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Case Study on the Failure of Duplex Stainless Steel Heat Exchanger from Thermal Shock

Shell & tube heat exchangers are prone to degradation from corrosion and fouling. Recent advents in the industry recommend the use of corrosion-resistant alloys to reduce failure risks. This paper addresses the case study on the two different failure incidents of a formic acid heat exchanger (material: SS 316L, UNS S31603) that failed due to the corrosivity of the service which was followed by the material upgrade to super duplex SS Grade (UNS S32750). The exchanger later failed due to unanticipated cracks at the tube-tube sheet weld joints. The study investigates the root cause(s) behind the failures in light of inspection findings, operating history, and a review of the material’s mechanical and metallurgical properties. This study also recommends mitigative measures to avoid such failure events.
Product Number: 51324-20923-SG
Author: Immad Ovais Rohela; Yasar Irshad; Ahmad Raza Khan Rana; Syed Umair Niaz Bukhari
Publication Date: 2024
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