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51318-11320-Study of Repetitive Failure of a Gas/Gas Heat Exchanger

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A case history of repeated failure of a gas/gas shell and tube heat exchanger in a gas dehydration unit in a gathering center. The investigation showed that corrosion products had resulted in the blockage.

Product Number: 51318-11320-SG
Author: Saleh Al-Sulaiman / Sundip Kuthe / Sharad Londhe / Abdul Razzaq Al-Shamari
Publication Date: 2018
Industry: Oil and Gas Production
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$20.00
$20.00

A Gas/Gas shell and tube heat exchanger in gas dehydration unit in gathering center of Oil & Gas production company had failed repeatedly over the years. To investigate the cause of this repetitive failure, detailed visual inspection & Non-Destructive testing (NDT) of a piece of shell plate and pieces of tube from an old scrapped gas/gas heat exchanger was carried out. Additionally X-Ray Diffraction (XRD), Inductively Coupled Plasma (ICP) and chemical analyses of deposits from tube and shell side were performed.

The investigation showed that corrosion products, consisting of particles of several forms of iron oxides-hydroxides, sulfides and carbonates that form the basis for the black powder phenomenon, along with sulfur deposits had resulted in the blockage of the Gas/Gas shell & tube heat exchanger, as well as under deposit corrosion. The incidence of pitting / under deposit corrosion of the tubes resulted in perforations in the tubes and leakages. The online corrosion (coupon) monitoring data also showed severe corrosion and pitting in the downstream of Gas/Gas exchanger.

Several recommendations have been made to prevent deposit accumulation and failures in the Gas/Gas heat exchanger.

Key words: Heat Exchanger, Chemical Analysis, Deposits, Sulfur, Corrosion

 

 

A Gas/Gas shell and tube heat exchanger in gas dehydration unit in gathering center of Oil & Gas production company had failed repeatedly over the years. To investigate the cause of this repetitive failure, detailed visual inspection & Non-Destructive testing (NDT) of a piece of shell plate and pieces of tube from an old scrapped gas/gas heat exchanger was carried out. Additionally X-Ray Diffraction (XRD), Inductively Coupled Plasma (ICP) and chemical analyses of deposits from tube and shell side were performed.

The investigation showed that corrosion products, consisting of particles of several forms of iron oxides-hydroxides, sulfides and carbonates that form the basis for the black powder phenomenon, along with sulfur deposits had resulted in the blockage of the Gas/Gas shell & tube heat exchanger, as well as under deposit corrosion. The incidence of pitting / under deposit corrosion of the tubes resulted in perforations in the tubes and leakages. The online corrosion (coupon) monitoring data also showed severe corrosion and pitting in the downstream of Gas/Gas exchanger.

Several recommendations have been made to prevent deposit accumulation and failures in the Gas/Gas heat exchanger.

Key words: Heat Exchanger, Chemical Analysis, Deposits, Sulfur, Corrosion

 

 

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