Professional Documents
Culture Documents
CHT. HPCL MR-Duplex
CHT. HPCL MR-Duplex
HPCL MR
1
Inspection Division HPCL-MR
Agenda
Limitations Repairs
Background
2
Inspection Division HPCL-MR
Background
Super Duplex Stainless Steel (SDSS)
Introduced for first time in salt water service in Yr. 2000 in MR DHDS.
Some of these super duplex exchangers failed within 4 years of
commissioning.
Total no of SDSS exchangers : 18
SDSS Exchanger failure : 3
4
Inspection Division HPCL-MR
Observations DSS
5
Inspection Division HPCL-MR
Observations DSS Contd…
Corroded seal weld and tube
6
Inspection Division HPCL-MR
Observations DSS Contd…
Pitting Type Corrosion at Tube Ends
7
Inspection Division HPCL-MR
Observations DSS Contd…
Pitting Type Corrosion at Tube ID
8
Inspection Division HPCL-MR
Observations DSS Contd…
Crevice Corrosion near GSS
9
Inspection Division HPCL-MR
Observations SDSS
10
Inspection Division HPCL-MR
Observations SDSS Contd…
Seal weld corrosion due to contaminated weld
11
Inspection Division HPCL-MR
Observations SDSS
Seal weld corrosion due to contaminated weld
12
Inspection Division HPCL-MR
Observations SDSS Contd…
Under deposition crevice corrosion
13
Inspection Division HPCL-MR
Investigations DSS
PMI & Microstructure examination
Chemical composition of Tubes, tube sheet
and HAZ found OK
Tube Microstructure found OK
Tube sheet Microstructure found OK
Weld and HAZ :Microstructure found OK
14
Inspection Division HPCL-MR
Investigations DSS
HYSIS Calculations on Tube Skin Metal Temperature
Shell Geometry Input
15
Investigations DSS
HYSIS Calculations on Tube Skin Metal Temperature
Bundle Details Input
16
Investigations DSS
HYSIS Calculations on Tube Skin Metal Temperature
Tube Skin Temperature Results
17
Investigations SDSS
18
Inspection Division HPCL-MR
Microstructure of Tube of Tube
Sheet Weld
CPT of SDSS is 75o C & CCT is 50o C. Silt and non smooth weld
finish can lead to deposition and aggravate crevice corrosion.
20
Inspection Division HPCL-MR
Root Cause
21
Inspection Division HPCL-MR
Failure Mechanism of Seal
Weld in SDSS
22
Inspection Division HPCL-MR
Importance of Nitrogen
Improved
austenite
reformation
in welding
Improved
Improved
strength Nitrogen phase
balance
Improved
corrosion
resistance
23
Inspection Division HPCL-MR
Repairs
24
Inspection Division HPCL-MR
Way Forward
Design Stage
25
Inspection Division HPCL-MR
Way Forward Contd..
Fabrication Stage
26
Inspection Division HPCL-MR
Way Forward Contd..
Operational Stage
27
Inspection Division HPCL-MR
THANK YOU
28
Inspection Division HPCL-MR
List of Failed Exchangers
S. No Equipment No. MOC Commissioning Failure Type of
Date Date Failure
1. 102-E-2009A/B DSS Aug’09 Sept’09 Tube
leak, FTS
grooving
2. 102-E-4090B DSS Sept’09 June’11 Tube
leak,
Channel
Barrel
grooving
3. 103-E-2018 B DSS Nov’09 Aug’10 Tube leak
4 103-E-2014 B DSS Nov’09 Dec’10 Tube leak
5 103-E-2010 C/D DSS Nov’09 Dec’10 Tube leak
6. 103-E-2001 B DSS Nov’09 Dec’10 Tube End
corrosion
Erosion
7. 103-E-2017 B DSS Nov’09 Dec’10 Tube leak
8. 103-E-2009B DSS Nov’09 Jan’10 Tube leak
29
Inspection Division HPCL-MR
List of Failed Exchangers
S. No Equipment No. MOC Commissioning Failure Type of
Date Date Failure
9. 103-E-2006 B DSS Nov’09 Mar’10 Tube leak
31
Inspection Division HPCL-MR
Investigations DSS
HYSIS Calculations on Tube Skin Metal Temperature
Baffle Input
32
Inspection Division HPCL-MR
33
Inspection Division HPCL-MR