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<p>Heat exchangers are critical components in thermal systems, facilitating efficient heat transfer between fluids through convection and conduction across tube bundles. However, extended exposure to aggressive service environments can severely compromise tube integrity. This study investigates the failure of heat exchanger tubes in an oil processing unit, attributing degradation to chloride-induced uniform corrosion. Comprehensive analyses were conducted using scanning electron microscopy with energy-dispersive x-ray spectroscopy (SEM-EDX), metallography, hardness testing, chemical composition assessment, heat transfer calculations, finite element thermal simulations, and corrosion product characterization. The tube material conformed to the ASME SA 214 carbon steel standard, with 0.152 wt.% C, 0.464 wt.% Mn, 0.0143 wt.% P, and 0.014 wt.% S, and exhibited hardness values ranging from 84.5 to 124.4 HV. Microstructural examination revealed a ferrite pearlite matrix typical of low carbon steels. Corrosion was primarily observed on the external (shell-side) surface, causing wall thinning from an initial 2.11&#xa0;mm to 0.76–1.45&#xa0;mm, amounting to over 60% material loss. EDX detected chlorine ion concentrations of approximately 0.6 wt.% in the corrosion products exceeding acceptable industrial limits and accelerating uniform corrosion. Severely thinned areas experienced elevated localized stresses due to increased wall temperatures under service conditions, further reducing mechanical integrity. No evidence of pitting, erosion, or mechanical overload was found. The results conclusively identify chloride-induced uniform corrosion as the principal failure mechanism.</p>

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Effect of Chloride-Induced Uniform Corrosion on the Structural Integrity of Heat Exchanger Tubes

  • 期刊论文

  • 发表日期：

    2025年12月19日

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  • Eka Febriyanti,
  • Amin Suhadi,
  • Adimas Aprilio Hardinanto,
  • Muhammad Syahril,
  • Aswandi,
  • Hadi Sunandrio,
  • Marsetiayu Ningsih,
  • Hamdani,
  • Barkah Fitriyana,
  • Rath Kautsar Firdaus,
  • Feri Karuana

摘要

Heat exchangers are critical components in thermal systems, facilitating efficient heat transfer between fluids through convection and conduction across tube bundles. However, extended exposure to aggressive service environments can severely compromise tube integrity. This study investigates the failure of heat exchanger tubes in an oil processing unit, attributing degradation to chloride-induced uniform corrosion. Comprehensive analyses were conducted using scanning electron microscopy with energy-dispersive x-ray spectroscopy (SEM-EDX), metallography, hardness testing, chemical composition assessment, heat transfer calculations, finite element thermal simulations, and corrosion product characterization. The tube material conformed to the ASME SA 214 carbon steel standard, with 0.152 wt.% C, 0.464 wt.% Mn, 0.0143 wt.% P, and 0.014 wt.% S, and exhibited hardness values ranging from 84.5 to 124.4 HV. Microstructural examination revealed a ferrite pearlite matrix typical of low carbon steels. Corrosion was primarily observed on the external (shell-side) surface, causing wall thinning from an initial 2.11 mm to 0.76–1.45 mm, amounting to over 60% material loss. EDX detected chlorine ion concentrations of approximately 0.6 wt.% in the corrosion products exceeding acceptable industrial limits and accelerating uniform corrosion. Severely thinned areas experienced elevated localized stresses due to increased wall temperatures under service conditions, further reducing mechanical integrity. No evidence of pitting, erosion, or mechanical overload was found. The results conclusively identify chloride-induced uniform corrosion as the principal failure mechanism.