Guideline

Tubes for Condensers

and other Heat Exchanges
for the Operation of
Steam Turbine Plants ‒
Copper Alloys

VGB-R 106e

Publisher
VGB PowerTech e.V.

Publishing house
VGB PowerTech Service GmbH
Verlag technisch-wissenschaftlicher Schriften
P.O. box 10 39 32, 45039 Essen, Germany
Phone: +49 201 8128-200
Fax: +49 201 8128-302
E-mail: [email protected]

ISBN 978-3-86875-026-3 (Print)

ISBN 978-3-86875-558-9 (eBook)

www.vgb.org
© All rights reserved.

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Preface
The "Tubes for condensers and other heat exchangers for the operation of steam turbine
plants" guidelines are currently split into three material groups (VGB-R 106 "Copper
Alloys", VGB-R 113 "Stainless Steels" and VGB-R 114 "Titanium").
The guidelines are intended to provide information to the operating company of combined
heat and thermal power plants so that they can order the correct piping for condensers
and heat exchangers and also to help them prevent faults and damage. To allow a better
understanding and to assess pipe damage, the guidelines contain material-specific
explanations and information in the form of photos illustrating typical damage symptoms.
Condensers and other heat exchangers in thermal power plants are practically always a
part of a cooling water system with open circulation or once-through cooling. The
suitability of metal tube materials and other materials or protective layers/coatings in the
cooling system is determined from the corrosion-chemical behaviour of the available
cooling water and also from economic and ecological aspects. These are dealt with in the
VGB Cooling Water Guideline "VGB-R 455".
Many other VGB guidelines deal with the details of components in cooling systems. Apart
from these, data from the VGB guideline "Kühltechnik in Kraftwerken - Cooling
Technology in Power Plants", which is currently being drafted, should also be used.
The suitability of metal tube materials for condensers and other heat exchangers for the
operation of steam turbine plants that are impinged with condensate or feed water is dealt
with in the VGB Feed Water Guideline "VGB-R 450".
Please share your experiences in the use of this guideline with us - also in combination
with other VGB guidelines - and send any proposed improvements to the VGB office.
From the group of operators and manufacturers, the following people were involved in
compiling the new version of the guideline:
Mr. Blomeier, Mr. Czolkoss, Mr. Daum, Dr. Gahl, Mr. Hahmann, Mr. Harling, Mr. Hartwig,
Dr. Kern, Mr. Krause, Mr. Kurth, Dr. Leidich (Chairman), Mr. Richter, Mr. Seipp,
Mr. Stangel, Mr. Zelinger, Ms. Parczyk and Ms. Ringhoff.
The Power Systems trade association within
the VDMA

We would like to thank all of the above for their involvement.

Essen, December 2010
VGB PowerTech e.V.

ISBN 978-3-86875-025-6

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Contents

Part 1 Materials, Manufacture and Testing.......................................................... 7

1.1 Materials ....................................................................................................... 7
1.2 Manufacture of tubes .................................................................................... 7
1.3 Testing.......................................................................................................... 7
1.3.1 Aim ............................................................................................................... 7
1.3.2 Text facilities ................................................................................................. 7
1.3.3 Testing by the manufacturer ......................................................................... 7
1.3.4 Subsequent testing by the purchaser's authorised material expert .............. 8
1.4 Identification and Transport .......................................................................... 9
1.4.1 Identification ................................................................................................. 9
1.4.2 Transport ...................................................................................................... 9
Part 2 Recommendations for Operation .............................................................. 9
2.1 General......................................................................................................... 9
2.2 Measures for the prevention of corrosion damage ....................................... 9
2.3 Condensers ................................................................................................ 10
2.3.1 Testing for leak-tightness before commissioning ........................................ 10
2.3.2 Commissioning ........................................................................................... 10
2.3.3 Avoidance of deposits ................................................................................ 11
2.3.4 Protective film formation under adverse conditions .................................... 13
2.3.5 Cathodic protection..................................................................................... 13
2.3.6 Shutdown periods ....................................................................................... 14
2.3.7 Continuous operation ................................................................................. 17
2.4 Other heat exchangers for the operation of steam turbine plants ............... 17
Part 3 Causes of Tube Damage .......................................................................... 19
3.1 Tube damage through operational influences ............................................ 19
3.1.1 Uniform surface corrosion .......................................................................... 19
3.1.2 Localised, shallow attack and pitting corrosion ........................................... 20
3.1.3 Pitting corrosion .......................................................................................... 21
3.1.4 Erosion corrosion ....................................................................................... 22
3.1.5 Corrosion fatigue ........................................................................................ 23
3.1.6 Corrosion caused by ammonia ................................................................... 24
3.1.7 Corrosion caused by carbon dioxide .......................................................... 25
3.1.8 Failures caused by tube vibration ............................................................... 25
3.1.9 Droplet erosion ........................................................................................... 26
3.2 Tube damage due to manufacturing and tooling ........................................ 27
3.2.1 Stress corrosion cracking ........................................................................... 27
3.2.2 Selective Corrosion .................................................................................... 29
3.2.3 Intergranular Corrosion............................................................................... 30
Part 4 Applicable guidelines and standards ..................................................... 31

Part 5 Literature ................................................................................................... 34

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Part 6 Appendix ................................................................................................... 37

Table 3 Table 1 from EN 12451 [1] „Copper of copper and copper alloys” ...... 37
Table 4.1 Table 2 from EN 12451 [1] „Mechanical properties of copper .................
and copper alloys“ ................................................................................... 38
Table 4.2 Table 2 from EN 12451 [1] „Physical Properties of copper and ...............
copper alloys on the basis of measured data for your information” ... 39
Table 5 Materials (copper alloys) comparison with some standards....................
outside EU................................................................................................. 40

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Part 1 Materials, Manufacture and Testing

EN 12451 [1] applies to seamless tubes made out of copper and ductile copper alloys
used in condensers and other heat exchangers. EN 12452 [2] applies to finned tubes
produced by the rolling of copper and ductile copper alloys. Consider the following
remarks in addition to the above:

1.1 Materials
The characteristic material, chemical, mechanical and physical properties are given in the
appendix, see Tables 3 and 4. For the purposes of the comparison of EN specifications
with international specifications, refer to Table 5.

1.2 Manufacture of tubes

According to EN 12451 [1] and EN 12452 [2] the surface of the tubes should be smooth.
The depth of roughness (Rz) can be measured to assess the condition of the inner
surface in accordance with Paragraph 4, VDI/VDE 2602, Page 2 [3]. The roughness value
should not exceed 3 µm for tubes made from brass alloys (CW706R and CW702R), or
2 µm for tubes made from copper-nickel alloys (CW352H and CW354H). These limiting
values apply to the longitudinal direction of the tubes when ready for shipment. It is
recommended that the tubes be shipped in a previously heated stress-relieved state (with
oxide skin) /1/.
Further recommendations: For the alloys CW706R (CuZn28Sn1As) and CW702R
(CuZn20Al2As) the Magnesium (Mg < 0,005 %) and Arsenic content respectively.
Phosphorus (As 0,020 - 0,035 %; P < 0,015 %; As + P 0,020 - 0,035 %) additionally, has
to be limited to prevent dezincification while preserving the inhibiting effect of arsenic and
minimising inter-granular corrosion /1/. According to the purchaser's order, as specified in
EN 12451 [1] and EN 12452 [2], the agreed upon customary heat analyses, within the
volume of the finished tubes, can be repeated on demand by the purchaser for additional
analyses of tube segments taken out of the production run.

1.3 Testing

1.3.1 Aim
The examination serves to insure that the agreed upon tube quality and specifications
have been fulfilled. Generally the tests will be made by the manufacturer. Testing by the
purchaser or the designated authorised material expert (hence called purchaser) has to
be cleared with the manufactafurer.

1.3.2 Text facilities

The tubes will be tested and approved on-site at the manufacturer's.

1.3.3 Testing by the manufacturer

The following quality control tests will be made by the manufacturer with tubes in their
delivery status. As far as these guidelines recommend an additional limitation to current
standards, they are then subsequently to be certified in context with the appropriate
testing.

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― Verification of the chemical composition according to EN [1], [2]

― Tensile test according to EN ISO 6892-1 [4]
― Expansion test according to EN ISO 8493 [5]
― Grading of particle size according to EN ISO 2624 [6]
― Visual inspection of inner surface of the tube
― Testing for residual stresses1 [7]
The demanded volume of tests of batch inspection samples as shown in EN 12451 [1],
Table 6.
― Eddy current testing accordance to EN 19712 [8]
The following measures have to implemented in relation to the eddy-current tests:
― Test personnel: should be suitably qualified according to EN 473 [9]
― Technical requirements
- fill level of the test coil > 0.8
- an 8 dB increase in test sensitivity levels
- calibration of the tube under test: Test drilling 0.8 mm; 3 Drill holes, each
displaced by 120°
― Test volume 100 %
― Check dimensions, visual inspection3

1.3.4 Subsequent testing by the purchaser's authorised material expert

The manufacturer should inform the purchaser approximately two weeks before
production start of the likely duration of production.
Subsequent testing of the tubes by the authorised materials expert is normally carried out
on a spot-check basis. For this purpose, the tubes are to be made available in a suitable
manner in storage batches of approximately 500 items in order to ensure that the quality
specifications and delivery dates agreed are met. Non-destructive testing like eddy-current
examination is carried out during a production run. Samples for destructive testing, to
check on the mechanical-technical properties and the internal structure are also taken out
of a normal production run.

1
Only for alloys CW706R, CW702R and CW300G according to DIN 50916
2
Additionally hydrostatic and pressure loss examinations are allowed
3
All approved measures to guarantee the inner and outer condition as well as dimensions and straightness oft he
tubes according to EN 12451

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1.4 Identification and Transport

1.4.1 Identification
Tubes must be identifiable by the following means:
1. Manufacturer
2. Alloy
3. Dimensions
4. Production specifications

1.4.2 Transport
Each delivery is to be clearly identifiable through provision of the following information:
manufacturer´s mark, dimensions, abbreviated material designation according to DIN EN
or material number, when required, the abbreviated number for the condition of delivery,
case numbers stencilled on crates and recorded in packing lists and or delivery notes.
The tubes must be delivered in sealed packing cases and must be packed so as to avoid
longitudinal movement and impact damage. In case of production nails can only be used
in the direction - inside to the outside.
The lids of the packing cases are to be secured with bands only [NO nails].
Protection from the weather is required during both transportation and storage.
Transport of the packing cases shall be conducted with appropriate auxiliary equipment in
order to avoid damage to, or bending of the cases.

Part 2 Recommendations for Operation

2.1 General
In condensers and other heat exchangers (e.g. air, oil and hydrogen coolers) besides
stainless steel and titan tubes, tubes made out of copper and copper alloys are also in use
(12).

2.2 Measures for the prevention of corrosion damage

On the water cooling side tubes made of copper and copper alloys develop protective
films, which once formed, provide satisfactory resistance against corrosion. This formation
of a protective film is to be understood as being the sum product of the chemical reactions
between the material of the tube and specific impurities present in the cooling water.
These reactions can therefore occur slowly, or quickly, depending on various boundary
conditions (e.g. temperature, flow rate, degree of salinity, oxygen content, pH-value). The
formation and retention of the protective film is essentially dependent on conditions during
commissioning and during subsequent operation. Only with a comprehensive protective
film can corrosion be prevented and the long service life of the tubes thus realised. The
necessary measures will be described in /2/, /3/, /4/, /5/.

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The measures listed in Section 2.3 have up to now only been standard practice with
condensers, since necessary preconditions for this type of corrosion are not always present in
other heat exchangers. For this reason, the special conditions for operation, of such heat
exchangers, is dealt with in Section 3. In principle the aim should be, with the exception of
condensers, that all heat exchangers are connected to a secondary cooling circuit. The heat
exchanger for the secondary cooling circuit can then be operated in an optimum manner, as
for the condenser itself.

2.3 Condensers
Condenser tubes are supplied by the manufacturer with clean surfaces and these must be
kept clean until the plant is commissioned. In general, condition upon delivery exhibits a
thin tightly adherent oxide film, caused by the process of annealing the tubes, and this
oxide film guarantees adequate corrosion protection prior to commissioning.
In some cases, white pickled and generally passivated tubes, or tubes which have been
shot blasted on the inside, are used.

2.3.1 Testing for leak-tightness before commissioning

Water used for leak-tightness testing on the steam side, and for alignment of the
condensers, shall be at least drinking water quality. Where possible, fully de-salinated
water should be used and the water can be made alkaline as a safeguard against
corrosion. Fully de-salinated water is a statutory requirement with condensers for nuclear
power plants. In the event that fluorescent agents are added to the water to aid leak
detection, the whole inventory must be discarded. Thorough rinsing with fully de-salinated
water is then necessary to guarantee that the required level of feed water purity is
attained.
Furthermore, if alkaline water or a fluorescent agent is used for leak-tightness testing, the
appropriate safe disposal of this water must be ensured and certified (record of proper
waste management).
General surface corrosion on the C-steel components of the condenser is unavoidable
after draining. This can be limited in extent by removal of water residues, if necessary with
dry air equipment.
Water used for leak-tightness testing on the cooling water side, and for alignment of the
condensers, shall be at least drinking water quality. On no account shall surface water
with impurities in the form of suspended solids and an increased salinity (guide value for
chloride content > 500 mg/kg) be used.
After drainage on the water cooling side, the condenser tubes shall be blown as dry as
possible with physical drying bodies with oil and water free compressed air. During the
time before commissioning, the manhole covers shall be left open, but covered with cloth
to ensure that the condensers are subjected to internal ventilation (see 2.3.6).

2.3.2 Commissioning
Despite the fact that the tubes were previously subjected to thorough cleaning, further
careful cleaning of the cooling water inlet system must take place before commissioning.
The possibility of foreign objects having entered the condensers can not be overruled,

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despite all necessary preventive measures. The tubes must be checked shortly before
commissioning and any blocked tubes cleaned and all matter or blockages removed.
These checks must be repeated as often as necessary, until the danger of blockages due
to foreign matter has been eliminated.
The commissioning period is of critical importance to formation of the protective film.
As far as possible following the installation of new condenser tubes, the cooling water
supply should remain continuous over a prolonged period. It is preferable to aim for a
switch from cold to hot operation without interruption. It must be taken into account that
protective film formation may take up to a year, depending on the quality and properties of
the cooling water. The more aggressive the cooling water is (e.g. high salinity, especially
when suspended solids are present), the more important continuous operation is for
protective film formation. It is therefore particularly important to try to avoid any kind of
deposit build up in the water cooling system.
During the operation of an automatic tube cleaning system, the minimum required flow of
cooling water has to be sufficient for the transportation of the cleaning agents and
abrasives used.
Under no circumstances should the velocity of the cooling water exceed the
recommended dimensioning limits for velocity (see VGB-R 455), as this could result in
erosion corrosion, especially at the cooling water inlet areas of the condenser tubes,
where it would inhibit the formation of the protective film.
All available equipment should be used to ensure trouble-free operation. This could
include: venting of the water cooling water chambers during times when the condenser is
set to siphon, a fully functional tube cleaning system and as required and when helpful,
chemical treatment of the cooling water (e.g. biocide treatment and iron(II)-hydro-sulphate
dosing of the cooling water; see page 10 - simultaneous shock dosing).
In the event that operation is unavoidably interrupted, consult Section 2.3.6.

2.3.3 Avoidance of deposits

Deposits in condenser tubes seriously interfere with the formation of the protective film.
They will also destroy, (through corrosion as a result of differential aeration cells /6/, /7/,
/8/) a protective film which has already formed. Deposits also diminish the heat
conductivity and lead to a loss of condenser efficiency, what ultimately results in
decreasing turbine power output. It must therefore be ensured that deposits are avoided.
These can occur through: the depositing of suspended solids from the cooling water
(fouling), precipitation of dissolved species organisms, exceedance of the solubility limits
(scaling) and through the growth of microbiological organisms (bio fouling).
Analysis of the cooling water at regular intervals is therefore strongly recommended (see
cooling water guidelines VGB-R 455).
One method by which deposits can be avoided is through the installation of a state-of-the-
art tube cleaning system. Operators' experience is a decisive factor in determining the
duration and frequency of cleaning periods and for this reason no recommendations are
given here.

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When in doubt, seek the manufacturer's advice, especially with regards to the right choice
of cleaning agents.

Fig. 1 Example of a tube cleaning system with cooling water filter

Checks on the tubing during shut down periods and observations during operation should
make the operator aware of condenser behaviour and enables the collation of experience
with the available cooling water.
The toxicity of materials containing copper restricts the growth of microbiological
organisms, more or less preventing their growth altogether, particular when a continuously
mechanical tube cleaning system is in regular use. Nevertheless, it has been known for
fouling to occur as a result of slime-forming bacteria, which could not always be removed
by mechanical tube cleaning.
Severe mussel growth can occur periodically in seawater and in brackish water, also
therefore in the water of certain rivers. Since mussels close their shells for the duration of
shock chlorine dosing, effective control is to be ascertained by continuous chlorine dosing.
Detailed information on the amounts of chlorine necessary and dosage periods in /9/, /10/.
Simultaneous shock dosing with iron(II)-sulphate (see Section 2.3.4) and chlorine is to be
avoided, since these substances produce a chemical reaction. Chlorine Shock dosing
should therefore be completed at least one hour before dosing with iron(II)-sulphate.
Continuous dosing with iron(II)-sulphate does not need to be interrupted for shock dosing
with chlorine.
A further possible aid to the avoidance of mussel growth is provided by reversing the
direction of flow in the cooling water system, thus causing fluctuations in temperature.
This repeated deviation from normal living conditions and coating with an anti-fouling
substance minimises mussel growth /11/.
Dead mussels are removed from the walls of the cooling water system and carried into the
condensers by the flow of the cooling water. With circulation cooling systems, endrainage
of foreign matter from the cooling tower bassin into the condenser can also lead to tube
blockages. Cooling water filters inserted directly before the condensers have proved
valuable in such cases.

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Deposits from suspended solids can be avoided in circulation cooling systems by the use
of dispersing agents and biocides, which can be used to kill microbiological organisms.
The range of such agents on offer is so vast that detailed information cannot be provided
here (see cooling water guideline VGB-R 455).
The use of chemical agents for cooling water treatment is usually limited by official
restrictions on the permissible residual concentrations which are present upon returning
the water to the effluent basin.

2.3.4 Protective film formation under adverse conditions

The characteristic tendency of copper alloys, to naturally form protective films is often
inadequate in particularly aggressive cooling waters, such as: seawater, brackish water
and fresh water of high salinity or available water which contains unfavourable complexing
agents /3/.
Dosing with iron(II)-sulphate is used to enable the formation of a protective film containing
hydrated iron oxide in continuous flow cooling systems(/12/ and Section 4 (EN ISO 8044
[10]).
These measures are not recommended for circulation cooling systems, corrosion
inhibitors are much more useful. Further details can be found in the following guidelines
(Section 4, VGB-R 455).

2.3.5 Cathodic protection

Under certain conditions, it is necessary to use cathodic corrosion protection on the
cooling water side of steam condensers and heat exchangers.
― Specifically, to avoid galvanic corrosion at the tube sheet, if the tube material exhibits a
more noble metal potential and other protective measures are not taken.
― To avoid corrosion erosion at the cooling tube inlet areas if the cooling water is rich in
suspended solids. A protection of the entire tube length is not possible.
Tube sheets and water chambers do not normally require cathodic corrosion protection,
because generally tube sheets made of less noble metalls usually have passive protection
against corrosion in the form of a thick epoxy coating, or are similarly plated. Water
chambers of condensers and heat exchangers are, as a rule, coated with epoxy, tar-
epoxy or clad with rubber (see recommended reading, cooling water guideline VGB-
R 455, Table 3).
Two procedures can be used for cathodic corrosion protection:
― Cathodic corrosion protection with sacrificial anodes
Zinc, aluminium, iron or magnesium anodes can be used. The anodes must satisfy the
special analyses requirements for composition as 'sacrificial' anodes in order that
passivation does not occur during operation.
― Cathodic corrosion protection with impressed current
In the main, platinised titanium anodes supplied by a D.C. current are used and the
level of the current is controlled by use of a reference electrode. The anode remains
unchanged and can be used over long periods of time.

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Note: Due to higher operational risks the use of sacrificial anodes for cathodic
protection is only possible with a stricter safety protocol. Protective equipment with
impressed current must not be operated during the wet conservation of condensers
(due to the danger of the formation of explosive gas mixtures).
The anodes are mounted, connected to the D.C. current, via the tube sheets or via the
water chambers. There must be an electrical connection between the tube sheet and the
water chamber. Careful maintenance of the cathode protection equipment at all times: e.g.
with impressed current protection with regular checks on the protective current levels and
the reference electrodes. Sacrificial anodes should be inspected manually and naturally
exchanged in good time, as required.

2.3.6 Shutdown periods

Shutdown periods are particularly dangerous for tubes made of copper and copper alloys
if the protective film has not yet formed, is not yet fully formed, or has localised damage,
as corrosion will then form under the films or coatings.
Table 1 shows the required treatment of condenser tubes, depending upon the duration of
the shutdown.
The treatment methods depend essentially upon the following critical points:
― Deposits in the condenser tubes,
― Salinity of and biological activity in the cooling water,
― Design of the cooling water system,
― Cooling procedures,
― Type of protective film formation, hydrated iron oxide film.
Criteria for treatment of the condenser tubes
― Deposits in the condenser tubes:
Decisions on the treatment of the condenser tubes must be based upon the condition,
after checking the tubes on the cooling water side, after draining.
Hereby the amount and the condition of the clogged tubes is to be considered. Helpful
is the documentation in a partition plan of the tubes.
Deposits in the condenser tubes can usually be avoided through the operation of a tube
cleaning system.
― Salinity of and biological contaminants in the cooling water:
Regular analysis of the cooling water is a critical factor in deciding upon the appropriate
treatment of the condenser tubes.
― Design of the cooling water system:
The question as to whether or not wet conservation using the operational cooling water
can be used for shutdowns of < 3 days duration when the condenser tubes are shown
to be free from deposits, depends upon the design of the cooling water system (see
Table 1). Either appropriate valves must be provided at the inlet and outlet ends of the
condenser, or the cooling water system must be so designed that all tubes remain full.

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Wet conservation can also be extended to accommodate longer shutdown times if

repeated operation (of at least one hour in duration) of the cooling water pumps, and
the tube cleaning system, takes place after approximately every 3 days of shutdown. lt
may be necessary to collect the solid cleaning agents from the tube cleaning system
before shutting down the cooling water pumps.
― Cooling procedures
For wet conservation with continuous flow water cooling, where the available cooling
water is either seawater, brackish or river water, the organic and inorganic suspended
solids and the altered chemical composition of the cooling water have to be taken into
account. In some cases, after drainage and flushing, the cooling water must be
replaced with drinking water for wet conservation, irrespective of the anticipated
duration of shutdown.
Wet conservation is generally unproblematic in closed-circuit cooling systems where
the additional water is flocculated because of the low content of suspended solids.
Thorough de-sludging is recommended, to cause a reduction in salinity before
shutdown.
― Manner of protective film formation: especially Hydrated iron oxide film
Drying out can destroy hydrated iron oxide film, if such a layer has formed on the tubes
(see Section 2.3.4). Rebuilding such a destroyed protective film usually requires that
the residues from the previous film are first thoroughly removed by suitable methods.
The drying out can be prevented if wet conservation is applied.
The following recommendations result from the mentioned boundary conditions (Table 1):

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Table 1 Treatment of condensers with copper-alloy condenser tubes upon shutdown of the water cooling system
Shutdown
Boundary conditions
1 to 3 days duration > 3 days
Keep condenser filled with cooling water in addition cooling water Operation every 3
Shut-off device in place, tubes without days
deposits

cooling water of high salinity1

Drain Condenser, clean, refill with cooling in addition cooling water Operation every 3
water days or other:
- drain condenser, flush3, refill3 and
Shut-off device in place, tubes with maintain full3 with level control pump
deposits - drain, flush3, dry, maintain dry
cooling water of low salinity2
Drain condenser, clean, refill with cooling In addition
water - operation every 3 days or
- drain, dry and maintain dry
cooling water of high salinity1
Drain condenser, clean if tubes with in addition, dry and maintain dry
3
Shut-off device not in place (Wet deposits, flush
conservation not possible) cooling water of low salinity2
Drain condenser, clean if tubes contain in addition, dry and maintain dry
deposits
1
cooling water of high salinity (> 500 mg Chlorid)
2
cooling water of low salinity (< 500 mg Chlorid)
3
de-mineralised water or drinking water of low salinity must be used
 17

2.3.7 Continuous operation

If the velocity of the cooling water is too high, this can also lead to the destruction of the
protective films due to erosion. This most often becomes apparent on the cooling water inlet
side of the condenser tubes, but can also affect the entire length of the tube. For this
reason, critical flow velocities for specific types of tubes should not be exceeded (see
Section 4, VGB-R 455). The operator should take appropriate measurements to insure that.
The cooling water velocity can also be raised in specific locations in the tubes through cross
sectional reductions (e.g. due to foreign matter) and again, this can lead to local attack
through erosion corrosion.
Following operational disturbances, such as destruction of the fine sieves or the opening of
the excess pressure flaps following blockage of the fine sieves, the condensers must be
visually inspected and foreign matter which has lodged in the tubes and the water chambers
must be removed. The affected condenser tubes including the cooling system must be
cleaned. During continuous operation, the velocity should not be allowed to fall to too low a
value, since in this event there is a danger clogging from abrasives balls from the tube
cleaning system or of deposit formation from the cooling water.

2.4 Other heat exchangers for the operation of steam turbine plants
The heat exchangers for the operation of steam turbine plants are categorized as follows:
1. “Heat exchangers in an open water cooling system”; are:
- Main turbine condensers
- SPAT condensers
- Intermediate coolers
- Heat exchangers of CO2 deposit plants (CCS) etc.
2. “Heat exchanger in closed circuit cooling systems”; including the frequently so called
“machine technical heat exchangers”; are:
- Generator gas coolers
- Generator-Stator water coolers
- Generator seal oil cooler
- Turbine oil cooler
- Turbine control liquid cooler
- Cooler of the sample drawing system
3. “Heat exchangers in water/steam circuits”; are:
- ND-preheaters
- Heaters
- Leaking-steam turbine coolers
- Small coolers, if necessary: feeding-pump seal coolers
- HD-preheaters

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What all heat exchangers for the operation of steam turbine plants have in common, is, that
in case of damage tremendous follow-up costs arise. Therefore special damage prevention
measures - as for the main turbine condenser - have to be set up, even if it is clear from the
construction that it is not a tube heat exchanger or the materials used are not listed in this
guideline.
It is state of the art to integrate the heat exchangers of group 2 into a closed circuit cooling
system with de-salinated intermediate cooling water, nearly free of suspended solids (see
Section 4, VGB-R 455).
If, because of local temperature conditions or out of economical reasons, singular heat
exchangers out of group 2 should be included into the open main cooling system, in
principle all measures applicable to condensers shall be carried out appropriately as far as
possible. Especially for the prevention of deposits. If constant (manually) cleaning is not
feasible, then continuously operating tube cleaning systems have to be installed for these
heat exchangers.
It is to be taken into account, that if higher wall temperatures are reached, in comparison to
a turbine cooler, more corrosion resistant materials have to be used (especially with
stainless steels).
Multiple intermediate coolers for the secondary circuit and numerous machine technical heat
exchangers are existent as operating and auxiliary coolers. The most commonly observed
type of damage there is shutdown corrosion in the auxiliary coolers - especially if the feed
water is of high salinity and rich in suspended solids.
To prevent damage in these heat exchangers sensible conservation measures, for the given
case, are to be appropriately implemented from Section 2.2. Best experience has been
made with dry conservation. The required mountings and valves for flushing and where
necessary drying have to be integrated during the planning stages of the plant.
A reduction of the cooling water feed stream, as a temperature regulation measure,
operating with water, which is highly salinated and rich in suspended solids, for coolers with
tubes made out of stainless steel, is only allowed within the limits of the cooling water
guideline VGB-R 455.
One possible means of maintaining a constant cooling water velocity in oil coolers involves
the oil- bypass temperature control. The desired lubricating oil temperature is achieved by
mixing the cold oil, which has passed through the oil cooler, with the hot oil. As a result of
the cooler always receiving the optimal amount of cooling water, the same cooling water
velocity is maintained in the tubes despite changes in the cooling water temperature. Even if
the water has a constant flow velocity in the tubes, the lack of a continuously operating tube
cleaning system makes it necessary to carry out frequent manual cleaning or to have a
pulsed water cleaning system installed.

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Part 3 Causes of Tube Damage

The following summary gives an overview of the various forms of corrosion and types of
damage which can occur in tubes of condensers and other heat exchangers. Operational
influences, outside influences out of manufacture and tooling and the use of less appropriate
materials can cause damage to the tubes. The VGB-R 455, R 450 guidelines, as well as
EN 12502-1 [11], EN 12502-2 [12], EN 12502-4 [14], EN ISO 8044 [10] should be consulted
regarding specific types of corrosion (see Section 4).

3.1 Tube damage through operational influences

Tube damage on the cooling water side /13/, /14/, /15/.

3.1.1 Uniform surface corrosion

If the pH value of the cooling water lies below 7.5 [12] or above 10, copper alloys can no
longer form and retain protective films. The corrosion rate increases and leads to uniform
surface attack.

Fig. 2 Visible begin of uniform surface corrosion caused by defective protective film

Fig. 3 Lateral section of Fig.2.

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3.1.2 Localised, shallow attack and pitting corrosion

Localised, shallow attack, with different corrosion rates of metal loss, occurs mainly under
deposits. The danger of localised shallow attack corrosion is high during shutdown periods
in condensers which remain full of cooling water and is particularly high for drained
condensers where residual cooling water is present in the tubes. The starting conditions for
this type of corrosion attack are provided by the formation of corrosive elements (bi-metal,
contact, galvanic, concentration and differential aeration cells; Fig. 2 to 4).
The corrosion attack is accelerated as a result of the transport of electrolytes (chlorides,
sulphates) to the anode and of the process of hydrolysis.
The following conditions can lead to the formation of corrosion elements:
― Dirt deposits
― Precipitation of water constituents from concentrated solutions,
― Bacterial growth,
― Foreign matter,
― Incomplete formation of protective films and covering layers
Corrosion can be stopped with a permanent removal of deposits.

Fig. 4 Localised, shallow attack underneath deposits of dirt as a result of differential aeration cells (CuZn28Sn1 As)
a) Internal surface with thick deposits
b) Cleaned internal surface showing localised, shallow attack

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Fig. 5 Metallographic section through a corroded location with shallow attack

3.1.3 Pitting corrosion

In pitting corrosion, the electrolytic stripping of metal occurs only locally in small areas on
the surface. Outside the corrosion pits (pin-like depressions) no surface attack is visible. The
depth of a corrosion pit is usually equal to, or greater than, its diameter. Pitting corrosion
occurs if non-porous, protective films contain randomly distributed defects (Fig. 6 and 7).

Fig. 6 Pitting corrosion (CuZn28Sn1 As)

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Fig. 7 Pitting corrosion: metallographic section through a corroded location (CuZn28Sn1 As)

3.1.4 Erosion corrosion

Erosion corrosion [10], [12] affects the processes taking place at the surface of the metal
and through turbulence, prevents the increased concentration of metal ions necessary for
protective film formation. Air bubbles and abrasive solids (e.g. sand, remains of mussel
shells, small pieces of concrete) and a reduction in pH-values intensify this effect
considerably. The corrosion products are continuously washed away.
A characteristic of erosion corrosion is, depressions which form are free from corrosion
products and that are hollowed out on the upstream side. These depressions often take on a
horseshoe shape. Disturbances occur preferentially on the water inlet side of the tubes due
to turbulences. A remedial measure here is the insertion of plastic caps with a flow
optimised exit form or the coating with epoxy resin. Excessive flow velocities can also occur
in individual tubes as a result of localised reduction in the cross-section due to the presence
of foreign matter (see Section 4).
Optimal hydrodynamic design of the water chambers is fundamentally desirable in order to
prevent erosion corrosion. Furthermore, foreign matter of a larger size should be trapped as
far as possible in screens, sieves or filters. Erosion corrosion as a result of sand can only be
prevented by reducing the flow velocity (see VGB-R 455). Satisfactory venting of the water
chambers to avoid the formation of air bubbles is absolutely required (Fig. 6 to 9).

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Fig. 8 Corrosion erosion (CuZn28Sn1 As)

Fig. 9 Longintudinal section, typical damage of corrosion erosion (-> flow direction)

3.1.5 Corrosion fatigue

Corrosive influences limit the fatigue endurance of materials. The cyclic bending stresses
which occur with tube vibration can lead to cracking of the protective film and allow the
aggressive medium to gain access to the metal surface. The resulting cracks have a
transgranular morphology [10] (Fig. 10 and 11) and are similar to those occurring with stress
corrosion cracking, without the existence of the specific preconditions for the latter.

Fig. 10 Corrosion fatigue: cracks originating from small regions of intergranular corrosion (CuZn28Sn1 As)

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Fig. 11 Metallographic section through a corroded region with (transgranular path of the corrosion fatige cracks,
CuZn28Sn1 As)

Tube damage on the steam/condensate side

3.1.6 Corrosion caused by ammonia

The dissolved gases in the turbine condensate, or the ones streaming in from air leakages,
are directed with steam guidance to the air extraction zone, correspondent to their pressure
and temperature solubility shortfalls. Mostly the gases oxygen, carbon dioxide, nitrogen and
with the right dosing also steam volatile alkalinization agents like ammonia /16/.
The remaining protective condensate films can be highly enriched in respect to the
distribution balance with responsive gases like oxygen, carbon dioxide, and ammonia and
form et. al. corrosion systems with the pressurised metallic materials. Saturation factors of
> 103 have been measured in and immediately before the air extraction zone.
The most well known is hence the resulting and formerly prevalent “ammonia corrosion”,
which leads to local dissolving of condenser tubes made out of Cu alloys (Fig. 12 and 13). It
also limits the ammonia tolerance for suchlike tubed condensers.
The rate of dissolution decreases in the following order: copper, brass, copper-nickel alloys.
Depending upon the cooling water properties, tubes made of copper-nickel, stainless steel
or titanium were inserted in the endangered zones as a remedial measure.

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Fig. 12 Corrosion caused by ammonia in the region of a support plate (CuZn28Sn1 As)

Fig. 13 Longitudinal, mettalographic section through a damaged region at a support plate

3.1.7 Corrosion caused by carbon dioxide

In special types of plant (e.g. seawater evaporators, evaporators in sugar factories, etc.),
damage to the tubes of heat exchangers can occur through the influence of carbon dioxide.
The progression of the attack and the appearance of the damage is similar to the corrosion
caused by ammonia. The remedial measures described in Section 3.1.6 apply in an
analogous way.

3.1.8 Failures caused by tube vibration

The tubes vibrate as a result of the incident steam flow. Extreme amplitudes - often as a
result of too high flow rates - can lead to the cyclic bending fatigue strength of the material
being exceeded and can result in fractures (Fig. 14 and 15).
Constructional remedial measures are necessary to prevent damage include lowering the
distance of support plates, reduction in the gap between tube and borehole in the support
plate or, as a subsequent measure, the use of clamps. These measures are more
successful in reducing vibration than the use of tubes of greater wall thickness.

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Fig. 14 Crack formation as a result of tube vibration (CuZn28Sn1 As)

Fig. 15 Crack formation as a result of tube vibration within initiation at chafing points

3.1.9 Droplet erosion

If the size and velocity of the droplets in the exhaust steam are too high, accelerated loss of
metal at the tube surface can occur (Fig. 16 and 17).
Possible design measures which have a high, remedial effect include, e.g. the use of baffle
plates, solid steel rods, protective shields made of plastic or diversion plates. Changing to
larger wall thicknesses, or to other tube materials, merely delays the initiation of damage.

Fig. 16 Roughening of the tube surface as a result of droplet erosion (CuZn28Sn1 As)

Fig. 17 Magnified corss section

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3.2 Tube damage due to manufacturing and tooling

3.2.1 Stress corrosion cracking

The following three factors are preconditions for the occurrence of stress corrosion cracking:
― Tensile stresses (also as residual stresses),
― Sensitivity of the material (basically the case with brasses),
― a specific corrosion medium (ammonia, amines, hydrogen sulphide and similar chemical
compounds).
A sufficiently high concentration of the corrosive medium only occurs under certain
conditions, e.g. during shutdown due to anaerobic bacterial decay of organic deposits
containing nitrogen (formation of ammonia). Pure copper, which is in itself not susceptible to
stress corrosion cracking, tends to suffer this form of damage in the presence of minute
quantities of phosphorus and arsenic.
Stress corrosion cracking has not been detected to date in condenser tubes made of
copper-nickel alloys. The susceptibility of brasses to stress corrosion cracking increases
with increased zinc content. Ammonia and ammonia compounds in combination with oxygen
and moisture, are particularly responsible for causing stress corrosion cracking if tensile
stresses are present.
In order to reduce the residual stresses arising from manufacture as far as possible tubes
are stress-relief anneald. As a result of the unavoidable residual tensile stresses arising
from the rolling-in procedure, especially with the bridging of great tolerances, tubes are
susceptible to stess corrosion cracking, actuated in the transition zone to its originally
fabricated state (Fig. 18 and 19).
Brass tubes which have not been stress-relief annealed can undergo stress corrosion
cracking with the formation of longitudinal or circumferential cracks as a result of the
residual tensile stresses from manufacture, or tensile stresses arising from operation, if a
high enough concentration of ammonia is present locally. The preconditions and remedial
measures described in Section 3.1.6 apply.

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Fig. 18 Stress corrosion cracking with crack initiation on the inside surface of the tube behind the rolled-in end
(CuZn28Sn1 As)

Fig. 19 Metallographic section through an incipient crack resulting from stress corrosion cracking (CuZn28Sn1 As)

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3.2.2 Selective Corrosion

This form of corrosion is called selective because the Zinc/Nickel content is dissolved from
the alloy to be flushed away and leaves just the copper behind, porous as a metal sponge.
Selective corrosion happens with copper/zinc (dezincification) and copper/nickel alloys
(denickelisation) as well as plug as fan form (Fig. 20 to 22). It happens only under deposits.
This is the case with copper/zinc alloys if they don´t have no or too low a stabilizer content
(arsenic and/or phosphorus).
The copper/zinc alloys specified in EN 12451 [1] are suitably resistant to dezincification,
insofar as the content of magnesium does not exceed the limit value mentioned in Section
1.2.

Fig. 20 Plug-type dezincification on unstabilised CuZn 20 AI 2 (cooling water side), above in original dismantled condition,
below pickled

Fig. 21 Logitudinal section

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Fig. 22 Magnification from Fig. 21

3.2.3 Intergranular Corrosion

Intergranular corrosion can occur with CuZn28Sn1 As and CuZn 20 Al 2 As if the arsenic
and/or phosphorus levels exceed the values given in EN 12451 [1]. Oversaturation then
occurs at the grain boundaries, which are selectively attacked by corrosion. The result is a
disintegration of the microstructure and an increase in the susceptibility to fatigue failures.
Deposits in the tubes favour the occurrence of intergranular corrosion (Fig. 23).

Fig. 23 Metallographic section through a condenser tube which has suffered intergranular corrosion under organic
deposits (CuZn28Sn1)

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Part 4 Applicable guidelines and standards

The present guidelines contain specifications for tubes for condensers and other heat
exchangers (copper alloys) for the operation of steam turbine plants. Condensers and other
heat exchangers in thermal power plants are with continuous flow or closed circuit cooling
always part of a water cooling system. Condensers and other heat exchangers in thermal
power plants equipped with continuous-flow or closed circuit cooling are always part of a
water cooling system. Suitability of cooling system materials such as: metallic tubes and
additional materials like protective films and coatings in the cooling system is determined
according to chemical-corrosive properties in contact with the cooling water available. Basic
economical and ecological principles are also given due consideration. These factors will be
covered in the VGB- cooling water guidelines “R455”.
There are numerous other VGB guidelines providing further details on water cooling system
components, in particular, the VGB guidelines currently being prepared “Cooling techniques
in Power plants”, which will soon be available and should be consulted for planning and
evaluation. These guidelines are mentioned only in the preface.

VGB-guidelines and data sheets

(1) VGB-R 110 Wärmeaustauscher und Speisewasserbehälter im Wasser-
/Dampfkreislauf von Kraftwerken
(2) VGB-R 113 Tubes for Condensers and other Heat Exchangers in the Operation
of Steam Turbine Plants (Stainless Steels)
(3) VGB-R 114 Tubes for Condensers and other Heat Exchangers in the Operation
of Steam Turbine Plants (Titanium Alloys)
(4) VGB-R 116 Preservation of Power Plants
(5) VGB-R 126 Recommendations for the Design and Operation of Vacuum Pumps
for Steam Turbine Condensers
(6) VGB-R 127 Richtlinie für den Turbinenbetrieb, 4/1985
(7) VGB-R 129 Empfehlung über den Winterbetrieb von Kraftwerks-
Nasskühltürmen, 1/1988
(8) VGB-R 130 Acceptance Test Measurements and Operational Monitoring of
Water-Cooled Surface Condensers
(9) VGB-R 135 Planning of Cooling Towers
(10) VGB-R 145 Guide for the Procurement of Steam Turbine Plants
- Part A, B and C
(11) VGB-R 450 Guidelines for Feed Water, Boiler Water and Steam Quality for
Power Plants / Industrial Plants
(12) VGB-R 455 Water Treatment and Use of Materials in Cooling Systems
(13) VGB-R 507 Rohrleitungsanlagen in Wärmekraftwerken, 2nd edition 2010
(14) VGB-R 609 Application, Design and quality-assurance criteria for the use of
fibre-reinforced plastics in power plant construction

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(15) VGB-R 611 Richtlinie für den Einsatz von Holz im Kühlturmbau, 1/1996
(16) VGB-R 612 Protection Measures on Reinforced Concrete Cooling Towers and
Chimneys against Operational and Environmental Impacts
(17) VGB-M 403 Aufbereitung von Betriebswasser und Kühlturm-Zusatzwasser durch
Entcarbonisierung bzw. Flockung und Entcarbonisierung
(18) VGB-M 621 Einsatzmöglichkeiten von Kunststoffen in Kühltürmen
(19) In preparation „Kühltechnik in Kraftwerken“ - “Cooling techniques in
Power plants”,

European standards (DIN EN and others)

The present guidelines contain dated and undated references to stipulations of other
publications. These normative references are marked in the text and the publications are
listed hereafter. Later changes or revised versions of these publications mentioned with
dated references only belong to these guidelines if they have been incorporated. For
undated references only the latest edition of the used publications is valid.
[1] EN 12451, Issue 1999-10
Copper and copper alloys - Seamless, round tubes for heat exchangers
[2] EN 12452, Issue 1999-10
Copper and copper alloys - Rolled, finned, seamless tubes for heat exchangers
[3] VDI/VDE 2602, Page 2, Issue 2008-10
Roughness measurement - Roughness measurement using contact (stylus)
instruments - Profile method - Setup, measurement conditions, procedure
[4] EN ISO 6892-1, Issue. 2009-12
Metallic materials - Tensile testing - Part 1: Method of test at room temperature
[5] EN ISO 8493, Issue 2004-10
Metallic materials - Tube - Drift-expanding test
[6] EN ISO 2624, Issue 1995-08
Copper and copper alloys - Estimation of average grain size
[7] DIN 50916, Issue. 1976-08
Testing of copper alloys; stress corrosion cracking test in ammonia, testing of tubes,
rods and profiles
[8] EN 1971, Issue 1998-12
Copper and copper alloys - Eddy current test for measuring defects on seamless round
copper and copper alloy
[9] EN 473, Issue 2008-09
Non-destructive testing - Qualification and certification of NDT personnel - General
principles
[10] EN ISO 8044, Issue 1999-11
Corrosion of metals and alloys - Basic terms and definitions

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[11] EN 12502-1, Issue 2005-03

Protection of metallic materials against corrosion - Guidance on the assessment of
corrosion likelihood in water distribution and storage systems - Part 1: General
[12] EN 12502-2, Issue 2005-03
Protection of metallic against corrosion - Guidance on the assessment of corrosion
likelihood in water distribution and storage systems - Part 2: Influencing factors for
copper and copper alloys
[13] EN 10204, Issue 2005-01
Metallic products - Types of inspection documents
[14] EN 12502-4, Issue 2005-03
Protection of metallic materials against corrosion - Guidance on the assessment of
corrosion likelihood in water distribution and storage systems - Part 4: Influencing
factors for stainless steels

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Part 5 Literature
The subsequently listed literature excerpts offer the opportunity to get further detailed
information on specific sets of problems processed in the marked passages and in general
description. The listed material covers case studies or, where appropriate, spezial
considerations and is not to be taken as mandatory statement of these guidelines. In
general these literature excerpts contain continuative literature and make deeper levels of
proficiency available. For a better orientation there are content details offered which refer to
the raised questions in the marked passages.
To distinguish obligatory standards from this cited literature the text is quoted in slashes.
/1/ Schleithoff, K.: Rohre für Dampfturbinenkondensatoren - Werkstoffwahl,
Anforderungen und Prüfungen. VGB-KRAFTWERKSTECHNlK 59 (1979), H. 5, S.
368-376. (ÆContent: Detailed exposition of the interaction of alloy components As
and P as well as testing of mechanical and technological properties of heat
exchanger tubes made of copper alloys)
/2/ Wendler-Kalsch, E.: Korrosionsverhalten und Deckschichtbildung auf Kupfer und
Kupferlegierungen. Z. Werkstofftechnik 13 (1982), S. 129-137. (ÆContent: Compre-
hensive review on the corrosion characteristics of copper alloys - Forming and
defects to oxided tube protective film formations of copper and copper alloys)
/3/ Fichte, W., Schleithoff, K: und Czolkoss, W.: Deckschichtstrukturen auf Kondensator-
rohroberflächen. Der Maschinenschaden 64 (1991) Heft 5 (ÆContent: Review on
protective film formation and interfering influences)
/4/ Bohnsack, Gerhard, Chemische Aspekte bei der Korrosion des Kupfers. Vulkan-
Verlag, Essen, 1997; ISBN 3-8027-2541-7.; (ÆContent: Detailed exposition of
chemical influences on the protective film formation of copper and copper alloys)
/5/ Effertz, P-H., Fichte, W., und Forchhammer, P.: Kühlwasserseitige Korrosion an
Kondensatoren und Kühlern in Kraftwerken. Der Maschinenschaden 46 (1973), H. 6,
S. 189-201. (ÆContent: Detailed exposition of protective film formation in heat
exchanger tubes made of copper alloys)
/6/ Krause, Siegfried: Fouling an Wärmeübertragungsflächen durch Kristallisation und
Sedimentbildung. VDI-Forschungsheft 637/1986,S.1-44; ISSN 0015-7899;
(ÆContent: Experimental and theoretical research on fouling processes on heat
exchanger surfaces with direct contact to liquid flow)
/7/ Glaze, F.: Verbesserte Kondensatorleistung und Erhöhung der Kühlrohrlebensdauer
durch Überwachung des Kondensators. VGB-KRAFTWERKSTECHNlK 64 (1984), H.
5, S. 422-428. (Æ Content: Outside influences of automatic tube cleaning systems on
the characteristics of heat exchanger tubes made of copper alloys)
/8/ Francis, R. Effect of pollutants on corrosion of copper alloys in sea water. Part 1:
Ammonia and chlorine; Part 2: Sulphide and chlorine; Br.Corros.J.1985; Vol 20, No 4,
p 167-182 (Æ Content: Detailed discription of concurrences of deposits on the
corrosive characteristics of heat exchanger tubes made of copper alloys)

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/9/ Jenner, H., Polman, H.J.G., van Wijck, R.: Four Years Experience with a New
Chlorine Dosing Regime against Macro Fouling. VGB PowerTech 9 (2004), S.28-30;
(Æ Content: Field report on mussel growth abatement by intermitting chlorination)
/10/ Held, H.D., und Schnell, H.G.: Kühlwasser. 5. Auflage, Vulkan-Verlag, Essen 2000.
(Æ Content: Integrated exposition of cooling water influences to heat exchanger
tubes)
/11/ Verelst, L., Girasa, E., de Vries, T.: On-site Evaluation of Fouling Release Coatings
for the Protection of Cooling Circuits against Micro Organisms. VGB PowerTech,
(2006), S. 65-68 (Æ Content: Test of various anti-fouling coatings on concrete in
combination with sea water)
/12/ Effertz, P.-H., und Fichte, W.: Kühlwasserseitiger Schutz von Kondensator- und
Kühlerberohrungen durch Eisensulfatdosierung. Der Maschinenschaden 49 (1976),
H. 4, S. 163-172. (Æ Content: Detailed discription of the treatment and of the effects
of iron(II)hydrosulphite dosing)
/13/ Wendler-Kalsch, E., Gräfen,H., Korrosionsschadenkunde; Springer-Verlag 1998;
ISBN 3-540-63377-4; (Æ Content: Discription of damage to copper and copper alloys
and their causes)
/14/ Engel, L.: Schäden an Kondensatoren. Haus der Technik, Vortragsveröffentlichungen
498, S.13-23 (Æ Conten:Discription of various damage to condenser tubes made of
copper alloys, steel, stainless steel and references for cooling water treatment)
/15/ Müller, R.O., und Scheidegger, R.: Korrosionsverhalten meerwassergekühlter
Kondensatorrohre aus Buntmetall. Elektrizitätswirtschaft 80 (1981), H. 5, S. 139-146.
(Æ Content: Overview of specific attacks in seawater and the concurrence of
measures in water cooling systems)
/16/ H.-G. Seipp; W. Fichte: Einflüsse von Kondensatoren auf die Chemie des Wasser-/
Dampfkreislaufes; VDI-Berichte 1421, S.209-225; ISBN 3-18-091421-1 (Æ Content:
Water and steam side corrosion of copper alloys)
/17/ Köhler, S.,: Selektive Korrosion von Kupfer-Zink-Legierungen; Materials and
Corrosion 47, 65-70 (1996) (Æ Content: Overview of de-zincification/ pitting;
Intergranular corrosion)

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 36

Table 2 Preferred tube dimensions and tolerances

(see also EN 12451 [1], Table 3)

Outer diameter1 Wall thickness

Lenght3
mm mm
15
19
21
23 As specified in order
As specified in order
24 e.g. 1,0; 1,25; 1,5
25,4
28
32
Permissible tolerances2, with respect to nominal dimensions
+0 -0,2 +10 -10 -0 +X4
mm % mm

1
Measurements of the outer diameter shall be carried out in two planes, at right anlges to each
other, of the same cross-section. No value shall deviate by more than -0.2 mm from the nominal
dimension.
2
Eccentricity and lack of roundness are included in the permissible tolerances.
3
Lengths are not standardised. In the design of new condensers, it is recommended that the tube
lengths are specified to whole, half or quarter meters.
4
Lenghts up to 2 m: +2 mm
above 2 and up to 8 m: +1 ‰, but not more than 5 mm
above 8 m: +0.8 ‰
Weight: the complete delivery weight shall not deviate by more than ± 5 % from the calculated
weight as ordered.

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37

Part 6 Appendix

Table 3 Table 1 from EN 12451 [1] „Copper of copper and copper alloys”

1)
Density
Materials Composition in % (mass fraction)
g/cm3
Abbreviated Others in
Number Element Cu Al As C Co Fe Mn Ni P Pb S Sn Zn approx.
short signs total
2)
min. 99.90 --- --- --- --- --- --- --- 0.015 --- --- --- --- ---
Cu-DHP CW024A 8.9
max. --- --- --- --- --- --- --- --- 0.040 --- --- --- --- ---
min. Rest 4.0 0.1 --- --- --- --- --- --- --- --- --- --- ---
CuAl5As3) CW300G3) 8.2
max. --- 6.5 0.4 --- --- 0.2 0.2 0.2 --- 0.02 --- 0.05 0.3 0.3
min. Rest --- --- --- --- 1.0 0.5 9.0 --- --- --- --- --- ---
CuNi10Fe1Mn3) CW352H3) 4)
8.9
max. --- --- --- 0.05 0.1 2.0 1.0 11.0 0.02 0.02 0.05 0.03 0.5 0.2
min. Rest --- --- --- --- 1.5 1.5 29.0 --- --- --- --- --- ---
CuNi30Fe2Mn23) CW353H3) 4)
8.9
max. --- --- --- 0.05 0.1 2.5 2.5 32.0 0.02 0.02 0.05 0.05 0.5 0.2
min. Rest --- --- --- --- 0.4 0.5 30.0 --- --- --- --- --- ---
CuNi30Mn1Fe3) CW354H3) 4)
8.9
max. --- --- --- 0.05 0.1 1.0 1.5 32.0 0.02 0.02 0.05 0.05 0.5 0.2
min. 76.0 1.8 0.02 --- --- --- --- --- --- --- --- --- Rest ---
CuZn20Al2As3) CW702R3) 8.4
max. 79.0 2.3 0.06 --- --- 0.07 0.1 0.1 0.01 0.05 --- --- --- 0.3
min. 70.0 --- 0.02 --- --- --- --- --- --- --- --- 0.9 Rest ---
CuZn28Sn1As CW706R 8.5
max. 72.5 --- 0.06 --- --- 0.07 0.1 0.1 0.01 0.05 --- 1.3 --- 0.3
1)
Information only
2)
Including Ag up to max. 0.015 %
3)
The corrosion resistant suitability of the materials as described in VGB-R 455
4)
Co max. 0.1 % is regarded as Ni
 38

Table 4.1 Table 2 from EN 12451 [1]

„Mechanical properties of copper and copper alloys“

Titel Tensile 0.2 %- Breaking Widening Hardness

strength Elastic limit strain
Material Condition HV
Rm Rp0,2 A
Abbreviated MPa MPa % %
short sign Number min. min. min. min. min. max.
R250 250 150 20 20 --- ---
H075 --- --- --- 20 75 100

Cu-DHP CW024A
R290 290 250 5 --- --- ---
H100 --- --- --- --- 100 ---

R3501) 350 110 50 30 --- ---

CuAl5As CW300G H0751) --- --- --- 30 75 110

1)
R290 290 90 30 30 --- ---
H0751) --- --- --- 30 75 105

R310 310 220 12 20 --- ---

CuNi10Fe1Mn CW352H H105 --- --- --- 20 105 150

R480 480 400 8 8 --- ---

H150 --- --- --- 8 150 ---

R4201) 420 150 30 30 --- ---

CuNi30Fe2Mn2 CW353H H0901) --- --- --- 30 90 125

1)
R370 370 120 35 30 --- ---
H0901) --- --- --- 30 90 120

CuNi30Mn1Fe CW354H
R480 480 300 12 20 --- ---
H120 --- --- --- 20 120 ---

1)
R340 340 120 55 30 --- ---
H0701) --- --- --- 30 70 100

CuZn20Al2As CW702R
R3901) 390 150 45 30 --- ---
H0851) --- --- --- 30 85 110

R3201) 320 100 55 30 --- ---

H0601) --- --- --- 30 60 90

CuZn28Sn1As CW706R
R3601) 360 140 45 30 --- ---
H0801) --- --- --- 30 80 110

1)
Annealed condition

Quoted Standards:
EN 12451-1999 „Copper and copper alloys: Seamless, round tubes for heat exchangers”
EN ISO 6892-1:2009 “Metallic materials - Tensile testing - Part 1: Method of test at room temperature“

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 39

Table 4.2 Table 2 from EN 12451 [1]

„Physical Properties of copper and copper alloys on the basis of measured data
for your information”

Titel E-Modul at Electrical Heat conductivity Average coefficient

20 °C conductivity at at 20 °C of thermal length
Material Condi-
20 °C expansion between
tion
Abbreciated 20 and 300 °C
2 -6
short sign Number MPa m/Ωmm Ws/mK 10 /K
R250 128 --- --- ---
Cu-DHP CW024A
R290

CuAl5As CW300G R3501) 123 10,2 85 18,0

1)
CuNi10Fe1Mn CW352H R290 130 5,3 45 17,0

CuNi30Fe2Mn2 CW353H R4201) 156 2,0 25 15,0

1)
R370 150 2,7 30 16,0
CuNi30Mn1Fe CW354H
R480 480 300 12 20,0

1)
R340 110 12,5 100 19,0
CuZn20Al2As CW702R
R3901) 110 12,5 100 19,0

1)
R320 108 14 110 20,0
CuZn28Sn1As CW706R
R3601) 103 14 110 20,0
1)
Geglühter Zustand

Quoted Standards:
EN 12451-1999 „Copper and copper alloys: Seamless, round tubes for heat exchangers“
EN ISO 6892-1:2009 “Metallic materials - Tensile testing - Part 1: Method of test at room temperature“

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 40

Table 5 Materials (copper alloys) comparison with some standards outside EU

Remarks:
The comparability of materials coming from different standardisation areas can only be approximated by their chemical composition.
The durability of tubes made from these materials e.g. against mechanical, corrosion chemical operational demands is amongst others
essentially defined by the involved manufacturing influences.
1) Material Country Standard Abbrivciated Cu % Al % As % C% Co % Fe % Mn % Ni % P% Pb % S% Sb % Sn % Zn % Others %
Material shoret min. min. min. min. min. min. min. min. min. min. min. min. min. min. min.
sign/Number max. max. max. max. max. max. max. max. max. max. max. max. max. max. max.
Kupfer DEU/EU EN Cu-DHP / 99,90 0,015-
12541 CWO24A 0,040
DHP Copper USA ASTM CU-DHP / 99,9min 0,015-
B 111 C12200 0,040
DPA Copper USA ASTM C14200 99,4min 0,15- 0,015- ---
B 111 0,50 0,040
95-05 Copper- USA ASTM C70400 Rest 1,3-1,7 0,3-0,8 4,8-6,2 0,05 1,0max
Nickel (RUS, B 111
CHN;
IND
Kor, etc.)
Kupfernickel DEU/EU EN CuNi10Fe1Mn/ Rest <0,05 0,1max 1,0-2,0 0,5-1,0 9,0- <0,03 <0,05 <0,5 0,2
10 12451 CW352H 11,0
1,0-1,8
Cupronickel for Japan H3300 C 7060 0,2-1,0 9,0- 0,05max 0,5max
condernser 11,0

90-10 Copper- USA ASTM C70600 Rest 1,0-1,8 0,10max 9,0- 0,05 1,0max
Nickel (RUS, B 111 11,0
CHN;
IND
KOR, etc.)
Kupfernickel DEU/EU EN CuNi30Mn1Fe/ Rest 0,05 0,1max 0,4-1,0 0,5-1,5 30,0- <0,02 <0,05 0,05 <0,05 0,2
30 12451 CW354H 32,0

Curponickel for Japan H3300 C7150 0,4-1,0 29,0- 0,05max 0,5max

condenser 33,0

70-30 Copper- USA ASTM C71500 Rest 0,4-1,0 1,0max 29,0- 1,0max
Nickel (RUS, B 111 33,0
CHN;
IND
KOR, etc.)
Kupfernickel DEU/EU EN CuNi30Fe2Mn2/ Rest 0,05 0,1max 1,7-2,5 1,5-2,5 29,0- 0,02 0,02 0,05 0,05 0,5 0,2
30 12451 CW353H 32,0

Cupronickel for Japan H3300 C7164 1,7-2,3 1,5-2,5 29,0- 0,05max 0,5max
condenser 32,0

70-30 Copper- USA ASTM C71640 Rest 1,7-2,3 1,5-2,5 29,0- 0,05 C=0,06max
Nickel-iron- (RUS, B 111 32,0 S=0,03max
manganese CHN;
IND
KOR, etc.)
Aluminium- DEU/EU EN CuZn20Al2As/ 76,0-79,0 1,8- 0,02- 0,1 <0,1 0,1 0,05 Rest 0,03
messing 12451 CW702R 2,3 0,06
76,0-79,0 Rest
Brass for JPN JIS C6870 T 76,0-79,0 1,8- 0,02-
condenser H3300 76,0-79,0 2,5 0,06 Rest
JIS C6871 T 1,8- 0,02-
H3300 76,0-79,0 2,5 0,06 Rest Si 0,2-0,5%
JIS C6872 T 1,8- 0,02- 0,2-1,0
H3300 (BSTF 3) 2,5 0,06

Aluminium ASTM 1,8- 0,02- 0,06max 0,07 Rest

USA
Brass B 111 2,5 0,06
(RUS,
CHN;
IND
KOR, etc.)
Zinnmessing DEU/EU EN CuZn28Sn1As/ 70,0-72,5 0,02- <0,07 <0,1 <0,1 <0,01 <0,05 0,9-1,3 Rest <0,3
12451 CW706R 0,06
70,0-73,0
Brass for Japan JIS C4430 T 0,02- 0,05 --- <0,05 0,9-1,2 Rest
condenser H3300 0,06
70,0-73,0
70,0-73,0
Admiralty USA ASTM B Admiralty M.A/ 70,0-73,0 0,02- <0,06 <0,07 0,02- 0,9-1,2 Rest
Metals (RUS, 111 C44300 0,06 0,1
CHN Admiralty M.B/ <0,06 <0,07 0,9-1,2 Rest
IND C44400
KOR, etc.) Admiralty M.C/
<0,06 0,02- <0,07 0,9-1,2 Rest
C44500
0,1

Quoted Standards:

EN 12451-1999 Copper and copper alloys: seamless round tubes for heat exchangers. This standard has an additional column for Co. For the materials CW252H
∙ VGB PowerTech
to CW254H a concentration DIGITAL
limit of 0.1 ∙ © 2016,asEssen,
% is regarded Ni. Germany ∙ CORPORATE LICENSE | Ordinary Members | INTERNAL USE ONLY ∙

ASTM B111/B 111M-09 Copper and Copper alloy: Seamless tube condenser and ferrule stock.

JIS H3300-09 Copper and Copper alloy: Seamless Pipe and Tubes. This standard has an additional column for Cu + Fe + Ni. For the materials C7060 to C7104 the
quantity concentration for Cu + Fe + Ni limited at min. 99.5 %.

ISO B 166 – ALPHA- 3 Country coding list.

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