surface and corrosion protection systems for the entire ... · pdf filesurface and corrosion...

Surface and corrosion protection systems for the entire cooling water cycle

plastocor-international SA

Company profile

General information plastocor-international SA owns rights to various systems and processes like durocor® and plastocor® systems, which serve the purpose of repairing and protecting important parts of the steam generating and chemical industry,e.g. tube sheets, water boxes and other cooling water cycle related equipment

The durocor® and plastocor® systems include:

–  cladding for tube sheet repair and protection –  tube lining and inlet for tube repair and protection –  coating for repair and protection of all cooling water cycle

related equipment, tanks, pipelines, etc.

01-12 plastocor-international SA 2

Advantages Since 1963 plastocor® systems have repaired and prophylactically protected thousands of heat exchangers and condensers preventing their owners from spending huge sums on their replacement.

plastocor® means an upgrade of service reliability and availability, an increase in efficiency and output resulting in life extension of the unit.

plastocor® trademark and the patented systems are registered in more than 50 countries


General information The fact that plastocor®/durocor® is protecting heat exchangers and condensers from corrosion and erosion in hundreds of conventional, nuclear and fossil power plants, as well as in about 90% of German and Swiss nuclear power plants, shows the enormous confidence engineers have in our systems. There is an urgent need to upgrade the power industry in developing countries as well as in industrialised countries in order to meet the fast rising demands for goods and electricity. Therefore plastocor®/durocor® systems bear an enormous potential by being available at any time, anywhere in the world and applicable within days or weeks to secure the performance of the equipment they protect. Consequently the needed lead-time is measured in weeks only.


Company history In the 1950s Dipl.-Ing. Ernst Kreiselmaier developed the plastocor® thick layer tube sheet cladding system used for the protection of utility main stream condensers.

In the early 1980s his son Richard H. Kreiselmaier extended corrosion and erosion protection to the inlet and outlet areas of the tubes.

In the 1990s this resulted in a full length tube lining system which protects tubes subjected to corrosion, erosion and fouling. After a reorganization in 2002 plastocor-international SA was founded and is now spearheaded by Richard H. Kreiselmaier, who comprises over 35 years of experience in the field of protective coatings.


plastocor-international SA today Meanwhile patented plastocor® coating systems have been applied to thousands of new and old fossil, conventional and nuclear power plants throughout the world. Today plastocor-international SA applies its systems through its own or affiliate personnel as well as through a network of approved applicators or licensees in regional locations. plastocor-international SA continues to look for new sales agents and applicators for selected regions in the world. Interested parties should contact us via e-mail at [email protected]


Systèmes –  cladding pour la réparation et protection de plaques à

tubes

–  Revêtements pour la réparation et la protection des équipements du cycle de refroidissement , réservoirs, conduites, échangeurs....

–  Revêtement inlet pour protection des entrées de tubes

–  Revêtement tube lining pour réparation et protection complète des intérieurs de tubes

–  Méthode RPR - Décapage par induction


Tube sheet cladding system 2000 When tubes are rolled into a tube sheet of dissimilar metal, a galvanic element is formed resulting in severe pit corrosion around the tubes. This leads to weakened rolling areas with the risk of leakage and costly shutdown times.

The plastocor-international SA epoxy cladding system 2000 for tube sheets is used for long term protection from galvanic corrosion and erosion of new tube sheets as well as for the repair of corroded tube sheets.

It has a proven track record of continued service in thousands of old and new installations since 1958 procuring leak tight tube-to-tube sheet joints.

Experience has shown that thin film tube sheet coatings (<1000 microns or 40 mils) are subject to mechanical and substrate deterioration because of long-term permeation.

The plastocor-international SA system completely covers the tube sheet and encapsulates the tube ends into an epoxy cladding of 3-5 mm (120-200 mils) thickness. In severe cases, it can be applied at a thickness of several cm.

plastocor-international SA 8 01-12

Coating systems P-400 •  water boxes •  tanks •  cooling water piping

P-400 is a specially developed series of solvent-free epoxy material, which protects water boxes of condenser and heat exchangers against erosion and corrosion or to prevent fouling. In addition P-400 is used in many special cases, e.g. in food industry, tanks circulating water inflow structures and buildings, containments etc. For special problems we provide custom made solutions.


Inlet coating Tube inlet erosion shortens the life-time of condenser tubes, often leading to the necessity of retubing, involving high costs and long shutdowns.

plastocor-international SA inlet can refurbish and indefinitely protect tubes against inlet and outlet erosion/corrosion.

Ou r inlet coating is applied in three coats of alternating colors to provide complete protection. It is normally installed to a depth of 5-8 inches (120-200 mm) but can be installed to any depth. It is performed in conjunction with the plastocor-international SA cladding system so as to confer maximum protection. Each coat is applied further down the tube than the previous coat (Three-Stage-Method).

This method creates a feathered termination eliminating the chance of step erosion, a common problem with the use of plastic or metal inserts.

The time and cost involved in the inlet coating are but a fraction of the cost of new tubes and is applicable within the span of a few days:

e.g. lining the 45’600 tube inlets of the NWK-Nuclear Power Plant Unterweser (GER), required only 20 workdays.

e.g. EDF estimates that “in comparison to the unprotected units, the 39 avoided leakages due to inlet coating have resulted in an additional operational profit of 1.2 Mio Euros/year considering a once-off investment of 120’000 Euros.


Inlet coating - technical data The cross-cut (50:1; see below) through a tube end of a steam-turbine condenser treated with the plastocor-international SA inlet process shows its states after 40’000 operation hours.

The first layer of P-400 IL (thick red layer) fills and covers the erosion/corrosion pitting. The second layer (white) forms an equally solid layer. The originally applied third layer (thin red layer) with approx. 40 microns has been worn away by erosion but has still about 20 microns remaining after

40’000 service hours.

Technical data of condenser: location...................................Nuclear Power Plant on the German North Sea coast at

the mouth of the river Weser tube material...........................CuZn 20 AIF 40 cooling water conditions: pH-value.................................7.2 bis 7.4 redoxpotential....................... 380 bis 420 mV bicarbonates.......................... 2.6 bis 2.8 mval/l NaCL....................................... 1000 bis 6500 ppm solids.......................................120 bis 500 ppm tube cleaning equipment: on-line cleaning system


Cross-cut 50:1

Tube lining The heat transfer rate of condenser and heat exchanger tubes will deteriorate with time because of the influence of fouling, corrosion and/or erosion.

When tube damage significantly reduces the efficiency of the condenser or unit, retubing is necessary. Retubing is expensive and requires considerable lead time for material acquisition and planning.

The internal special coating of tubes is an attractive alternative for prolonging the life of condensers and heat exchangers. It can also raise the efficiency of condensers and coolers by reducing fouling.

Tubes based on copper alloy and coated with plastocor-international SA tube lining prevent the loss of copper and zinc ions into the cooling water and reduce other environmental problems.

The main advantage of internal tube lining is faster completion and shorter lead time as compared to retubing.


inner tube surface before tubelining

inner tube surface after tubelining

Tube lining For this reason, our tube linings are used to prolong the life of condensers and heat exchangers. In the future, this technology could be a reliable alternative to retubing.

The tube lining was developed in the 80’s as a special procedure for lining the entire length of tubes. With this method, it is possible to apply a defined layer of epoxy coating down the entire length of the inner tube surfaces on site in a short time.

Tubes with a total length of up to 50 feet (approx. 15m) and an internal diameter of approx. 3/4 inch and more can be coated. Tubes protected with this tube lining system have had a service life of more than 9 years, in some cases up to date.


360°spray nozzle in retraction mode

tube lining new uncoated tube

tendency for reduction in heat transfer values for coated and uncoated tubes

Tube lining working steps

picture 1:

patented tube lining equipment


Repair of heat exchangers With plastocor-international SA repair and maintenance products, even scrapped heat exchangers can be refurbished to a practically new condition within the shortest of time.


Repair of pumps It is also possible to refurbish scrapped pumps to a practically new condition in only a short period of time by applying high wear-resistant plastocor-international SA materials, like plastocor-international SA ceramic.


Some clients of plastocor-international SA


Contact us

plastocor-international SA

Avenue de la Gare 3 CH-3960 Sierre

Tel: +41 27 456 49 55 Fax: +41 27 456 58 55

[email protected] http://www.plastocor-international.com


surface and corrosion protection systems for the entire ... · pdf filesurface and corrosion...

Documents