Proven in the field
Installations & Project Gallery
TTT technology isn’t just an engineered concept. It’s working in HRSGs and power-generation facilities in the United States and internationally.
From individual tube repairs and TTHC installations to engineered header replacements and larger pressure-part projects, Tuff Tube Transition technology has been applied to address real-world maintenance, reliability and outage challenges.
Featured project
Wise County, Texas
Engineered reheat header replacement
When repeated reliability concerns led to the replacement of reheat headers at Vistra Energy’s Wise County facility, Viking Vessel Services engineered, fabricated and installed replacement headers incorporating TTT connection technology.
Finite Element Analysis was used during the engineering process to evaluate the replacement configuration. According to the customer’s written testimony, the resulting tube-to-header connection was determined to be 53% stronger than the original OEM connection.
The customer’s competing proposals using conventional installation methods estimated six to eight weeks for installation. Viking completed installation of the new headers in five days.
Engineered
Fabricated
Installed
In serviceProject video
Watch the Wise County Field Installation
Field installation and replacement of the Wise County reheat headers using TTT connection technology.
Project results
5 DAYS
Header installation
53% STRONGER
Tube-to-header connection compared with the OEM connection, according to project FEA cited by the customer
150+ STARTS
Reported by the customer following installation
ZERO FAILURES REPORTED
At the time of the customer’s written testimony
The customer also reported two post-installation inspections with no signs of premature failure or unanticipated wear or stress.
Explore the Header Integrity ProgramInternational installation
EDF Bouchain CCGT — France
HP economizer TTHC installation
Following multiple operational leaks in a highly stressed HP economizer, EDF Bouchain selected TTT technology as part of its reliability strategy.
The project involved the installation of 204 Tuff Tube Header Connections (TTHCs) with onsite Viking Vessel QA/QC support.
In its reference letter, EDF Bouchain specifically recognized Viking Vessel’s commitment and professionalism in both design and field services and described the solution as being tailored to the plant’s requirements within a very short timeframe.
EDF stated that the solution was expected to increase the exchanger’s lifespan by approximately eight times compared with the original design.
- Installed
- 204 TTHCs
- Application
- HP Economizer
- Location
- Bouchain, France
Project gallery
Independent industry coverage
Combined Cycle Journal has documented the Bouchain HP economizer story across two complementary articles — from the original tube failures and EDF's engineering investigation through the subsequent implementation of TTT connection technology.
The problem
Case Studies on HP Economizer Tube Leaks at Bouchain CCGT
Written by EDF Bouchain Mechanical Manager Guillaume Grognet, this detailed case study documents the recurring HP economizer tube-to-header leaks, difficult repair access, root-cause investigation and finite-element analysis that identified thermal fatigue and high stress at the original tube-to-header weld.
Read the original Bouchain case studyThe solution
HRSG Reliability and Performance Takes Center Stage at EHF2025
Combined Cycle Journal's coverage of the 2025 European HRSG Forum follows the Bouchain story forward, including Guillaume Grognet's presentation of the plant's experience and the subsequent TTT solution implemented on the HP economizer.
Read the EHF2025 follow-upTTT in the field
From individual repairs to complete pressure-part solutions
TTHC Installations
Tube-to-header connection applications
TTHC Installations
Installation in progress
TTPS Installations
Tube-to-tube TTPS sleeve connection
Header Work
Multiple-connection header installations
SIMPLIFIED FIT-UP
Self-aligning fit-up and fillet-welded connection geometry
RESTRICTED ACCESS
Mirror welding in a confined-access area
ORBITAL WELDING
Mechanized orbital welding during TTT field installation
ORBITAL WELDING
Orbital welding head positioned on a TTT connection
FIELD INSTALLATION
Field fit-up during outage execution
Field Installation
TTT technology during outage execution
TTPS Installations
Completed sleeve connections
Global reach
TTT around the world
From its origins in Texas, Tuff Tube Transition technology has expanded into power-generation facilities around the world.
Explore locations where TTT technology has been supplied or installed.
Built in Texas. Working around the world.
Engineered solutions. Field-proven applications. Global reach.
Whether the requirement is an individual tube repair, recurring tube-to-header failures, an engineered header replacement or TTT integration into a larger HRSG pressure-part project, our team can help determine the appropriate solution.