INTEGRITY DEPARTMENT

INSPECTION SECTION

Failure of oil cooler tubes for

Gas Turbine ,GT5

Prepared By : Ahmed Reyad

Reviewed by : Juttada Venu Approved By : Hamad Jaber

04/08/2016
 Failure of oil cooler tubes for Gas Turbine ,GT5

Introduction
Oil coolers of gas turbine 5, GT5, were offered for inspection based on water quality issue (oil contamination
was reported).
Visual inspection was performed for the coolers, where sever pitting was observed at the tube ends of cooler
(E61401B/5). Shell-side testing had been performed, where 26 leaked tubes were detected, which had been
plugged, to raise the number of plugged tubes to 29 out of 200, which is almost 15%.
This report will study the possible causes of this damage based on the available data of the cooler and the
inspection observations, along with suggested measures to avoid repeating the possible damage.
Material of Construction
Tube Admiralty Brass (cartridge brass (C26000) No of tubes 200 Tube O.D 16 mm
Tube Sheet Naval Brass Shell Carbon Steel
Parameter Design and Operating Conditions ,Tube Side
Design Temperature 121°C Design pressure 10.5 psi
Fluid Boiler Feed Water (as per operation side) Flow rate 90 m3/hr.
Discussion
- Based on reviewing the collected data, specially tube material, along with the inspection observations,
the observed damage is probably due to a very common corrosion mechanism with this type of
material (Brass Alloy) called Dezincification
- Dezincification is a corrosion mechanism that causes selective removal of zinc leaves a relatively
porous and weak layer of copper, this damage mechanism is usually occur with brasses contain more
than 15% Zn, as in our case.
- There are two common types of dezincification exhibited in brass:
1- Uniform, layer type
2- Localized, plug-type.
- In our case plug-type dezincification is probably the governing type, where localized corrosion was
observed in the accessible areas of the tubes, also this type favors alkaline condition (water PH 9, see
attached).
- Dezincification is favored by stagnant flow or slowly moving conditions that allow deposits to settle
out on tubing surfaces, which produces dezincified areas as a result of crevice corrosion mechanisms
and causes higher temperature due to insulating effect of the deposit. This point might be applicable
in our case, if the cooler is isolated (out of service) and water was kept inside.
Recommendations
- Based on the inspection observations and the related references; it is recommended to upgrade the
tube material to alloy resistant to dezincification, Copper-Nickel Alloy (90-10 or 70-30) would be
recommended.
- In all cases, for the current coolers (GT4 & GT5), as well as in case of upgrading the material, stagnant
conditions should be avoided to prevent dezincification and pitting corrosion.
- It is recommended to follow manufacturer instructions in regard to corrosion inhibitor injection and
the testing of its protection efficiency.

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 Failure of oil cooler tubes for Gas Turbine ,GT5

Attachments
- Oil Cooler datasheet and drawing.
- Water analysis.
- Manufacturer instruction for inhibitor injection.

References
- Corrosion engineering by Mars g. Fontana.
- NACE, Basic corrosion, 2014.
- NACE, Corrosion Control in the Refining Industry.
- ASM Handbook Volume 13B Corrosion: Materials.

Internal pitting of the tubes were observed

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- PMI result for tube of oil cooler in GT4

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