The present paper describes a study case of the failure investigation of Duplex stainless steel (UNS S31803) on the tube and tube sheet section of a shell and tube heat exchanger BEM TEMA type with seawater as the cooling medium. Although UNS S31803 offers high strength, high resistance to chloride-induced SCC, and high resistance to pitting attack in chloride environments, in this study case, the heat exchanger experienced some material degradation; 26 tubes were leaked and plugged on both sides, and scales plugged 76 tubes. The examination in this study case revealed the formation of biofilm inside the tubes, XRD examination revealed that the film contained aragonite (CaCO3), and by using microstructural examination on the inner surface of the tube, the austenite grains were preferentially attacked by crevice corrosion. In this case, the failure was caused by crevice corrosion, and crevice corrosion was enhanced by microbiological-induced corrosion (MIC). Recommendations to avoid similar failures are also suggested in this paper.
The present paper describes a study case of the failure investigation of duplex stainless steel (UNS S31803) on the tube and tube sheet sections of BEM TEMA-type shell and tube heat exchanger with seawater as the cooling medium. The heat exchanger’s shell design pressure was 22.6 MPa at 422 K, and the tube design pressure was 1 MPa at 339 K. Although UNS S31803 offers high strength, high resistance to chloride-induced SCC, and high resistance to pitting attack in chloride environments, the heat exchanger in this study experienced some material degradation after 28 months of use; 102 out of 270 tubes failed, 26 tubes leaked and were plugged on both sides, and scale plugged 76 tubes. The examination in this study case revealed the formation of white-colored biofilm inside the tubes; XRD examination revealed that the film contained CaCO3. Using microstructural examination on the inner surface of the tube, the austenite grains were shown to have been preferentially attacked; this phenomenon is typical in duplex stainless steel which fails due to crevice corrosion. According to the examination result, the failure in this case was caused by crevice corrosion between the substrate and surface deposits that was enhanced by microbiological-induced corrosion (MIC). Recommendations to avoid similar failures are also suggested in this paper.
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