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01162 EROSION-CORROSION FAILURES IN CHEMICAL PLANT STEAM CONDENSATE PIPING SYSTEMS

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Product Number: 51300-01162-SG
ISBN: 01162 2001 CP
Author: Ali A. AI-Beed, A. Kh. Bairamov, Mohammed Al-Sonidah
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Carbon steel piping systems in several plants have failed under different applications, due to erosion-corrosion. This paper presents a variety of case histories where single-phase and two-phase steam flows, caused erosion-corrosion damage mainly at turn points of elbows and heat exchanger tubes. It was observed that the presence, even of a small amount, of the vapor phase can significantly increase the velocity of the condensate. The results of metallographic, SEM, elemental (EDX), X-ray Photon Spectroscopy (XPS) and Fourier Transform Infrared Spectroscopy (FTIR) analyses and corrosion rate calculated for each case are presented. The main causes of the failures are discussed and recommendations are provided to avoid similar problems in the future. Keywords: Steam condensate, piping system, erosion-corrosion, air cooler tubes, elbows, impingement, carbonic acid, thermal conductivity.
Carbon steel piping systems in several plants have failed under different applications, due to erosion-corrosion. This paper presents a variety of case histories where single-phase and two-phase steam flows, caused erosion-corrosion damage mainly at turn points of elbows and heat exchanger tubes. It was observed that the presence, even of a small amount, of the vapor phase can significantly increase the velocity of the condensate. The results of metallographic, SEM, elemental (EDX), X-ray Photon Spectroscopy (XPS) and Fourier Transform Infrared Spectroscopy (FTIR) analyses and corrosion rate calculated for each case are presented. The main causes of the failures are discussed and recommendations are provided to avoid similar problems in the future. Keywords: Steam condensate, piping system, erosion-corrosion, air cooler tubes, elbows, impingement, carbonic acid, thermal conductivity.
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Multiple leaks occurred with a carbon steel pipe carrying hot condensate water (300F and 140 psi).  A root cause analysis was performed, including visual and metallographic examination of two failed samples chemical, analysis of weld metal and base metal and chemical analysis of water samples.  Results show that flow accelerated corrosion (FAC) was the responsible mechanism leading to the failures.
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