TITANIUM SURFACE CONDENSER TUBING - THE FIRST THIRTY YEARS

By: Dennis J. Schumerth of VALTIMET, Inc. Tustin, CA

INTRODUCTION
Titanium, most commonly used for surface condenser tubing production, is commercially pure (cp), Gr. 2
material manufactured to ASTM B-338-03/ASME B-338 (1). Over the years, ASTM has expanded B-338 to
include 35 different grades most alloyed to produce specific properties covering severe chemical service to
aerospace to prosthetic to architectural uses (see Figure 1). While Gr. 2 is commonplace for tubing, the softer
Gr. 1 is typically used for kinetic bonding while alloyed grades offer superior corrosion resistance and higher
strength at elevated temperatures.

While the number of titanium grades has dramatically increased, the tube gauge or wall thickness of titanium
has likewise decreased. Where seamless, 18 BWG (0.049"/1.245mm) was introduced in the late 1950's,
welded seam, 25 BWG (0.020"/0.5mm) and even 27 BWG (0.016"/0.4mm) is now commonplace (see Figure
2). The first complete installation of Grade 2 titanium condenser tubing in a US power plant occurred in 1972
at the 490 MWe ConEdison - Arthur Kill Unit #3 (2, 14). Following comparative testing of competing tube
materials, a partial titanium re-tube, followed by a complete replacement of the remaining aluminum bronze
(C608800) tubes, eliminated severe corrosion problems after only 17 months of operation. Thirty years later,
the Arthur Kill Unit #3 (a current NRG holding) remains fully operational and a growing fleet of nearly 300
new, modularized and re-tubed titanium surface condensers have been installed worldwide. These units have
provided power plant operators with more than three decades of corrosion-free operation - indeed a new
industry hallmark of availability and capability.

comparative testing of competing tube materials, a partial titanium re-tube, followed by a complete
replacement of the remaining aluminum bronze (C608800) tubes, eliminated severe corrosion problems after
only 17 months of operation. Thirty years later, the Arthur Kill Unit #3 (a current NRG holding) remains fully
operational and a growing fleet of nearly 300 new, modularized and re-tubed titanium surface condensers have
been installed worldwide. These units have provided power plant operators with more than three decades of
corrosion-free operation - indeed a new industry hallmark of availability and capability.
COMPOSITION & PROPERTIES
The characteristics of Gr. 2 titanium are exceptionally well suited to the power plant surface condenser. The
combination of high strength, corrosion resistance, light weight and more importantly, the development of
successful fabrication and testing processes within both the tube vendor and the shop environment has
advanced the dramatic increase in the use of this material over the past 30 years.

Figure 3 & Table 10 (1) list the comparative mechanical and physical properties of typical condenser tube
materials. The tables have been prepared as a general guideline for the designer to apply mechanical properties
of the intended material.

CORROSION RESISTANCE
Over the past 30 years, the performance of Gr. 2 titanium in the power plant surface condenser has been
exemplary. The material is generally immune to chlorides and other halides present in most process streams
(5, 13). In addition, titanium remains unaffected by aggressive phenomenon including steam and particle
erosion, crevice corrosion, galvanic attack, SCC and MIC. The few past tube failures were initially, and
continue to be, associated with mechanical damage and extraneously induced, fatigue-related vibration.
During the 1980's, several galvanic corrosion issues were reported that piqued industry concern. In these
cases, condensers were re-tubed with titanium using the existing and unprotected brass or aluminum bronze
tubesheets. Once the industry recognized the dilemma of such a dangerous galvanic couple, high performance
epoxy coatings were used as an effective remedy. In 1982, the Baltimore Gas & Electric Company was the
first utility to modularize their surface condenser at Calvert Cliffs Unit with titanium tubes and clad titanium
tubesheets. This evolution not only eliminated the galvanic couple at the tube-to-tubesheet joint but became
the precursor to future applications that employed an entire titanium tube/tubesheet interface.
MIC or microbiologically influenced corrosion can attack materials inducing severe pitting. Titanium,
uniquely among the common engineering materials, appears to be immune to MIC. Laboratory studies
confirm (6) that titanium is resistant to the most aggressive aerobic and anaerobic organisms with no reported
events. Naturally occurring manganese on condenser tubes or alternatively, bio-mineralized manganese oxide
is a phenomenon can cause severe pitting of condenser tubes. It is an insidious problem in that it induces
pitting by changing the potential of the tube material. Titanium is immune to this type of attack because it has
a very high chloride pitting potential (on the order of +10V). Austenitic stainless steel, in the same
environment, has a pitting potential very close to its rest potential (less than +1V) (13) and can be susceptible
to pitting attack when oxidizing compounds are present that raise the threshold potential (7).
HEAT TRANSFER
Little in the way of innovation has taken place over the past several decades in terms of how power plant
surface condensers are designed. Several techniques are available to the designer to determine the overall heat
transfer rates or coefficient within a steam surface condenser.
These may include methods proposed by HEI (Heat Exchange Institute) or EPRI (Electric Power Research
Institute). The HEI method is often used for the design of new units and allows a more direct comparison of
competing designs. The EPRI method is more effective for calculating the performance of existing units and
partial load calculation. Table 17 identifies included can be used to identify the thermal conductivity
differences between the various tube materials. It is noteworthy that that conductivity of titanium is not as
good as the copper and brass alloys but better than the austenitic stainless steels.

DESIGN CONSIDERATIONS
Since the Baltimore Gas & Electric - Calvert Cliffs first use of a complete titanium tube/tubesheet interface,
solid or explosively clad titanium tubesheets have become the accepted practice for new units. Should a solid
plate be selected, a gasketed flange joint on both the carbon steel shell and waterbox side of the condenser is
typically employed. Titanium can only be welded to titanium; thus, a gasket is required at this interface.
Explosively clad tubesheets can be used when the shell flange is eliminated allowing the parent steel backing
of the clad tubesheet to be welded directly to the condenser shell. In certain cases, this weld joint becomes
attractive in terms of air inleakage prevention at the waterbox to shell interface.
Ideally, any titanium re-tube should consider the use of replacement titanium tubesheets (either solid or clad).
This compatibility not only offers the advantages of a rolled and welded tube joint but also prevents ligament
stretch when expanding titanium tubes into a radial. Tubesheets can be replaced providing accurate templates
of the existing tubesheet are produced at the site or drawings are made available from the OEM. Practically
speaking however, the existing tubesheets are typically reused for reasons of both economics and logistics.
Rolled-only tube joints employing a variety of tubesheet materials and ID groove assistance (serrations) have
demonstrated a high degree of success and continue to be the method of choice for field re-tubes. In either
case, waterboxes can either be coated or protected with an impressed current cathodic protection system.

Condenser waterboxes also deserve attention as a condenser component. Care must be exercised to protect the
vulnerable carbon steel from galvanic attack in high chloride or high conductivity cooling water. High solids
epoxy coatings used in conjunction with IC or sacrificial systems have proved to be highly successful over the
past 20 years. In particular, cast iron should also be coated since the presence of the large titanium cathode
increases the graphitization rate of the cast iron.
If an impressed current protection system exists within the condenser system, the location of the anodes,
reference cells and operating parameters should be examined to ensure the system is compatible for operation
with titanium tubes. The following are suggested guidelines. However, it is a good idea to enlist the services
of a reputable corrosion-engineering house for final confirmation.

These guidelines were adopted following a hydriding event at Florida Power & Light - St. Lucie and Turkey
Point 2 nuclear units. An improperly designed IC system, operating at excessive potentials for more than six
years, hydrided selected tubes to almost 50% of their tube wall thickness. The system was redesigned and to
date, no tubes have been replaced. As a closing anecdote, prior literature (8) has discussed hydriding and IC
system settings in terms of automatic voltage potential control. The use of sacrificial anodes should carry a
similar cautionary note. Sacrificial anodes should be selected to produce negative potentials of < - 0.85VSCE.
Where zinc, cast iron or aluminum may be selected, magnesium should be avoided due to its high negative
potential.
MODULAR REPLACEMENT
The modular change out of an existing surface condenser rather than a tube-for-tube replacement has found
significant merit over the past 25 years. In this concept, most condenser internals including tubes, tubesheets,
support plates, support structure and waterboxes are removed. Prefabricated tube bundles or modules are
transplanted into the vacant condenser shell. Certain advantages are associated with this type of condenser
rehabilitation (8, 9).

The rationale for the modular change out can be justified on a wide variety of variables. They may include
metallurgical upgrades tied to water chemistry changes, condenser leaks causing contamination of the boiler
or HRSG feedwater, turbine up rates which require subsequent improvement in condenser capacity tied to
operating license extensions, specific outage requirements and a host of others. A number of case studies are
worthy of investigation.
In 1981, the first titanium modular change out occurred at the Baltimore Gas & Electric - Calvert Cliffs Unit
No. 2 (17). The rationale was driven by a need to select a replacement tube material that would resist steam
impingement/erosion, eliminate tube-end pitting, provide inlet end erosion resistance from incoming debris
and prevent damaging tube vibration with a redesigned tube bundle support structure. In 1982, VEPCO (18),
as a result changing secondary plant chemistry from phosphate to all-volatile (AVT), installed prefabricated
titanium modules consisting of 71,320 0.875" x 22 BWG tubes. In 1987/1988, (15) supported by a
management-sanctioned directive to improve fleet heat rate, the ConEdison, Ravenswood Unit 1 refurbished
their condenser with titanium modules. The reasons were indeed compelling and included degraded heat rates
due to condenser leaks. These leaks linked significant increases in maintenance costs due to boiler waterwall
failures due to hydrogen induced waterwall tube leaks from salt water ingress into the boiler. A modular
change out was chosen which allowed for a complete single source turnkey redesign incorporating welded
titanium tube joints. Yet another example was the Arkansas Nuclear One (Units 1 & 2) (16). During 1997,
ANO-1 completed a titanium modular change out of their surface condenser. Here, the reasons were quite
different and included the requirements for removal of the copper-based materials from the condenser system

and elimination of tube ID erosion, steam impingement, ammonia grooving, inter-granular corrosion and
vibration damage. Of particular concern was copper transport and deposit throughout the secondary system,
which has been identified as detrimental to the integrity of the steam generator tubing. In addition, an 8%
power up rate was to be incorporated into the replacement condenser design coupled with bundle-out-ofservice protection. The most recent change out will occur in 2005 where Omaha Public Power District - Ft.
Calhoun will install new modules to reduce maintenance costs and improve reliability in support an operating
license extension. To date, more than 35 modular condenser change outs have been successfully completed.
VIBRATION
Prior to the last decade, engineers designing base-loaded, fossil and nuclear plant surface condensers
approached tube vibration with a cavalier attitude. Large, robustly designed condensers equipped with
generous flow areas, experienced few operating problems. Infrequent steam dump conditions (10 to 20%
load), rapid decay times after trip and little if any effort at condensate recovery produced a relatively trouble
free product.
Conversely, with the advent and popularization of combined cycle gas-fired plants, a host of new operational
nuances were encountered. Multiple HRSG's, multiple starts per month/per year, 200% bypass conditions,
complex multiple steam dump lines with varying pressures and dump systems and DCS desuperheating
stations that can operate continuously or intermittently - with or without spray atemporation, has created an
entire new set of design challenges. As a result of these new and potentially damaging operating conditions,
more exacting methods exist today that will limit tube deflection and predict damaging vibration. One method
that can be proposed is the methodology identified in the Ninth Edition, Addendum 1 of the HEI.
Specifically, new Section 5.5 - Turbine Bypass Guidelines (10) provides more definitive information in terms
of energy release and noise abatement measures. Other proven methods employ the velocity-dependent
Conners method to limit the natural frequency to safe values. Excessive tube vibration in a surface condenser
can result in flow-induced fatigue failure at or near the support plates - either mid span or at the plate itself.
Titanium's hardness and fatigue resistance acts to minimize vibration damage. However, its lower modulus
(vs. steel or copper-nickel alloys) must be considered in the design to keep deflection within acceptable limits.
NDE TESTING
Titanium, and in particular, welded tubing manufactured to ASTM B-338-03 undergoes considerably more
exhaustive post-process testing than other competing materials. Mandated nondestructive testing includes
both electromagnetic (E-C) and ultrasonic testing (U-T). B-338-03 also requires a final pneumatic test - either
air underwater (AUW) or pressure differential (P-D). Most competing materials require only an E-C test and
any final pneumatic test such as AUW becomes merely an optional, non-mandatory (Supplement) test. In
addition, many titanium-tubed condensers face the prospect of a post-manufacturing, I.D. probe, E-C test to
establish a baseline or default position. Future NDE testing can then be compared against this baseline to
establish a condition analysis of the equipment over the anticipated life.
CONCLUSION
To the casual observer, titanium's successful service life beginning with the first complete titanium-tubed
condenser in Staten Island New York in 1972 continuing 30 years, 300 condensers and 300 million feet later
may appear mundane - an exercise in predictability to the untrained eye. However, when one considers the
technical evolution of this material from the "gun barrel" mentality of the 50's to initial reluctance by the
pundits through product and process improvement to today's standard as the material of choice in aggressive
water environments, the successful evolution of this material can be considered as far from mundane. Today,

designers, fabricators and users alike have linked the clear technical advantages of the metal with a long-term
lifespan commercial position providing the industry with a near-seamless performance profile not offered by
any other material. The results of our thirty-year service exam paper confirm our expectations and clearly
demonstrate the continued use and confidence in Gr. 2 titanium tubing and tubesheet plate for power plant
surface condensers.
REFERENCES
1. American Society for Testing & Materials: (ASTM) B-338-02
2. Twenty Years Service with Titanium Tubed Condensers: Donald M. McCue & John A. Mountford - TIMET 48th Annual U.S. Sea Horse Institute Meeting,
August, 1992
3. HEI vs. EPRI Heat Transfer Rates in Surface Condensers:
1997

Donald M. McCue & Dennis Schumerth - Valtimet & John Mountford - TIMET IJPGC November

4. Titanium Surface Condensers & Heat Exchangers - A Practical Guide in Theory and Application: Dennis J. Schumerth - Valtimet & Donald M. McCue
Valtimet IJPGC PWR Vol. 33, 1998
5. Thin-Wall Titanium Condenser Tubing - Explore the Opportunities: Dennis J. Schumerth Valtimet IJPGC - 1999
6.

Impact of alloying on Microbiologically Influenced Corrosion - A Review: P. Wagner & B. Little Materials Performance, Volume 32, No. 9, September 1993

7. Effect of Biomineralized Manganese on Pitting Corrosion: Olesen, B.H., N. Yurt, Z. Lewandowski Materials & Corrosion (2001) and Power Magazine,
September 2002
8.

Valtimet Titanium Tubing Design & Fabrication Handbook: October, 2003

9. Thin-Wall Titanium Condenser Tubing - The Next Plateau: Dennis J. Schumerth Valtimet IJPGC - 2002
10. Heat Exchange Institute: (HEI) 9th Edition & Addendum 1
11. Titanium Metals Corporation: (TIMET)
12. Ocean Temperature Difference Power: Unit Research Project, Kobe Steel & Saga University
13. Corrosion Resistance of Titanium: Titanium Metals Corporation (TIMET)

Publication, 1999

14. Titanium Metals Corporation: (TIMET) Installation Records

15. A Titanium Tube Modular Condenser Change out at the Ravenswood Generation Station: ASME PWR Vol. 1980
16. Modular Condenser Replacement at ANO-1 Solves Operating Problems and Improves Performance: ASME PWR Vol. 34 1999
17. Shop Tubed Modules - Calvert Cliffs Nuclear Plant - Unit No. 2. Maryland Shipbuilding Paper: circa 1981.
18. Surry Units 1 & 2 Condenser Rebuild: Nuclear Engineering Conference July 25- 28, 1982. Messrs. R.W. Calder & D.J. Cortin.