Proceedings of IJPGC'02

2002 International Joint Power Generation

Conference
Phoenix, AZ, USA, June 24-26, 2002
Conference Paper No. IJPGC2002-26121

THIN-WALL TITANIUM CONDENSER TUBING

THE NEXT PLATEAU
Principal Investigator
Dennis J. Schumerth
Valtimet, Inc.
Tustin, CA
ABSTRACT:
prudent to examine key ingredients that would
warrant consideration of this "next-plateau"
gauge material. Indeed, work is currently
underway exploring the technology required to
fabricate condenser tubes as thin as 30 BWG
/0.013"/0.3 mm.

Commercially pure (cp.) titanium and its alloys

provide excellent resistance to general and
localized corrosion attack under most oxidizing,
neutral and inhibited reducing conditions in
aqueous environments. Titanium is also notable
for its outstanding resistance to chlorides and
other halides generally present in most process
streams. In addition, titanium resists other
malicious phenomenon including steam and
particle erosion, crevice corrosion, galvanic
attack and MIC. Given this general corrosion
immunity, designers have increasingly applied
thin-wall condenser tubing in pursuit of cost
savings and performance enhancement.

In summary, the paper will present and

summarize substantive evidence suitable for
comparison
against
previously
acquired
empirical data and prior art.
BACKGROUND
Previous work, completed during the mid 90's
and published in 1999 (1, 2, 6, 7), suggested the
properties of thin-wall titanium could provide
attractive options to the designer/user in terms
of habitat suitability, long-term reliability and
performance and economic savings.

Typically, these thin-wall applications have, over

the past several years, been limited to 25 BWG
or 0.020"/0.5mm walls or heavier.
The
"industry" has, out of necessity, moved to
address the special nuances of the 25 BWG
including design, procurement, handling,
fabrication and testing parameters with
increasing success. It would appear however,
that designers, operators and pundits alike
require further education and refinement on the
specific
operational
characteristics
when
integrated into the powerplant environment.

Empirical and actual testing was used at that

time to compare the prevailing wisdom of
heavier wall tubing usage vs. the newly
introduced thin-wall.
Actual testing involving fatigue properties, both
from internal pressure and external excitation,
demonstrated highly admirable characteristics.
Buckling strength or longitudinal compression
tests were evaluated employing Euler's
equations and found to be well within acceptable
limits (1,6).
Other key issues including
mechanical expansion and resultant pullout
strengths were compared against heavier wall
tubing. The results suggested a rolled and

Considerable work has been recently completed

investigating even thinner wall titanium tubing.
This paper will address the essential data
elements of this expanded research focusing
specifically on Grade 2 titanium in 27 BWG or
0.016"/0.4mm. Since a significant portfolio of 27
BWG installations is rapidly taking shape, it is

welded joint should be employed when

considering tube
walls less than 22
BWG/0.028./0.7mm. This procedure is highly
recommended for both solid and clad
tubesheets.
Support plate spacing was
evaluated employing steam-loading calculations
applied to design base, bundle out of service
and turbine bypass conditions.

TABLE 2
TEST NO
1
2
3

PROCESS
MECHANICAL EXPANSION
MECH EXP + ID GROOVE ASSISTANCE
MECH EXP + TIG WLD. (NO ID GROOVE)

TABLE 3

Data is now available which can directly

compare the previous papers' investigations and
findings (l) against more mature, practical and
demonstrable findings.
In addition, the
installation experience at the time of the paper's
presentation, which was limited to several
installations in Japan and Europe plus a host of
desalination units, was considered inadequate.

Tube Material

Titanium Gr. 2 B-338

Tubesheet Material
Tube Size - OD & BWG
Drill-Out Hole
Tubesheet Hole
Joint Configuration

Titanium Gr. 2 B-265

.866"/22mm x .016'/0.4mm
.875"/22.225mm
See Table 2
See Table 2

It is clear, upon examination of the new data

scatter in Figure 2(3), that pullout loads are
comparable to the results demonstrated in the
previous 1999 work. This data similarity is not
surprising and suggests practical and achievable
results in a manufacturing environment.

PULL-OUT LOADS
One of the most important elements of this
paper's investigation is a comparison and
confirmation of the suitability, or lack thereof, of
tube-to-tubesheet loads in a commercially
repeatable environment using the 27 BWG
tubing. Previous testing, completed in 1999
(Figure 1), confirmed that pullout loads,
employing a mechanically expanded joint alone,
were not sufficient to support the necessary
safety factors required by the designer.
However, when tube welding was added to
supplement the rolled-only joint, acceptable
pullout loads resulted. The tube parameters
identified in the below Table 1 were used to
develop the Figure 1 results.

TUBE-TO-TUBESHEET EXPANSION
Five-roll, mechanical expansion of the 27
BWG/0.016"/0.4mm thin wall titanium tube
should range from 7 to 12% wall reduction. The
following classic formula should be used when
calculating the per-cent wall reduction.
% Wall Reduction = D - (DE -2T)
2T
where

TABLE 1
Tube Material
Tubesheet Material
Tube Size
Drill-Out Hole
Tubesheet Hole
Joint Configuration

1.

Titanium Gr. 2 B-338

Titanium Gr. 2 B-265
1"/25.4mm
1.1"/28mm
Plain - No Serrations
Mech Exp or Exp & Weld

2.

Nominal tube expansion should not exceed the

tube OD by 3%.
Five (5) roll expanders are recommended where
the OD/T ratio is greater than 25 (8).
where

Additional pullout testing was recently completed

which, when evaluated, could be directly
compared against results reported in the
previous work. In this case, this new testing was
completed using the three, expansion/weld
processes
identified
in
Table 2
and
tube/tubesheet parameters noted in Table 3.

D = Hole Diameter
DE = Inner Tube Dia. after Expansion
T = Tube Wall

OD = Nominal tube OD
T = Wall thickness

Expansion beyond the upper limit may actually

reduce pullout loads and potentially, induce tube
cracking or incipient failure of the mechanical
joint. In fact, historical results employing heavier
wall tubing suggest the percent expansion need
not be as high as the thin-wall counterparts less than 10%.

configuration and quality.

However, these
operations may influence weld speed resulting in
increased
tube-to-tubesheet
weld
time.
Understand the thinner the tube wall, the more
the tubesheet will become an ever-larger heat
sink. In addition, the more the tube wall is
reduced, the higher degree of difficulty in
repairing the weld.

TUBESHEET & SUPPORT PLATES

Particular care must be paid to the fit and finish
of the drilled tubesheet plate holes. When
considering thin wall titanium, this author
suggests tubesheets be drilled to TEMA Close
Fit Tolerance.
This operation prevents
excessive tube-to-tubehole clearance, which
may induce undesirable tube deformation during
the rolling operation.

VIBRATION
Operational nuances, not normally encountered
with more traditional designs, may come into
play more often when evaluating the use of thin
wall titanium. These phenomenon are deserving
of special consideration by the designers and
would include, but not limited to, the following.

ID groove assistance employing multiple

serrations or concentric rings clearly enhances
pullout strength. Serrations to a depth of
0.004"/.1mm or less are typical. Others prefer
ID
surface
enhancement
or
controlled
roughness (< 50 microns Rz) to achieve the
desired results. What is ultimately used to
enhance pullout and sealing should be left to the
discretion of the designer based on actual
testing and results.

Peripheral Tubes
Heavier walled tubes, typically reserved as
"optional" or for the first several rows only, may
require a deeper bundle penetration.

Support plates should be drilled to HEI

standards and deburred or chamfered on both
sides of the plate. Indeed, wire brush operations
may not suffice in terms of complete removal of
chip material left behind after drill bit exit. This
"both sides" operation is strongly suggested to
eliminate or at least minimize any scratches or
"exit wounds" that could be imparted to the tube
OD. It is presumptuous to assume that support
plate orientation during cage assembly will
segregate all one-sided drilled plates in the
direction of tube entry. Hoping the tube bullet will
break any burr on the un-chamfered side is a
bold assumption indeed and could result in
unanticipated
problems
associated
with
subsequent base line E-C or other postassembly testing.

Larger OD Tubes
The use of 1"/25.4mm or larger tubes may
reduce the vibration potential.

Flow Induced Vibration

Steam flow may penetrate deeper into the
bundle requiring close examination of flowinduced excitation parameters.

Bundle Flow Areas

Entrance and exit areas, steam lanes, etc. in
and around the bundle may have to be
increased requiring additional surface area.

TUBE-TO-TUBESHEET WELDING
Tube-to-tubesheet welding, employing a TIG
process with shielding gas, is strongly
recommended when using thin-wall tubing
(under 22 BWG/0.028"/0.7mm) and solid
titanium tubesheets.
It is imperative when
employed in a clad or bi-metallic tubesheet
arrangement. Be advised that titanium can only
be welded to titanium - no other commercially
available material is metallurigically compatible.

Support Plates
As many as one or two additional support plates
may be required.

Steam bypass & bundle-out-of-service

Anomolies associated with steam bypass
conditions and off-design operation will require
careful "what if" scrutiny.

Increasing the tube protrusion beyond the face

of the tubesheet and reduced weld-bead heat
input to the tube-tubesheet interface may prove
successful
in
enhancing
the
nugget

In terms of the support plate spacing, earlier

experimental work and empirical data (1),
concluded support plate spacing should be
reduced as a ratio of tube wall vs. HEI allowable
deflection. In the case of 27 BWG tubing, a ratio
of .76 determined the minimum spacing to be
29". It would now appear that support plate
spacing for 27 BWG tubing should fall into a
range closer to the 24".
HANDLING AND LOGISTICS

Figure 3

To date, there is no evidence that suggests any

greater degree of difficulty in handling the 27
BWG tubing vs. the heavier walled cousins.
However, it is recommended that tube boxes be
placed in close proximity and elevation to the
bundle entry area to prevent the possibility of
kinking or bending which can result from
excessive tube movement.
Care must be
exercised to prevent any denting during the
fabrication process, as this stress riser could
eventually become an incipient point of high
cycle fatigue failure.

Of particular significance are the low E-C

(Electromagnetic or more commonly, Eddy
Current Testing) & UT (Ultrasonic Testing)
rejection rates for the final product. Coupled
with precise control of the diameter, nugget
geometry and weld-undercut discipline, users
can be assured that the product will perform in a
manner meeting the requirements of ASTM B338-01a.
CLEANING
In support of actual, in-service conditions, where
fouling will most certainly take place, Conco
Systems of Verona Pennsylvania performed
tests on sample titanium tubes manufactured to
ASTM B-338 Gr. 2.

Protection of the exposed tubing in high velocity

and peripheral areas of the bundle must also be
addressed. Dummy tubes, impingement rods
and other measures must offer complete
protection for the tubing from mechanical impact
damage.

Three tests were performed on the sample

material (0.9450"/24mm outside diameter (OD) x
27 BWG/0.016"AVW/0.4 mm wall thickness).

TUBE MANUFACTURING
Tubing produced by the supply mills to the
standards of ASTM B-338 must adhere to the
highest levels of quality but result in acceptable
levels of mill productivity and yield. All this must
take place before the condenser fabricators are
convinced that the material is suitable for use in
a surface condenser.
Grade 2, 27 BWG
titanium tubing has been successfully produced
for a number of years.

Visual Inspection
E-C Examination
Hydrostatic Test

The tests were conducted using various Conco

tube cleaning tools including type(s) C3S, C4S
and C3X.
A visual inspection was performed comparing
an as-received sample section vs. a sample
section that had various tube cleaning tools
"shot" or driven through. Each section was
examined after the test and compared against
each other. No noticeable visual or dimensional
differences were discernable up to a 10X
magnification.

Yet in terms of productivity, yields have been

less than desirable. However, over the past
several years, full production runs of the strip
material supplied from numerous sources have
proved highly successful setting the standard for
commercial use.

An as-received sample was again examined

using a Zetec MIZ-27 Analyzer. Only minor drift
signal anomalies were recorded probably
associated with the tube weld. The signals were

considered insignificant. The same sample was

again "shot" with the three (3) tube cleaning
tools identified above. The results noted no
rejectable or signals of consequence. In fact,
the signals first recorded during the parent-tube
test, actually reduced in magnitude after the
samples were cleaned.

Reducing the wall thickness of the tubing

reduces the weight of the tubing.
It is
noteworthy that the weight of a 27 BWG titanium
tube ranges between 55 & 60% (depending on
diameter) when compared to its 22 BWG
counterpart.
These weight reductions and resultant uplift
considerations require a more robust analysis of
the foundation loads, bolting, expansion joints
and other condenser components that would be
impacted by the weight reduction. In addition,
larger flow areas associated with thinner walled
tubes can influence circulating water flow and
pump NPSH considerations.

Finally, a third sample was hydrostatically tested

to a pressure of 2100 PSI. No failures occurred
noting only expected minor plastic OD
deformation in the range of 0.015". In point of
fact, surface condenser tubes would never
experience such high pressure. Even the use of
individual tube hydro testing, which operates in
the range of 645 PSI, (ASME UG-27 max
working pressure calculation), falls well below
either the 2100 PSI or a burst pressure of a 27
BWG titanium tube (.016"/0.4mm) calculated at
3191 PSI/220 Bars.

Certain conditions may preclude the complete

removal of existing condenser tubes or, plant
logistics make removal commercially impractical.
In addition, a straight retube may prove more
costly, present dissimilar material constraints
and modules do not provide the required
payback.

Condenser tube fouling is real and a fact of life

within an operating powerplant surface
condenser. It is apparent, after reviewing the
test conditions and results, that this proven type
of cleaning system has no effect on the
mechanical properties of the tube. If this axiom
is true for scraper cleaning systems, other, more
benign cleaning methods including sponge balls,
brushes, water lances, etc. can be utilized with
little or no apprehension.

Sleeving existing condenser tubes with ultra thin

wall titanium is currently under test and
consideration. The thin wall is hydraulically
expanded full length into the parent tube with the
tube ends mechanically anchored in each
tubesheet. Should additional embellishment be
considered beyond just the sleeve replacement,
a multi-part epoxy coating can be applied to add
corrosion resistance while enhancing the tube
pullout load characteristics.

OTHER CONSIDERATIONS
An HEI Ninth Edition Supplement, soon to be
released, will address, among other issues, new
criteria to be applied for steam bypass
conditions. Clearly, additional work is needed by
this august group beyond even this Supplement
to address issues specific to combined cycle
applications. Notable and unfortunate as of this
writing is the absence of any HEI Standards
information relating to metal resistance and/or
correction factors for tubing less than 25 BWG.
Designers must therefore, address the heat
transfer characteristics of 27 BWG tubing
independently.
The thermal conductivity of
titanium is readily available (8) (150 BTU/hr ft F/in) and the metal resistance can be easily
(8)
developed from existing data in Figure 4.
should alternate rating methods be employed.
Designers will find that reducing wall thickness
improves the heat transfer characteristics of
titanium when compared to other materials.

INSTALLATION HISTORY
The Japanese Titanium Society reported in
(3,6,7)
successful installations of 27
earlier work,
BWG Gr. 2 titanium in both desalination and
powerplant applications.
These installations
have been in service for over 15 years with no
documented problems. Table 4 identifies more
recent vintage installations primarily in France
and in the UK. It is noteworthy however, that
condenser manufactures in the US are now
evaluating the use of this gauge material

Mechanical expansion techniques, tubesheet

and support plate fit & finish, tube-to-tubesheet
welding and other processes appear to be
successfully practiced in today's environment.
They are clearly, not future technical folly but
proven technology that exists today.

TABLE 4
27 BWG/.016"/0.4mm INSTALLATION LIST
(Partial)
YEAR

DIM/OD

KM

DESTINATION

1981

17

FRANCE

1999

12.7

FRANCE

1999

16

12

FRANCE

1999

22

926

SPAIN

1999

24

253

GB

2001

20

FRANCE

2001

24

144

MALAYSIA

2001

21

288

VIETNAM

2001

24

294

GB

2002

21

137

PORTUGAL

Efforts to address the nuances of combined

cycle steam exhaust and bypass conditions will
require additional work by professional societies
and the manufacturers alike.
Current
techniques are frankly, not adequate to predict
certain dangerous operating conditions.
Tube mill production runs of strip material
supplied from numerous sources have produced
successful yield and production goals setting the
quality standard for commercial use. Handling,
at both the supplier and fabricator levels, does
not appear to present logistical issues nor
invoke any specialized or precautionary steps.

CONCLUSION
Given continuing, industry-wide pressure to
reduce costs, improve performance and
significantly contribute to improved online
availability and capability, a transition to less
costly, high performance materials is inevitable.
In the case of surface condensers employing 27
BWG or 0.016"/0.4mm tubes, the opportunity
exists to examine, evaluate and realize the
potential merits of reduced or thin wall tubing.

An analysis of cleaning techniques has

confirmed the future suitability of both the tube
and the cleaning systems.
Recall the object of this paper, which was to
evaluate additional, recently acquired data to
compare, validate and expand on prior work.
This author believes that practical confirmation
of this work has indeed, been documented and
achieved. Confirming the validity of prior art
while expanding directly into newly developed
technology and practical issues provides merit
for future examination of thin wall titanium
condenser tubing.

Notable in the work just presented, and a key

element in this paper's investigation, is a clear
confirmation of acceptable pull out loads.
Welded-only tube joints, and/or welded joints
employing
I.D.
enhancement,
clearly
demonstrate the repeatable practicality of
achieving an acceptable tube joint within a shop
manufacturing environment.

Figure 1
Tube Pull-Out Loads Tests - 1999

7000

Pu ll-o u t Lo ad s (lb s.)

6000
5000
4000
3000
2000
1000
0
30 BWG

27 BWG

25 BWG

Rolled Only

22 BWG

Roll & Weld

Figure 2
Tube Pull-Out Load Test - 2001
18

% W all Reduction

16
14
12
10
8
6
0

500

1000

1500

2000

2500

3000

3500

Pull-Out Loads (lbs.)

Mech Exp

Exp + ID Groove
7

Exp + Weld

4000

Figure 4
TITANIUM METAL RESISTANCE
METAL CORRECTION FACTORS
SUPPLEMENT TO TIMET TUBE BOOK TABLE 10 - 1996 REV.
TUBE

BWG

WALL

FACTOR

Metal

O.D

THICKNESS

(FM)

Factor

IN/mm

IN/mm

1/25.4

25

1/25.4
1/25.4

(RM)

0.020/0.508

0.95

1.3607

26

0.0180.457

0.96

1.2222

27

0.016/0.406

0.97

1.0853

1/25.4

30

0.013/0.330

0.99

0.9867

0.875/22.225

25

0.020/0.508

0.95

1.3576

0.875/22.225

26

0.018/0.457

0.96

1.2232

0.875/22.225

27

0.016/0.406

0.97

1.0878

0.875/22.225

30

0.013/0.330

0.99

0.8787

0.75/19.05

25

0.020/0.508

0.95

1.3702

0.75/19.05

26

0.018/0.457

0.96

1.2293

0.75/19.05

27

0.016/0.406

0.97

1.0908

0.75/19.05

30

0.013/0.330

0.99

0.881

Notes:
Supplement to TIMET Tube Book Table 9 Metal Correction Factor (Fm)
Based on 0.875" O.D. @ 7 ft/sec C@ 700 F
Material = Gr. 2 Titanium
RM (Metal Resistance ) =
1 x 10 -4
2 0
BTU/hr ft F
FM (Factor) Titanium Gauge Correction Factor
DMc 3/31/00

REFERENCES
1.

Schumerth, - "Thin-Wall Titanium Condenser Tubing Explore the Opportunities." PWR - IJPGC
ASME 2000

2.

Schumerth, McCue - "Titanium Surface Condensers & Heat Exchangers - A Practical Guide and
Application." PWR-Vol 33 IJPGC Volume 2 ASME 1998

3.

HEI - Heat Exchange Institute

4.

HEI Standards - Ninth Edition

5.

ASME Boiler & Pressure Vessel Code

6.

Japan Titanium Society - 1984 - Multiple Authors - et al. "Get More Advantages By Applying
Titanium Tubing Not Only For Power Plants But Also For Desalination Plants."

7.

Japan Titanium Society - Multiple Authors - et al. Thinner Wall Welded Titanium Tubes For
Seawater Desalination Plant.

8.

CONCO Systems - January, 2002 - Thin Wall Titanium Tube Testing

9.

TIMET Codeweld Tube Book - 1984

Section UG-27

(plus subsequent revisions)