Failure analysis on abnormal leakage of shell and tube heat exchanger in specialty chemical plant

Ma, Siyuan; Bi, Tong-Tong; Gong, Yi; Yang, Zhenguo

doi:10.1016/j.engfailanal.2022.106859

Cited by 7 publications

(2 citation statements)

References 20 publications

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“…Shell and tube heat exchangers have been widely used as heat transfer equipment prevalent in refineries for transferring heat between fluids stored in shells and tubes, and with the large-scale application of such heat exchangers, leakage incidents from their tube bundles are common (Liu et al , 2021; Tong et al , 2023; Ma et al , 2023). Hydrogenation heat exchangers are also a main type of shell and tube heat exchanger.…”

Section: Introductionmentioning

confidence: 99%

Effect of hydrogen on the pitting corrosion behavior of Incoloy 825

Li,

Yao,

Guan

et al. 2024

ACMM

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Purpose In this paper, the authors aim to study the effect of hydrogen on the pitting corrosion behavior of Incoloy 825, a commonly used material for heat exchanger tubes in hydrogenated heat exchangers. Design/methodology/approach The pitting initiation and propagation behaviors were investigated by electrochemical and chemical immersion experiments and observed and analyzed by scanning electron microscope and energy dispersive spectrometer methods. Findings The results show that hydrogen significantly affects the electrochemical behavior of Incoloy 825; the self-corrosion potential decreased from −197 mV before hydrogen charging to −263 mV, −270 mV and −657 mV after hydrogen charging, and the corrosion current density increased from 0.049 µA/cm2 before hydrogen charging to 2.490 µA/cm2, 2.560 µA/cm2 and 2.780 µA/cm2 after hydrogen charging. The pitting susceptibility of the material increases. Originality/value Hydrogen is enriched on the precipitate, and the pitting corrosion also initiates at that location. The synergistic effect of hydrogen and precipitate destroys the passive film on the metal surface and promotes pitting initiation.

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Section: Introductionmentioning

confidence: 99%

Effect of hydrogen on the pitting corrosion behavior of Incoloy 825

Li,

Yao,

Guan

et al. 2024

ACMM

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“…The replacement and repair of equipment in various industries is often required due to corrosion. In petrochemical refineries, corrosion is a major cause of plant shutdowns [5].…”

Section: Introductionmentioning

confidence: 99%

Analysis of Causes and Protective Measures against Corrosion Perforation in the Shell-Side Outlet Flange of a Sour Water Steam Heater

Liang,

Duan,

2024

Coatings

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Heat exchangers, as essential devices for facilitating heat transfer, have found a variety applications in various industries. However, the occurrence of corrosion-related failures in real-world scenarios remains a prevalent problem that can lead to catastrophic incidents. This paper investigates the problem of corrosion perforation on the outlet flange of a heat exchanger in a sour steam stripper from a petrochemical company. Failure analysis was performed using physical testing and chemical analysis, metallographic examination, microscopic observation, and energy spectrum analysis. Intergranular corrosion experiments and flow calculations were performed to verify the analysis. The results indicate that the main cause of the flange corrosion perforation was the formation of a highly concentrated NH4HS aqueous solution during the cooling process of the NH3, H2S, and water vapor in the fluid passing through the heat exchanger, and the velocity was too high, which triggered alkali-sour water washout corrosion. To prevent the recurrence of similar corrosion perforations, recommendations for material and process optimization are proposed to effectively reduce the safety production risks in refinery units and provide valuable information for the safe long-term operation of a sour steam stripper.

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Failure analysis on unexpected fracture of tube-to-tubesheet joints of a circulating oil steam generator

He,

Wang,

et al. 2023

Engineering Failure Analysis

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Failure analysis on abnormal leakage of shell and tube heat exchanger in specialty chemical plant

Cited by 7 publications

References 20 publications

Effect of hydrogen on the pitting corrosion behavior of Incoloy 825

Effect of hydrogen on the pitting corrosion behavior of Incoloy 825

Analysis of Causes and Protective Measures against Corrosion Perforation in the Shell-Side Outlet Flange of a Sour Water Steam Heater

Failure analysis on unexpected fracture of tube-to-tubesheet joints of a circulating oil steam generator

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