Power plant steam condenser tube replacement represents a major maintenance milestone that most facilities face only once in a generation. These massive systems, with their wide range of designed capacities depending on thermal demands, require comprehensive expertise and careful coordination to execute successfully.
When the time comes for this critical project, you need more than just tube replacement – you need complete condenser restoration that addresses every component and extends equipment life for decades to come.
Our Turnkey Approach to Condenser Re-tube Projects
We provide complete turnkey solutions for condenser tube replacement projects, serving as your single point of responsibility for the entire scope of work including re-tube operations and epoxy coating system applications.
Our qualified, multi-trade specialists consistently demonstrate the craft-level competence required to lead these complex turnkey projects from start to finish.
Comprehensive Project Scope
A complete condenser restoration involves multiple integrated services:
- Complete tube removal and replacement with precision installation
- Roller expansion of new tubing for optimal tube-to-tubesheet sealing
- Waterbox restoration and coating during tube replacement downtime
- Tubesheet protection using advanced epoxy cladding systems
- Quality control testing to ensure sealing specifications are met
Recent International Project: 50+ Year Condenser Restoration
A recent international project demonstrates our comprehensive approach to once-in-a-generation condenser restoration. We completed three condenser re-tube and cladding projects for this client, with the most recent involving a condenser that had operated for over 50 years using copper alloy tubes.
using Curran International’s
polymeric epoxy
cladding system.
Project Specifications and Challenges
The scope of this major restoration included:
- Condenser shell with two tube bundles, each containing 4,853 tubes
- 16-foot diameter tubesheets with extensive galvanic corrosion damage
- 90/10 CuNi tubes, 23mm diameter and approximately 26 feet long
- Carbon steel tubesheets and waterboxes without cathodic protection
- Fresh water cooling system from nearby water source
Access and Logistics Solutions
The waterbox design featured hinged end covers that enabled tube access, though some tubesheet sections had marginally compromised access. However, this challenge had minimal impact compared to the alternative of removing and reinstalling the entire waterbox systems.
Systematic Execution: From Planning to Completion
Phase 1: Tube Removal and Installation
Our systematic approach began with:
- Complete removal of existing copper alloy tubes that had served for over 50 years
- Installation of new tubing with precision alignment and positioning
- Roller expansion process to achieve optimal tube-to-tubesheet sealing integrity
- Hydrostatic testing performed by plant personnel to verify sealing specifications
The client collected the removed copper tubes and benefited from their scrap metal value – an additional economic advantage of the restoration process.
Phase 2: Surface Preparation and Protection
Following successful tube installation and testing:
- Butyl plugs protected new tubes during surface preparation operations
- Waterbox interior preparation for tubesheet coating application
- Grit blast surface prep to achieve NACE 1 “white metal” cleanliness
- Forming plugs used to set precise thickness for polymeric epoxy cladding
Phase 3: Advanced Coating System Application
Our 100% solids, two-part polymeric epoxy coating system provides comprehensive protection suitable for all cooling water systems, with superior resistance to cathodic disbondment and exceptional adhesive strength.
Multi-Layer Application Process
- Liquid grade epoxy “prime” coat wets-in corroded pits at tube/tubesheet joint crevices
- High-build polymeric cladding troweled across tubesheets for structural protection
- Top coat liquid epoxy creates glossy finish and completes the coating system
The final coating system filled pitted areas, protects against new corrosion, and provides a uniform finish of approximately 180 mils across the tubesheet.
Project Results: On-Budget, On-Schedule Success
Measurable Project Outcomes
- Total project duration: 30 days including two local holiday breaks
- Nearly 6,500 labor-manhours expended for complete restoration
- On-budget execution with proven results for the power generation facility
- Local labor integration providing economic benefits to the community
Long-Term Value Delivered
The completed restoration provides:
- Decades of additional service life from the restored condenser system
- Protection against galvanic and velocity/erosion corrosion through advanced coatings
- Maintained tube-to-tubesheet sealing integrity for reliable operation
- Comprehensive component protection extending beyond just tube replacement
Why Integration Matters: Coupling Re-tube with Coating
The added-value of high-functionality epoxy coatings protects mild steel condenser components from multiple forms of corrosion while maintaining critical sealing integrity. Tightly coupling the re-tube and tubesheet epoxy coating is essential for optimal long-term performance.
Strategic Timing Advantages
- Waterboxes can be removed before re-tube events for concurrent coating application
- Tubesheet coating work completed after tube replacement ensures comprehensive protection
- Integrated project management eliminates coordination delays between separate contractors
The Economics of Once-in-a-Generation Investment
When you’re making a major investment in condenser restoration that’s expected to last decades, comprehensive protection makes economic sense:
Traditional Approach Limitations
- Tube replacement alone addresses only part of the corrosion problem
- Unprotected tubesheets continue deteriorating, limiting new tube life
- Separate coating projects require additional mobilization and downtime costs
Our Integrated Value
- Single-point responsibility eliminates coordination issues and finger-pointing
- Comprehensive restoration addresses all condenser components simultaneously
- Proven expertise in both mechanical and coating specialties
- Quality control maintained across all project phases
Ready for Your Once-in-a-Generation Project?
When your condenser reaches the point where tube replacement becomes necessary, make sure you’re getting complete restoration value from your investment. Our turnkey approach ensures every component receives the attention and protection needed for decades of reliable service.
Contact us at (281) 339-9993 or reach out to edeely@curranintl.com for more information about our comprehensive field and turnkey condenser restoration services.
With extensive experience in major condenser restoration projects worldwide, we provide the integrated expertise needed to maximize your once-in-a-generation investment in critical power plant equipment.
