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51313-02118-Corrosion of a Shell-and-Tube Heat Exchanger

Picture for Corrosion of a Shell-and-Tube Heat Exchanger
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Product Number: 51313-02118-SG
ISBN: 02118 2013 CP
Author: Jeffrey Xie
Publication Date: 2013
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Inspection revealed that tubes of a shell-and-tube heat exchanger suffered wall loss on both the inner (ID) and outer diameter (OD) surfaces to a degree of threating the operation reliability of the heat exchanger. The shell side is cooling water and the tube side is the process side. A metallurgical characterization was conducted on the heat exchanger carbon steel tubes to investigate the failure mechanism and provide potential recommendations for mitigation.

Tubes and scales were characterized in term of microstructure morphologies and compositions using SEM/EDX TGA-FTIR and XRD techniques. The tubes were found to suffer corrosion on both ID and OD surfaces in the form of pitting corrosion. The pitting corrosion was present on the entire ID surface but was shallower than the pitting corrosion on the OD surface. Pitting corrosion on the OD surface was predominant and would be responsible for potential leaking. Detailed characterization indicated that pitting corrosion on the OD surface was the result of tuberculation under deposit; while the pitting corrosion on the ID surface was due to presence of hydrochloric acid formed between the condensed water and organic chloride in the process gas stream.

The severity of pitting corrosion on the OD surface was revealed to be related to o’clock positions of the tubes i.e. 3:00 and 9:00 o’clock positions were most severe; while the 6:00 o’clock position was free of corrosion and the corrosion at 12:00 o’clock position lie in the middle. These were the result of accumulation of deposits on the OD surface especially at the interface bridging the tubes resulting in severe corrosion at the 3:00 and 9:00 o’clock positions due to tuberculation under deposit; and no corrosion at the bottom of the tubes (6:00 o’clock).
 

Inspection revealed that tubes of a shell-and-tube heat exchanger suffered wall loss on both the inner (ID) and outer diameter (OD) surfaces to a degree of threating the operation reliability of the heat exchanger. The shell side is cooling water and the tube side is the process side. A metallurgical characterization was conducted on the heat exchanger carbon steel tubes to investigate the failure mechanism and provide potential recommendations for mitigation.

Tubes and scales were characterized in term of microstructure morphologies and compositions using SEM/EDX TGA-FTIR and XRD techniques. The tubes were found to suffer corrosion on both ID and OD surfaces in the form of pitting corrosion. The pitting corrosion was present on the entire ID surface but was shallower than the pitting corrosion on the OD surface. Pitting corrosion on the OD surface was predominant and would be responsible for potential leaking. Detailed characterization indicated that pitting corrosion on the OD surface was the result of tuberculation under deposit; while the pitting corrosion on the ID surface was due to presence of hydrochloric acid formed between the condensed water and organic chloride in the process gas stream.

The severity of pitting corrosion on the OD surface was revealed to be related to o’clock positions of the tubes i.e. 3:00 and 9:00 o’clock positions were most severe; while the 6:00 o’clock position was free of corrosion and the corrosion at 12:00 o’clock position lie in the middle. These were the result of accumulation of deposits on the OD surface especially at the interface bridging the tubes resulting in severe corrosion at the 3:00 and 9:00 o’clock positions due to tuberculation under deposit; and no corrosion at the bottom of the tubes (6:00 o’clock).
 

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Picture for Microbiologically Influenced Corrosion of Heat Exchanger Tubes
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51314-3795-Microbiologically Influenced Corrosion of Heat Exchanger Tubes

Product Number: 51314-3795-SG
ISBN: 3795 2014 CP
Author: Hussain Almahamedh
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Picture for Corrosion of a Vertical Shell and Tube Heat Exchanger
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51315-5473-Corrosion of a Vertical Shell and Tube Heat Exchanger

Product Number: 51315-5473-SG
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Picture for 51318-11059- Review of a UNS N04400 Heat Exchanger Tube Failure in Cooling Water Service
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51318-11059- Review of a UNS N04400 Heat Exchanger Tube Failure in Cooling Water Service

Product Number: 51318-11059-SG
Author: Mel Esmacher / Kumar Kembaiyan / Tony Navarrete / Andrew Rentsch
Publication Date: 2018
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A polyethylene unit experienced a gas leak within a high pressure tube and shell heat exchanger. Failure analysis revealed that the tube wall loss was beneath residual deposits. Preventative measures and improvements in inspection & cleaning procedures are discussed.

 

 
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