Technical Report from the year 2013 in the subject Materials
Science, grade: B, Robert Gordon University Aberdeen, course: MSc
Oil and Gas Engineering, language: English, comment: Well Done ,
abstract: A high pressure gas cooler located in an offshore
platform have been operating for more than 10 years. Throughout
that period the gas cooler have been subjected to several tube
failures, the failures have caused gas leak from the tube side.
Several materials upgrades have been used to contain the tube
failure. The last choice was to use a more corrosion resistant
material Hastelloy C22. Crevice corrosion has been reported as the
primary failure mechanism. The tube and tube plate joined surfaces
have been exposed to high temperature which is relatively higher
than the critical crevice temperature of Hastelloy C22. There was a
poor heat transfer between the shell side fluid and tube side due
to a small heat transfer area and low fluid velocity in the
affected zone. Stress corrosion and fatigue corrosion accounted for
the secondary failure mechanism which ultimately caused a crack in
the tubes. Other possible reason identified to cause crevice
corrosion was the mechanical rolling expansion technique.
Oftentimes it creates rear crevices on the tubes with enough
geometry to develop crevice chemistry. Mitigation methods such as
hydraulic expansion technique, heat treatment for residual stresses
and baffle design enhancements have been proposed in this report.
Key words: shell and tube heat exchanger failure; Hastelloy C22
material; tube failure; localized corrosion; crevice corrosion;
internal pitting corrosion
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