CASE HISTORY
NO. R7573
SEPTEMBER 2004
CLIENT:
Conoco Phillips
Sweeny Refinery
Old Ocean, TX

UNIT:
Claus Boilers (2)
189 tubes each, Carbon Steel
2½” O.D. x 7 BWG

Operating Temperature
Operating Pressure
Shell Side (Steam)
In 240°F / Out 474° F
520 psig
Tube Side (Acid Gas)
In 2705°F/Out 753°F
12 psig

PROBLEM:

Sulfitic corrosion affecting first 12” of Carbon Steel tube ends.Conoco-Phillips and Fluor Daniel developed a new design for the repair of this exchanger, including CTI Shields used in conjunction with ceramic ferrules. This not only saved “alot of money” vs. retubing, but increased the efficiency and reliability of the unit.


SOLUTION:

Installation of 378 CTI Shields, fabricated from Type 316 Stainless Steel. Shields were 18” long with a wall thickness of 0.049”. A hybrid expansion was performed by hydraulically expanding the Shields for their full length followed by a mechanical expansion for the first and last inch. Ceramic “hex head” ferrules were then installed into the inlet ends of the new CTI Shields in order to handle the extremely high temperatures.

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