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Heat Exchanger Tubes

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Heat Exchanger Tubes

Heat Exchanger Tubes

Inchtain

(Petroleum)

(OP)

27 Jan 24 17:54

Dear Colleagues,

We have a Condenser that experienced a rapid failure of its tubes.

If the cooling water treatment was improved, do we still need to think about altering the material used.

Saying that, I wonder if SA 334 Gr. 1 carbon steel material was a good choice for this Condenser tubes; and how to guarantee the supplier will provide high quality tubes and of the same specifications needed when ordering them.

The Condenser parameters and construction is as follows:

Designation Shell Side Tube Side
Design Pressure (kg/cm2) 26 18.5
Design Temperature (ºC) 100 70
Fluid Refrigerant Propane Cooling Water
No. of Passes 1 2
Construction Code ASME VIII Div. 1 & TEMA Class R
Stress Relief None Yes, only for Channel Chamber
Radiography Full Spot

Component Material Design Thick.(mm) Corrosion Allow.(mm)
Shell ASME SA 516 Gr. 60 25 3
Elliptical Heads ASTM A 516 Gr. 60 19 (Min. 17 after forming) 3
Tubes ø = 19.05 mm (Ł = mm) SA 334 Gr.1 2.11 -
Tube Sheets SA 350 LF 2
Insulation No

And how to verify the baffles and tie-rods condition when re-tubing this condenser following the removal of the old tubes? and in case of tube break during the extraction, which is the best practice to remove the remained debris inside and clean the shell knowing that this Condenser is a fixed tube sheet heat exchanger?

I really appreciate your valuable feedback.

Thanks and best regards,

Replies continue below

Recommended for you

RE: Heat Exchanger Tubes

(Petroleum)

27 Jan 24 19:46

Cs tubes, for cooling water systems will not be a good choice.

RE: Heat Exchanger Tubes

EdStainless

(Materials)

27 Jan 24 23:33
You typically run as thin of tubes as possible which means zero corrosion allowance.
You need to look at what alloys that may be in your application.
With CS tubesheets it usually also involves coating the tubesheets (two or three layer high build epoxy)
When you retube every tube is removed, all baffle holes cleaned and gauged, all tubesheet holes are cleaned and gauged for size.
All of the internals should be inspected.
After all this is your only chance to see everything.

CS tubes in condenser service are rare.You typically run as thin of tubes as possible which means zero corrosion allowance.You need to look at what alloys that may be in your application.With CS tubesheets it usually also involves coating the tubesheets (two or three layer high build epoxy)When you retube every tube is removed, all baffle holes cleaned and gauged, all tubesheet holes are cleaned and gauged for size.All of the internals should be inspected.After all this is your only chance to see everything.

= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, consulting work welcomed

RE: Heat Exchanger Tubes

Inchtain

(Petroleum)

(OP)

28 Jan 24 06:11

Thanks for replying.

So, what other suggestions to upgrade the tubes material? and how to guarantee that the supplier will provide high quality tubes and of the same specifications needed when ordering them?

RE: Heat Exchanger Tubes

EdStainless

(Materials)

28 Jan 24 19:36
1. Select a material
2. Get to know the specs
3. Right a short spec (don't repeat anything in the ASTM) if you want additions
4. Buy from mills that you know, if you don't know them visit them.
This is part of the procurement cost.

There are Cu based alloys (often CuNi) and stainless steels (alloys better than 316).1. Select a material2. Get to know the specs3. Right a short spec (don't repeat anything in the ASTM) if you want additions4. Buy from mills that you know, if you don't know them visit them.This is part of the procurement cost.

= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, consulting work welcomed

RE: Heat Exchanger Tubes

(Petroleum)

29 Jan 24 22:25

Ed gave you the answer

RE: Heat Exchanger Tubes

Dhurjati Sen

(Materials)

16 Feb 24 05:09

Check the tube edges (the portion that protrudes out of the tube sheet) to assess cooling water corrosion.

Pull out a failed tube to check shell side corrosion.

I will not worry much about the tie rods and the baffles at the moment.

Rushing for a material upgradation without a proper failure analysis is not desirable.

You need to determine whether the corrosion is shell side, or tube side, or BOTH.Check the tube edges (the portion that protrudes out of the tube sheet) to assess cooling water corrosion.Pull out a failed tube to check shell side corrosion.I will not worry much about the tie rods and the baffles at the moment.Rushing for a material upgradation without a proper failure analysis is not desirable.

FUYI BRUSH are exported all over the world and different industries with quality first. Our belief is to provide our customers with more and better high value-added products. Let's create a better future together.

See also:
Water Ripple Stainless Steel Sheet
How to Select Diamond Honing Pads?

DHURJATI SEN
Kolkata, India

RE: Heat Exchanger Tubes

MJCronin

(Mechanical)

16 Feb 24 13:49

... as a suggestion, I believe that you might be well served to explore the corrosion-enhanced properties of the Duplex Stainless alloy tubing ()over 304/316 series

Even the ultra-conservative ALFA LAVAL people seem to be standardizing on this alloy choice for their oilfield condensate sevices.

https://www.alfalaval.com/globalassets/documents/m....

https://ebin.pub/corrosion-control-in-the-oil-and-...

https://nickelinstitute.org/media/8dab1e8a/...

MJCronin
Sr. Process Engineer

As always, EdStainless seems to be on point .... CS was a bad choice... as a suggestion, I believe that you might be well served to explore the corrosion-enhanced properties of the Duplex Stainless alloy tubing ()over 304/316 seriesMJCroninSr. Process Engineer

RE: Heat Exchanger Tubes

2

EdStainless

(Materials)

16 Feb 24 17:22
It has much better CSCC resistance, it isn't immune but it has usable resistance.
It has much higher strength, which usually leads to thinner tubes.
You would likely go down to 0.065" or maybe thinner.
And the CTE isn't that different from steel (much closer than an austenitic SS or Cu alloy).
It is also widely available.
When you order a duplex SS always specify A923, without accepting on the micro.
This will require a special corrosion test to verify that the HT was correct.

is a good option. It has better pitting/crevice corrosion resistance than 316.It has much better CSCC resistance, it isn't immune but it has usable resistance.It has much higher strength, which usually leads to thinner tubes.You would likely go down to 0.065" or maybe thinner.And the CTE isn't that different from steel (much closer than an austenitic SS or Cu alloy).It is also widely available.When you order a duplex SS always specify A923, without accepting on the micro.This will require a special corrosion test to verify that the HT was correct.

= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, consulting work welcomed

RE: Heat Exchanger Tubes

rscosta

(Materials)

8 Mar 24 11:06

Without more details it is hard to provide a good answer.

There is no question that either copper alloys, super duplex SS and other corrosion resistant alloys would offer great benefits over carbon steel. However, I can think of
cases where carbon steel utilization is acceptable depending of the cooling water system type and respective water treatment program. As an example, many close loop CW systems present very low corrosion rates for well (chemically) treated systems.

Thanks

RE: Heat Exchanger Tubes

EdStainless

(Materials)

8 Mar 24 17:53
Most plants will not do this, saying that it costs too much to shut down.
But they take a system that would have lasted 20 years and destroy it in one day.
What does that cost?
It is a rare discipline.

The catch with most CS cooling water systems that rely on treatment is that you have to have procedures in place that assure if treatment is lost that the system will be shut down.Most plants will not do this, saying that it costs too much to shut down.But they take a system that would have lasted 20 years and destroy it in one day.What does that cost?It is a rare discipline.

= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, consulting work welcomed

RE: Heat Exchanger Tubes

Krausen

(Mechanical)

24 Mar 24 12:11

Quote (EdStainless)

is a good option. It has better pitting/crevice corrosion resistance than 316.
It has much better CSCC resistance, it isn't immune but it has usable resistance.
It has much higher strength, which usually leads to thinner tubes.
You would likely go down to 0.065" or maybe thinner.
And the CTE isn't that different from steel (much closer than an austenitic SS or Cu alloy).
It is also widely available.
When you order a duplex SS always specify A923, without accepting on the micro.
This will require a special corrosion test to verify that the HT was correct.

EdStainless - What are your general thoughts on the tube-to-tubesheet joint design when using tubes with CS tubesheets? Being that is a much harder/stronger material compared to CS, do you typically strength/seal weld these joints to avoid any potential issues with rolling the harder tubes to the softer CS tubesheets? If so, do you recommend providing a weld overlay of (or 300 SS material) to the tubeside of the CS tubesheet to help match the metallurgy of the tube-to-tubesheet strength/seal welds?

EdStainless - What are your general thoughts on the tube-to-tubesheet joint design when using tubes with CS tubesheets? Being that is a much harder/stronger material compared to CS, do you typically strength/seal weld these joints to avoid any potential issues with rolling the harder tubes to the softer CS tubesheets? If so, do you recommend providing a weld overlay of (or 300 SS material) to the tubeside of the CS tubesheet to help match the metallurgy of the tube-to-tubesheet strength/seal welds?

RE: Heat Exchanger Tubes

EdStainless

(Materials)

25 Mar 24 15:56
But it really depends on how corrosive the service is.
If CS tubesheets will hold up then use stronger CS grades so that they are closer to the strength of the .
The yield strength of isn't that high, and with thinner tubes this shouldn't be an issue to roll.
I have seen much greater differences work fine.
Seal welding will work but if you are welding directly to CS you will likely need a Ni alloy filler (C276?).
The most common solution is no weld and to shop epoxy coat the tubesheets.
A three layer high build system will be very durable and seal very well.
I am not a fan of overlay for these lower alloys.
Duplex overlays are problematic because of trying to achieve phase balance (issues with both cooling rate and dilution).
Using a 316L overlay in two layers would likely cost as much as a solid SS tubesheet.
Just not worth it.

Ideally I would like to see tube sheets. You would need this for strength welds.But it really depends on how corrosive the service is.If CS tubesheets will hold up then use stronger CS grades so that they are closer to the strength of the .The yield strength of isn't that high, and with thinner tubes this shouldn't be an issue to roll.I have seen much greater differences work fine.Seal welding will work but if you are welding directly to CS you will likely need a Ni alloy filler (C276?).The most common solution is no weld and to shop epoxy coat the tubesheets.A three layer high build system will be very durable and seal very well.I am not a fan of overlay for these lower alloys.Duplex overlays are problematic because of trying to achieve phase balance (issues with both cooling rate and dilution).Using a 316L overlay in two layers would likely cost as much as a solid SS tubesheet.Just not worth it.

= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, consulting work welcomed

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News

Material pricing and availability can fluctuate based on market supply and demand, the quantity required for your exchanger, and the components needed. Copper was a low-cost option a few years ago, but now due to supply, it is more expensive than stainless steel. Conversely, Titanium used to be one of the most expensive alloys but is now more reasonably priced. Typically, the more nickel content in a metal, the higher the price.

Here is the relative ranking for some of the common metal material options by price from highest to lowest:

1. MOST EXPENSIVE: Nickel 200, also known as UNS N, is a commercially pure nickel alloy. It is one of the most widely used nickel alloys due to its excellent mechanical properties and high corrosion resistance. Nickel 200 consists of 99.6% pure nickel, with small amounts of impurities such as iron, copper, and manganese.

2. Alloy 625, also known as Inconel 625, is a nickel-based superalloy known for its excellent strength, corrosion resistance, and high temperature performance. It is composed mainly of nickel, with significant amounts of chromium and molybdenum, along with smaller additions of niobium, iron, and other elements. Alloy 625 is widely used in various industries, including aerospace, chemical processing, oil and gas, and marine applications.

3. Monel 400 is a nickel-copper alloy known for its excellent corrosion resistance in various environments. It is composed of approximately 67% nickel and 30% copper, with small amounts of iron, manganese, carbon, and silicon. Monel 400 is highly resistant to corrosive substances such as acids, alkaline solutions, and saltwater. It is often used in applications where resistance to corrosion, erosion, and high temperatures are essential.

4. Hastelloy C22 is a nickel-chromium-molybdenum alloy known for its exceptional corrosion resistance in a wide range of aggressive environments. Hastelloy C22 is particularly resistant to pitting, crevice corrosion, and stress corrosion cracking. Hastelloy C22 is often chosen for chemical processing and waste treatment.

5. Hastelloy C-276 is a nickel-molybdenum-chromium alloy that is renowned for its corrosion resistance and high-performance properties. While similar to Hastelloy C22, Hastelloy C-276 has lower chromium content, easier weldability, and slightly higher upper temperature limits. Hastelloy C-276 is used in various industries, including chemical processing, pollution control, pulp and paper production, and petrochemical applications.

6. Duplex  is a super duplex stainless steel alloy that offers excellent strength, corrosion resistance, and durability. It is part of the duplex stainless steel family, which combines the desirable properties of both austenitic and ferritic stainless steels. Duplex is characterized by its high levels of chromium, molybdenum, and nitrogen, providing superior resistance to corrosion and high mechanical strength.

7. AL6XN is a high-performance austenitic stainless steel alloy that offers exceptional corrosion resistance and mechanical properties. It is specifically designed to withstand highly corrosive environments, including chloride-rich environments, acids, and seawater. AL6XN is known for its versatility, making it suitable for various applications in industries such as chemical processing, pulp and paper, oil and gas, and desalination.

8. Titanium is a lightweight metal known for its high strength, low density, and excellent corrosion resistance. Titanium is widely used in various industries due to its unique combination of properties.

9. Duplex is a stainless steel alloy with a combination of austenitic and ferritic microstructures, known as a duplex structure. It offers excellent strength, corrosion resistance, and durability, making it suitable for a wide range of applications. Duplex is highly popular in industries such as oil and gas, chemical processing, marine, and pulp and paper.

10. 316L stainless steel is a commonly used grade of stainless steel known for its corrosion resistance, high strength, and versatility. It is an austenitic stainless steel alloy with low carbon content, making it suitable for various applications where resistance to corrosive environments is essential. It is widely used in marine applications, chemical processing, dairy, and pharmaceuticals.

10. 304L stainless steel is a commonly used grade of stainless steel known for its corrosion resistance, versatility, and ease of fabrication. It is an austenitic stainless steel alloy with low carbon content, which enhances its weldability and reduces the risk of sensitization to intergranular corrosion. In comparison to 316L SS, 304L SS has no molybdenum content and it&#;s less resistant to chloride-induce corrosion. It is suitable for general-purpose uses that don&#;t require the enhanced corrosion resistance of 316L SS.

12. LEAST EXPENSIVE: Carbon steel is a type of steel that primarily consists of iron and carbon, with other elements present in smaller amounts. It is one of the most commonly used materials in the manufacturing and construction industries due to its affordability, strength, and versatility.

Typically, the higher priced alloys are also in shorter supply, due to lower demand and the higher cost of carrying inventory. This directly affects the lead-time of these materials, often by 2-4 times that of more common alloys like carbon steel and stainless steel. Quantity of these higher alloys can also greatly affect price. Steel mills typically don&#;t run small batches of tubes or plate or they will charge for the entire mill run if they do.

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