plastocor® Technology minimises the costs of maintenance and repair in condensers and heat exchangers, plus loss of equipment life while optimising operational budgets.
Thanks to over 60 years in the business and our vast experience and know-how, at plastocor-international SA we understand the importance of protecting and optimising the efficiency of the entire cooling water cycle. Enhancing performance efficiency of condensers and heat exchangers while simultaneously reducing operational and maintenance costs is possible thanks to our pioneer technology – a made-to-measure combination of plastocor® Cladding, Inlet, Tube Lining and High-Performance Coatings Systems.
A focus on the original plastocor® Inlet Coating System is a fine example of how our smart, simple solutions provide sustainable economic results. Condenser and heat exchanger tubes damaged by inlet / outlet end corrosion and erosion can be immediately repaired and protected, thereby eliminating leakages, instead of being ultimately replaced which involves very high costs. Its feathered termination further erases the chance of step-erosion, a common problem with the use of plastic or metal inserts.
Retubing, which involves replacing corroded tubes with new ones, fouling, or unforeseen shutdowns due to leakages caused by damaged tubes imply major costs and/or a severe reduction in efficiency and output reliability. At plastocor-international SA, our aim is to minimise the costs of loss of equipment life due to tube erosion and corrosion and the subsequent loss of productivity due to resulting leakages. As the plastocor® Inlet Coating System securely seals the tube-to-tube-sheet joint and secures a leak-tight transition between the tube sheet and the tubes, the risk of galvanic corrosion as well as the probability of leakages is practically eliminated.
The plastocor® Inlet Coating System is applicable to both tube inlet and outlet and is applied via a unique 3-step method. This multiple-colour coating system makes it possible to calculate the remaining lifetime of coated tubes after any given time of operation, allowing for expert planning and optimisation of maintenance budgets.
Our track record in the field has proven that effective leakage reduction leads to a high return on the initial investment as equipment availability rates improve, maintenance costs are considerably reduced, and productivity improves as output reliability increases. The following two case studies highlight this point.
At plastocor-international SA we take our customer satisfaction seriously and are proud that we hold working relationships that span over 15 years, like that with Electricité de France (EDF). Our intervention of applying plastocor® Inlet System at the EDF Nuclear Power Plant Saint Alban showed that reducing the number of leakages by just 60% could result in direct savings of about €6m due to avoided loss of production.
Here we can see how important protection, maintenance and repair of condenser and heat exchanger tubes are and how investing in protective internal coatings like the plastocor® Inlet Coating System is a cost-effective alternative to conventional, expensive options like retubing.
Results from our intervention at the EDF Nuclear Power Plant of CRUAS are also impressive. After the first cycle of operation, the results of applying the plastocor® Inlet Coating System found that an estimated 39 avoided leakages resulted in an additional operating profit of €1,18m, in comparison to unprotected units. The coating was not only applicable to new tubes of the same material after retubing, but also to used tubes in other units of the plant. In CRUAS, applying the original plastocor® Inlet Coating System resulted in a ten-time return on investment in one year.
Furthermore, applying the plastocor® Inlet Coating System in combination with the original epoxy plastocor® Cladding System, used in the protection and repair of tube sheets, creates a uniform and smooth transition from water box through tube sheet to tube interior. This further reduces not only the chance of galvanic corrosion pits but also fouling and turbulence, which raises flow efficiencies.
plastocor® systems are fully compatible with each other and used in combination make for the ultimate protective technology for the entire cooling water cycle. Your one-stop shop for performance efficiency and excellent return on investment.
To learn more, please contact the company via the enquiry form.