GUWAHATI REFINERY INSPECTION DEPARTMENT

GR/TS/IP/09/18 SUB: Failure analysis report of stabilizer trim cooler (56-E-17) in ISOM unit The subject cooler was opened after suspected leakage on 21.09.11. The OEM M/s Anup engineering and PMC M/s UHDE were also called for discussion on the repetitive failure of this cooler. The observations , repair jobs carried out , reasons of failure and recommendations are detailed in the report below. Process parameter and M.O.C : A) Process Parameters Operating Fluid: Shell side-Stabilizer Overhead (Naphtha), Tube side-Cooling water Operating Pressure: Shell side-12.7Kg/Cm(g), Tube side-4.033Kg/Cm(g) Operating Temperature (Inlet/Outlet): Shell side-55/40C, Tube side-34/40C B) Material of Construction (M.O.C) Shell: SA516 GR.60 N (Killed Carbon steel) Tubes: SA789 UNS31803 (Duplex stainless steel) Floating Head & Stationary head Tube sheet: Originally (SA266 GR.2N+Duplex 2205 Weld Overlay) ,(now SS316) Floating Head Dish: SA516 GR.60 N (Killed Carbon Steel) Channel Box: SA516 GR.60 N (Killed Carbon Steel) Location of leaking cooler (056- E-17) 7.10.11

Observations:

1) Grooves were noticed all along the floating head tube sheet gasket surface. The length of the grooves
varied from (3, 6, 12 Oclock position) to 3 max. Length (9 oclock position). These grooves are at new locations different from the previously repaired one in July 2011.

Photograph: Grooves on floating head gasket surface

2) The gasket was inspected after opening, the same was found in good condition.

3) Pass 3, 4 and 6 tube end thinning & erosion were noticed at the floating head side. Erosion marks were
also noticed inside the tubes (approx 1 portion) in these tubes of pass 3,4 6. The external surface of the tubes were found to be in good condition. Remaining tubes in other passes were found in good condition. On the tube sheet face roughening/erosion/grooving was noticed.

Photograph: Tube end thinning / grooves on floating head tube sheet

4) No corrosion was noticed in the floating head strip lining carried out in july 2011 . At two locations the
weld joint was found cracked.

Photograph: Deposit on the floating head cover

Photograph: Crack in the strip lining of floating head

5) Lot of deposits were noticed in the channel box and floating head (Cooling water side). The anodes were
corroded/ missing. The paint finish coat was found partially damage however the primer was intact.

Photograph: Anodes corroded/ missing

Photograph: Paint Finish coat partially damaged

6) Yellowish & blackish color deposits were noticed in the shell cover and tube external surface.

7) Thickness survey of the connected 4 dia. Line ex- stabilizer column,C-11 to E-17 to V-17 was carried out
and found satisfactory. Repair jobs carried out:

1) The grooves on the tube sheet gasket surface were weld built up using duplex filler (SFA 5.4 E 2209) and
flush Ground/DP tested. 2) Crack in the floating head strip lining at 2 locations were repaired after removing the existing crack and weld built using ER309Mo electrode.

3) The complete channel box inside surface was cleaned manually and painted with 2 coats of high built 4)
epoxy finish coating (200 microns DFT). Anodes were fixed in the channel box (all passes). After completing all hot jobs the exchanger was hydro tested. No tube leak was noticed. New gasket was provided for the floating head.

Probable reason of corrosion: Repeated failures on gasket surface was discussed with OEM M/s Anup engineering. It was learnt that after weld overlay of 12.5mm duplex stainless steel (SS 2205 grade) over CS plate, the remaining portion was machined to dimension. It was opined that after machining the remaining weld overlay composition (diluted layer) may not be confirming to the required / actual composition, hence causing corrosion by either bimetallic corrosion mechanism/or by crevice corrosion. The corrosion was localized at this spot due to area effect (small anodic area, large cathodic area). After the formation of grooves on the floating head tube sheet, the leakage started from the gasket face. The shell side fluid (higher pressure) entered the water side and accelerated the corrosion. The MOM with OEM and PMC is enclosed as Annexure-1 Recommendation:

1) Since the tube bundle is no more reliable, the existing tube bundle shall be replaced with a solid duplex
tube sheet (both fixed and floating head) in place of existing weld overlaid tube sheets. The floating head cover and channel box shall be cladded (by explosive bonding only) with duplex SS and the existing partition plates shall be accordingly upgraded to duplex SS. It is also proposed to increase the tube size from 20O.D to 25 O.D to reduce /eliminate the erosion observed in pass 3,4 and 6. Suitable corrective engineering for removing the velocity effect to prevent erosion may be incorporated in the new design. Alternatively , The complete tube bundle shall be upgraded to Titanium tube bundle. Design changes related to tube size etc shall be considered to counter the effect of high velocity/ erosion in floating head side. (Action by Projects / Mech Maint.)

2) Adequate quantity of Duplex ER 2209 filler wires and electrode (SFA 5.4 E 2209, dia 3.15mm/ or 4mm,)
shall be kept available for meeting any exigency. (Action by Mech Maint.) 3) Remaining cooler/condensers of MSQ shall be offered for internal inspection during total s/d or opportunity s/d to assess the condition of the exchangers. (Action by Production/ Process / Mech Maint.)

(Sushil Guria) IPE

(Mahendra Pal) IPM

To: DMML (U)/ DMPN (MSQ)/ SPSE SMNM (U)/ SPNM (U)/ SPJM Cc: CMNM/ CPNM/ CTSM/ CPJM DGM (P)/ DGM (Maint) /DGM (TS)/DGM(PJ)

For N.A please

For kind information Please.

GM

ANNEXURE- 1