MANAGING CORROSION CHALLENGES ASSOCIATED WITH HEAT EXCHANGERS For Presentation at GPA-GCC Special Session on Corrosion Management in Gas Processing Facilities Manama, Bahrain November 28, 2007 MANAGING CORROSION CHALLENGES MANAGING CORROSION CHALLENGES ASSOCIATED WITH HEAT EXCHANGERS ASSOCIATED WITH HEAT EXCHANGERS For Presentation at GPA-GCC Special Session on Corrosion Management in Gas Processing Facilities Manama, Bahrain November 28, 2007 November 28, 2007 M. A. Saleem & A. A. Hulaibi M. A. Saleem & A. A. Hulaibi Saudi ARAMCO Saudi ARAMCO Uthmaniyah Gas Plant Uthmaniyah Gas Plant Southern Area Gas Operations Southern Area Gas Operations
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MANAGING CORROSION CHALLENGESASSOCIATED WITH HEAT EXCHANGERS
For Presentation atGPA-GCC Special Session on
Corrosion Management in Gas Processing FacilitiesManama, Bahrain
November 28, 2007
MANAGING CORROSION CHALLENGESMANAGING CORROSION CHALLENGESASSOCIATED WITH HEAT EXCHANGERS ASSOCIATED WITH HEAT EXCHANGERS
For Presentation atGPA-GCC Special Session on
Corrosion Management in Gas Processing FacilitiesManama, Bahrain
November 28, 2007November 28, 2007
M. A. Saleem & A. A. HulaibiM. A. Saleem & A. A. HulaibiSaudi ARAMCOSaudi ARAMCO
Uthmaniyah Gas PlantUthmaniyah Gas PlantSouthern Area Gas OperationsSouthern Area Gas Operations
Review Corrosion Challenges Associated with Review Corrosion Challenges Associated with Heat Exchangers and the Integrity Management Heat Exchangers and the Integrity Management Programs being implemented for Safety & Programs being implemented for Safety & Reliability Enhancement.Reliability Enhancement.
Process OverviewProcess OverviewC2+ to Yanbu& Ju'aymah
C2+sphere
Acid Gas Sulfur to TruckLoading
SulfurRecovery
Sweet Gas
Gas Treat
AssociatedGas
SlugCatchers
Cond toCrude Inj
Khuff Gas
KhuffConditioning
To SalesGas Grid
SEC PowerGeneration
In-PlantFuel Usage
Chilldown
C2+NGL
HP
DGA
Fuel Gas Comp.
Sales Gas Comp.
HP Fuel
LP Fuel
Functionality of Heat Exchangers
Heat exchangers (HE) are crucial for plant
Operations. HE help to achieve:
• Heat transfer between two process streams
• Phase transformation
Types of Heat Exchangers
HE are of different types and the design depends
on Process requirements.• Air Cooled
• Shell & Tube
• Double Pipe
• Plate & Frame
Based on the application, HE are categorized as:• Condenser, Reboiler,
Shell side (Tube External) Corrosion Dissolved Oxygen
Lack of Adequate Treatment
Internal Corrosion:Under deposit
Closed Recirculating Cooling System
Pumping
Station
To Cooling Tower
From Cooling Tower
Heat Exchanger
Surge Tank
Batch Chemicals
Make-up Water
A Typical Cooling Water System
Cooling Water Heat Exchanger
HE Type: Shell & Tube
Service: Shell side: Cooling Water
Tube side: Cooling Tower Water
Shell/Tube sheet Material: Carbon Steel
Bundle Material: Aluminum Bronze
Number of Tubes:
Mode of Attack: Localized Tube sheet Deterioration
CW Heat Exchanger Tube sheet
CW Heat Exchanger Tube sheet
CW Heat Exchangers – Tube sheet
CW HE Tube sheet – After Restoration
Heat Exchanger Restoration
Cooling Tower
Type: Cross flow Cooling Tower
Service: Cooling Water
Tube side: Cooling Tower Water
Material: Redwood
Number of Tubes: 1595
Mode of Attack: Chemical & biological
Cooling Tower Structure & Basin
Cooling Tower Wood Deterioration
Treated Wood -Susceptibility to MIC
Boiler Feed Water Heat Exchanger
HE Type: Shell & TubeService:Shell side: Steam Condensate Return StreamTube side: Boiler Feed WaterShell Material: Carbon Steel Tube Material : Aluminum Bronze Number of Tubes: 2294/Unit Mode of Attack: Dealloying
Boiler Feed Water Heat Exchanger
Dearator Feed Water (Tube-Side)
DGA Steam Condensate (Shell-Side)
Steam Condensate Tanks D-102
A/B
To Dearators D-103 A/B/C
E110 -A E110 - B E110 -C
E110 -D E110 -E E110 - F
DGA Steam Condensate (Shell-Side)
Condensate Stripper Reboiler
Type: Shell & Tube
Service:
Shell side: Sour Wet HC
Tube side: Steam
Shell Material: Carbon Steel
Tube Material : Carbon Steel
Mode of Attack: External Pitting/Fouling
Tube Bundle: External Fouling
Regen. Steam Condenser
Type: Air Cooled
Service: Steam
Material: Carbon Steel
Number of Tubes: 273/unit
Mode of Attack: ?
Regen. Steam Cond. - Closed Header Box
Root Causes
• Mode of Operation• Contaminants• Metallurgical • Design • Corrosion• FoulingNeed For Corrosion Management program with Predictive & Preventive Strategies
•• Enhance MonitoringEnhance Monitoring::Video BorescopingVideo BorescopingMagnetic Flux Leakage (MFL) Magnetic Flux Leakage (MFL) Internal Rotary Inspection System (IRIS)Internal Rotary Inspection System (IRIS)Laser Optic Tube Inspection System (LOTIS)Laser Optic Tube Inspection System (LOTIS)Remote Field Eddy Current (RFEC)Remote Field Eddy Current (RFEC)
•• Explore suitable corrosion protection options:Explore suitable corrosion protection options:New Clad Fabrication Vs Strip lining of existing New Clad Fabrication Vs Strip lining of existing equipment,equipment,Use of tube inserts than retubingUse of tube inserts than retubingThermal Sprayed Coatings , CoatingsThermal Sprayed Coatings , CoatingsCorrosion Inhibition, VCICorrosion Inhibition, VCI
Expand R&D For Better Understanding of the New problemsExpand R&D For Better Understanding of the New problems
•• Partner with CSD/BPC in CAST ValidationPartner with CSD/BPC in CAST ValidationPrediction of corrosion and scaling tendencies in BFWPrediction of corrosion and scaling tendencies in BFW
Diagnose process stream chemistry variationsDiagnose process stream chemistry variations
•• HE are critical Process Equipment and require periodic HE are critical Process Equipment and require periodic comprehensive integrity assessment.comprehensive integrity assessment.
•• Identify Damage Mechanisms. Corrosion trend can be Identify Damage Mechanisms. Corrosion trend can be generic but can also be plant specific, which requires careful generic but can also be plant specific, which requires careful evaluation. evaluation.
•• Conventional NDE techniques have Limitations. Advanced Conventional NDE techniques have Limitations. Advanced NDE is crucial. NDE is crucial.
•• Establish comprehensive process stream monitoring programEstablish comprehensive process stream monitoring program
•• Enhance Corrosion Monitoring ProgramEnhance Corrosion Monitoring Program
•• Evaluate the Monitoring Data in coordination with other Evaluate the Monitoring Data in coordination with other disciplinesdisciplines
•• Ensure an Active OnEnsure an Active On--Stream Inspection ProgramStream Inspection Program
•• Partner with Other Organizations or JIP Partner with Other Organizations or JIP
•• Implement the Integrity Management ProgramImplement the Integrity Management Program