Despite two previous re-tubing efforts with carbon steel tubes, the problem persisted, with tube leaks occurring in less than two years each time. The culprit: hydrochloric acid (HCl) present in the gas process, which was corroding the tubes and posing a serious safety risk due to the potential for gas leaks.

The Corrosion-Resistant Solution

After experiencing repeated failures with standard retubing, the energy provider was looking for a long-term solution. They recalled a conversation with CTI Services at a trade show where the potential of high quality corrosion resistant tube liners was discussed. Given the severity of the leaks and safety concerns, the company chose Kelvion's Full-Length Tube Liners™ made from C276 alloy, a material known for its superior corrosion resistance, particularly in harsh environments such as those involving HCl.

The solution was to install 1,016 CTI Full-Length Tube Liners, each with a 0.028" wall thickness, which were hydraulically expanded to fit the full length of the parent tubes. To ensure a secure fit, the liners were also mechanically expanded at both ends. This thin-walled alloy corrosion barrier would significantly extend the life of the heat exchangers without compromising the pressure performance of the original carbon steel outer tubes.

Success and Customer Satisfaction

After more than a year in service, the Full-Length Tube Liners have successfully prevented any tube leaks. This solution not only solved a critical safety issue, but also provided long-term operational stability for the utility. 

The energy company's Front End Engineering Design (FEED) team played a key role in the project, making the necessary design changes to ensure the new solution met the technical requirements of their gas processing operations. With the involvement of their in-house engineers as well as external teams, thermal testing was carried out to validate the performance of the new design and ensure compliance with industry standards. 

Kelvion's CTI services provided a solution to a rare problem for a major US gas company, restoring the functionality of their critical stabiliser overhead air fin condensers. By installing corrosion-resistant full-length tube liners, the utility avoided costly equipment replacements, extended the life of its heat exchangers and eliminated potential safety hazards. This successful project highlights Kelvion's expertise in providing tailored, cost effective solutions to the power industry.