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Company profile

Surface and corrosion protection systems for the entire cooling


water cycle

plastocor-international SA
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.

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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
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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.

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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.

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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
info@plastocor-international.com

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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

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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.

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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.

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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.

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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

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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 inner tube surface before tubelining
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 after tubelining

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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 360°spray nozzle in retraction mode
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 tube lining
and more can be coated.
Tubes protected with this tube lining system have
new uncoated
had a service life of more than 9 years, in some tube

cases up to date. tendency for reduction in heat transfer


values for coated and uncoated tubes

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Tube lining working steps

picture 1:

patented tube lining


equipment

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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.

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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.

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Some clients of plastocor-international SA

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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
info@plastocor-international.com
http://www.plastocor-international.com

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