Summer!
This season, Curran International is taking a break from tradeshows and conferences—but there’s still plenty happening! Whether you’re a sports fan, beach lover, or just looking for a little adventure, here’s where you can catch us:
- Houston Astros – 24 home games in July and August at air-conditioned Minute Maid Park
- Galveston Beach – Enjoy the sun with average water temps of 85°F and daytime highs around 86°F
- Louisiana Casinos – Try your luck at Golden Nugget, L’Auberge, and Coushatta, all within 3 hours’ drive
- Live Music – Catch Santana and the Doobie Brothers at Cynthia Woods Mitchell Pavilion, July 7
- Fishing Fun – IFA Redfish Tour, Texas Division, August 12
- NFL Preseason – Texans vs. Detroit Lions, August 17
