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EXPERTS IN HEAT EXCHANGER AND CONDENSER SERVICES

GMA Ambarli (Istanbul) Fuel-Oil Power Plant Requalification Coating tube sheets – water boxes Condensers Unit 40 - 50

G.M.A s.r.l. Final report, June 13th 2011

NON-DESTRUCTIVE CONTROLS – INTERNAL PIPE LINING, SHEETS AND INLETS COATINGS – TUBES CLEANING – WATER TANKS www.gma-tech.com

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SCOPE Coating of tube sheets and water boxes of two condensers having each:  11500 tubes  4 tube sheets (total surface 50 m2)  4 water boxes (the water boxes in the rear part are divided in two – total surface 180 m2)

www.gma-tech.com

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JOB DESCRIPTION The condensers were coated by a old neoprene membrane which was severely damaged and needed to be removed. The following solutions were adopted: - High thickness coating using Phencote 2000 of tube sheets - Protective coating of water boxes with Phencote HR 60 WB The job was performed using Turkish personnel under the supervision of 2 GMA workers (one engineer and one technician) and was successfully completed in 5 weeks.


DEGREASING

Degreasing of the condensers, in order to remove dirt and grease due to re-tubing activities. After cleaning the tubes were blown with compressed air in order to allow complete evacuation of water.


PLUGS INSTALLATION

Installation of protective polyethylene plugs on tubes which will protect tube ends during application of high thickness coating on tube sheets


ABRASIVE BLASTING

The surfaces of tube sheets and water boxes were blasted to SA 2 ½ grade; before painting the following analsys were performed: - Visual - Roughness - Soluble salts (Bresle) - Dust


COATING OF TUBE SHEETS (1)

HR60 Primer (applied by roller)

Phencote 2000 T.S. Applied by spatula (3-5 mm)

Grinding of surface after complete drying of paint


COATING OF TUBE SHEETS (2)

Surface after grinding: plugs are now viewable

Cleaning and removal of plugs

Application of 1 – 2 layer(s) of HR60 (topcoat)


COATING OF WATER BOXES

3-4 layers of Phencote HR60 W.B. Applied by roller with a DFT of 800 microns Very important: continuos verification of ambient conditions (temperature, RH and dew point)


FINAL INSPECTION

A 2-days session with final customer in order to evaluate: - Visual aspect - Dry Final Thickness - Adhesion of coating (pull-off test) - Absence of porosities (spark test)


EXPERTS IN HEAT EXCHANGER AND CONDENSER SERVICES

GMA

NON-DESTRUCTIVE CONTROLS – INTERNAL PIPE LINING, SHEETS AND INLETS COATINGS – TUBES CLEANING – WATER TANKS www.gma-tech.com

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Coating condensers 40-50 Fuel oil PP