Experimental and Numerical Investigation on Erosion Corrosion of the Air Cooler Tube Bundle in a Residue Hydrotreating Unit

Corrosion leakage occurred in the 14th tube bundle in the first row of a residual oil hydrotreating air cooler after operating for two years.The failure location was 0.5 m from the outlet header box.In this paper,the erosion corrosion of the air cooler tube bundle was investigated by experimental and numerical methods.Visual inspection,scanning electron microscopy(SEM),and X-ray diffraction(XRD)experiments were performed,and the failure morphology and material composition confirmed that the damage was caused by erosion corrosion.The shear stress transport k–ωturbulence model(SST-k–ω)was then used to investigate the flow and erosion corrosion characteristics,combined with mass transfer,corrosion rate,and ionization equilibrium models.The numerical simulation results revealed that the water phase volume fraction increased with flow and heat transfer in the fluid,which increased the mass flow rate and concentration of hydrogen sulfide.The mass transfer coefficient and corrosion rate were proposed as important parameters to characterize erosion corrosion.Moreover,the local concentration of wall shear stress was found to increase the risk of erosion corrosion.The predicted high-risk area was consistent with the actual failure area,which verified that this failure incident was attributable to erosion corrosion by the water phase.

Development and Application of On-Line Corrosion Monitoring Device for Condenser Tube

This paper introduces the development and industrial application of an on-line corrosion monitoring device for condenser tubes. Corrosion sensors are made up of representative condenser tubes chosen by eddy current test, which enable the monitoring result to be consistent with the corrosion of actual condenser tubes. Localized corrosion rate of condenser tubes can be measured indirectly by a galvanic couple made up of tube segments with and without pits. Using this technology, corrosion problems can be found in time and accurately, and anticorrosive measures be made more economic and effective. Applications in two power plants showed the corrosion measurements are fast and accurate.

Effect of Ca2+ and Mg2+ on CO2 Corrosion Behavior of Tube Steel

Effects of Ca2+ and Mg2+ on the CO2 corrosion behaviors of tube steel were studied in simulated oil-field environment.The influence of Ca2+and Mg2+ on the corrosion rate and morphologies of corrosion product layer was determined by scanning electron microscope and measuring mass loss.Potentiodynamic polarization and impedance spectroscopy were used to investigate the change of electrochemical characteristic parameters of corrosion product layer and corrosion dynamic process.The results show that with Ca2+ and Mg2+ in electrolyte,the morphologies and microstructures of corrosion product layer changed obviously,thus affecting the corrosion process.

Predictive Model for Corrosion Rate of Oil Tubes in CO_2/H_2S Coexistent Environment Part Ⅰ: Building of Model

Based on an analysis of the existing models of CO 2 corrosion in literatures and the autoclave simulative experiments, a predictive model of corrosion rate (r corr) in CO 2/H 2S corrosion for oil tubes has been established, in which r corr is expressed as a function of pH, temperature (T), pressure of CO 2 (P CO 2) and pressure of H 2S (P H 2S). The model has been verified by experimental data obtained on N80 steel. The improved features of the predictive model include the following aspects: (1) The influence of temperature on the protectiveness of corrosion film is taken into consideration for establishment of predictive model of the r corr in CO 2/H 2S corrosion. The Equations of scale temperature and scale factor are put forward, and they fit the experimental result very well. (2) The linear relationship still exists between ln r corr and ln P CO 2 in CO 2/H 2S corrosion (as same as that in CO 2 corrosion). Therefore, a correction factor as a function of P H 2S has been introduced into the predictive model in CO 2/H 2S corrosion. (3) The model is compatible with the main existing models.

A comprehensive comparison on vibration and heat transfer of two elastic heat transfer tube bundles

Elastic heat transfer tube bundles are widely used in the field of flow-induced vibration heat transfer enhancement. Two types of mainly used tube bundles, the planar elastic tube bundle and the conical spiral tube bundle were comprehensively compared in the condition of the same shell side diameter. The natural mode characteristics, the effect of fluid-structure interaction, the stress distribution, the comprehensive heat transfer performance and the secondary fluid flow of the two elastic tube bundles were all concluded and compared. The results show that the natural frequency and the critical velocity of vibration buckling of the planar elastic tube bundle are larger than those of the conical spiral tube bundle, while the stress distribution and the comprehensive heat transfer performance of the conical spiral tube bundle are relatively better.

THE INFLUENCE OF RESIDUAL STRESS ON THE CORROSION RESISTANCE OF H68A BRASS TUBES IN SEA WATER

This paper reveals the morphological characteristics of the cracks formed in H68A brass tubes fully immersed in seawater, and studies the depth profiles of the residual stress of the tubes. Tbe great residual stress in the wall results in stress-corrosion cracking, and the unique morphology of the cracks is due to the uneven distribution of residual stress through the depth of the tube.

Experimental Research on Resistance Characteristics of H-type Elliptical Finned Tube Bundles

阻力特性是换热器的基本特性之一，流体横掠换热管产生的绕流扰动是换热器阻力恶化的主要因素。为分析前排绕流对后排阻力的影响规律，分别对管排数2-10不等的换热管进行阻力特性试验研究，同时为定量分析管排数对阻力特性的影响规律，定义了管排阻力修正系数，并根据实验数据给出了其在不同管排数下的取值，具有重要的工程意义；同时基于冷态阻力特性试验台进行实验研究，得到κ=1及κ=1.6的经典椭圆管的阻力特性公式Eu，并研究不同管型及布置方式对其的影响规律。

Heat transfer characteristics of air cross-flow for in-line arrangement of spirally corrugated tube and smooth tube bundles

An experimental study on heat transfer and resistance coefficients of linearly arranged smooth and spirally corrugated tube bundles in cross-flow was performed. The heat transfer and resistance coefficients are presented in this paper with transverse and longitudinal tube-pitch and tube geometries taken into account. The experiment's results can provide technical guidelines for application to horizontal air preheater with arranged in-line spirally corrugated tube bundles, especially to the air preheater for CFBCBs (Circulating Fluidized Bed Combustion Boilers).

High-Temperature Corrosion of Protective Coatings for Boiler Tubes in Thermal Power Plants

High-temperature corrosion is a serious problem for the water-wall tubes of boilers used in thermal power plants. Oxidation, sulfidation and molten salt corrosion are main corrosion ways.Thereinto, the most severe corrosion occurs in molten salt corrosion environment. Materials rich in oxides formers, such as chromium and aluminum, are needed to resist corrosion in high-temperature and corrosive environment, but processability of such bulk alloys is very limited. High velocity electric arc spraying (HVAS) technology is adopted to produce coatings with high corrosion resistance. By comparison, NiCr (Ni-45Cr-4Ti) is recommended as a promising alloy coating for the water-wall tubes, which can even resist molten salt corrosion attack. In the study of corrosion mechanism, the modern material analysis methods, such as scanning electron microscopy (SEM), X-ray diffractometry (XRD) and energy dispersive spectrometry (EDS), are used. It is found that the corrosion resistances of NiCr and FeCrAI coatings are much better than that of 20g steel, that the NiCr coatings have the best anti-corrosion properties, and that the NiCr coatings have slightly lower pores than FeCrAI coatings.It is testified that corrosion resistance of coatings is mainly determined by chromium content, and the microstructure of a coating is as important as the chemical composition of the material. In addition, the fracture mechanisms of coatings in the cycle of heating and cooling are put forward. The difference of the thermal physical properties between coatings and base metals results in the thermal stress inside the coatings. Consequently, the coatings spall from the base metal.

The Hot Corrosion Performance of NiCr-Cr_3C_2 Cermet Coating to Boiler Tube

Three kinds of NiCr-Cr 3C 2 cermet coatings were designed and deposited by the subsonic velocity flame spraying, and their performances of hot corrosion performance were evaluated in comparison with 102G, 20G boiler tube steel, FeCrAl, NiCrTi, Ni50Cr and NiCrAlMoFe-Cr 3C 2 coatings, which are widely used at present for protection of boiler tubes. Meanwhile,the influence of sealer on the hot corrosion resistance of various coatings and the mechanisms of coating corrosion were explored.

Study on corrosion resistance of the BTESPT silane cooperating with rare earth cerium on the surface of aluminum-tube

Bis-3-(triethoxysilyl)propyltetrasulfide(BTESPT) silane-rare earth cerium composite coatings on aluminum-tube were prepared at 60 °C by immersion method.The performance of composite coatings to protect the aluminum-tube against corrosion was investigated with potentiodynamic polarization curves,electrochemical impedance spectroscopy(EIS),and salt spray test(SST).The results of potentiodynamic polarization curves and EIS indicated that the self-corrosion current decreased by two orders of magnitude and the i...

A Study of Water Treatment Chemical Effects on Type I” Pitting Corrosion of Copper Tubes

It is known that one of the causes of pitting corrosion of copper tubes is residual carbon on the inner surface. It was confirmed that type I” pitting corrosion of the copper tube is suppressed by keeping the residual carbon amount at 2 mg/m2 or less, which is lower than that of the type I’ pitting corrosion, or by removing the fine particles that are the corrosion product of galvanized steel pipes. The developed water treatment chemical was evaluated using three types of copper tubes with residual carbon amounts of 0 mg/m2, 0.5 mg/m2, and 6.1 mg/m2. The evaluation was conducted for three months in an open-circulation cooling water system and compared with the current water treatment chemical. Under the current water treatment chemical conditions, only the copper tube with a residual carbon amount of 6.1 mg/m2 showed a significant increase in the natural corrosion potential after two weeks, and pitting corrosion occurred. No pitting corrosion and no increase in the natural corrosion potential were observed in any of the copper tubes that were treated with the developed water treatment chemical. In addition, the polarization curve was measured using the cooling water from this field test, and the anodic polarization of two cooling waters was compared. For copper tubes with a large amount of residual carbon, the current density near 0 mV vs. Ag/AgCl electrode (SSE) increased when the developed water treatment chemical was added.

Experimental Study of Condensation Heat Transfer on Tube Bundles in Large Power Plant Condensers

In order to clarify the effect of condensate inundation on steam condensation in a large tube bundle, condensation heat transfer and the condensate flow pattern in the tube bundle have been experimentally investigated. Test tube bundle consists of 36 cooling tubes, 12 condensate supply tubes and 24 un-cooled dummy tubes. Cooling test tubes are made of copper and have an outer diameter of 19.1 mm and condensing length of 150 mm, Steam flows horizontally through the test tube bundle at gap velocities 15-27 m/s at pressures of 8.8 kPa. In this study, experimental data about condensate flow pattern and condensation heat transfer in a tube bundle were collected for the optimization of tube arrangement in large power plant condensers.

Correlation of seawater corrosion and processing of Cu Ni alloy tubes

The investigations on the effect of the initial surface and microstructure on the seawater corrosion of Cu Ni alloy tubes were carried out by processing, electrochemical methods and natural seawater exposure as well as SEM. Deformation had more impact on the final microstructure of the tubes than the annealing time did, and at the deformation of 32% and annealing temperature 550～600 ℃ for 1 h the tubes was completely recrystallized microstructure. As increasing the volume fraction of recrystallization, the homogeneity of microstructure and the corrosion resistance increased. The residual carbon film produced on the inner surface of the tubes during the processing, had higher corrosion potential than the alloy substrate and good electronic conductivity, so accelerating the dissolution of the substrate in seawater, and the non protective and loose corrosion product film formed. Immersed in natural seawater, the tubes of incomplete recrystallization, consisting of deformed and recrystallized grains, displayed intergranular corrosion, which resulted from corrosion micro cells built between deformed and recrystallized grains and the preferable transportation of electrons on the boundaries of both the grains. In contrast, the recrystallized alloy tubes formed the uniform and compact corrosion product film under which no corrosion was found.

Localized Corrosion in Copper Tubes by Volatile Organic Substance

An unusual form of localized corrsion in copper tubes was detected early in service and in leakage tests after manufacturing.The morphology of this corrosion is similar to that of an ant's nest when viewed in cross section. The corrosion mechanisms, cases ofant's nest corrosion, and preventive measures are presented.

Effect of Radial Expansion of Cr-Mo Steel Tubes on Their Corrosion Behavior in Sea Water

This paper studies the effect of expansion ratio on the corrosion rate of the expanded tubes exposed to sea water as well as the microstructure changes caused by the expansion of Cr-Mo steel tubes to large permanent deformations. 2.25 Cr-1.0 Mo steel (schedule 40 and schedule 80) tubes were subjected to various expansion ratios of 10%, 15%, 20%, and 25% by pushing conical mandrels through them using a piston. The microstructure was also studied to determine the effect of the expansion on the grain structure of the material. Microscopic examination of the expanded tubes revealed that grains elongate along the direction of the hoop stress and this elongation increases with an increase of expansion ratio. Moreover, it was found that corrosion rate and hardness increase with an increase in expansion ratio.

Ammonia corrosion analysis of copper tubes and experimental research on non-copper improvement for heat exchanger in power plant

Ammonia corrosion in copper tube will affect the safety of boiler running in power plant. Therefore, no copper in heating system has become a technical orientation in heat exchanger reconstruction, This paper analyzes the condition and mechanism of ammonia corrosion occurring in copper tube used in coal-fired power plants. Using a general steam condensation testing equipment only for horizontal single tube, with water vapor and water as working fluid, on two types of steel tube with 2-side enhancement heat transfer, namely, a spirally fluted tube and a ratchet tube with internal spiral groove （RISG tube） which was developed recently, a set of experimental tests are conducted to investigate the characteristics of heat transfer and hydromeehanics. In order to compare easily, both one copper smooth tube and one steel smooth tube are also used in the experiment. The experimental results, which get from single horizontal tube, show that the overall heat transfer coefficient of steel spirally fluted tube are improved by 10%o to 17%, and that of the steel RISG tube（22%-28%） is better than steel spirally fluted tube, its flow resistance coefficient is only increased by 22% to 66% when compared with smooth tube. Based on a lot of experimental data, the steel spirally fluted tube and the steel RISG tube were applied in a low pressure preheater and an oil-cooler of some or other power plant respectively. The field testing results showed that their heat transfer coefficient with each types of enhancement heat transfer tubes were improved by 2.5% and 21%-45% comparing with copper smooth tube heat exchangers. Both basic and field experiment indicates that the steel tube with 2-side enhancement heat transfer is an ideal choice for heat exchanger reconstruction in no copper issue in power plants.

Simple Measurement of Carbon Films on Copper Tubes and Their Effects on Corrosion

It has been reported that pitting corrosion in copper tubes occurs due to the effect of a carbon film produced by the influence of undergoing an oil and heat treatment. As a quantitative method for determining the residual carbon amount, it has been reported that the inner surface of a copper tube can be dissolved with a mixed acid to collect and analyze the adhering carbon;however, this method is dangerous and difficult. Therefore, two methods were examined as a simple quantitative method for obtaining the residual carbon amount using copper tubes with known residual carbon amounts. One method utilizes X-ray photoelectron spectroscopy (XPS), and the other method utilizes the potential difference between the carbon film-adhered surface and carbon film-removed surface. In regard to XPS measurement, a linear correlation was found between the spectral intensity of C and the residual carbon amount;therefore, XPS measurements were considered to be effective as a simple measurement method for the carbon film on the inner surface of a copper tube. In the evaluation method by measuring the corrosion potential, a correlation was observed between the potential difference ΔE and the residual carbon amount of the inner surface of the tube and the outer surface of the polished tube. It is considered possible to estimate the residual carbon amount from the prepared calibration curve. Through these studies, it is suggested that the carbon film was non-uniformly present on the surface of the copper tube. Therefore, the galvanic current was measured, and the effect of a non-uniform carbon film on corrosion behavior was investigated. As a result, in the measurement of galvanic current, the current flowed from the copper tube with a large amount of residual carbon (cathode) to the copper tube with a small amount of residual carbon (anode). In addition, the higher the area ratio of the carbon film was, the larger the galvanic current tended to be.

Heat Transfer and Resistance Characteristics of Conical Spiral Tube Bundle Based on Field Synergy Principle

Conical spiral tube bundle are universally used in heat transfer enhancement in heat exchangers.The heat transfer and resistance of the tube bundle are affected greatly by the conical structure,so the analysis of it is necessary.In order to a further evaluation,the heat transfer and resistance characteristics of conical spiral tube bundle are investigated with regression analysis based on numerical simulation data.The correlations of heat transfer and pressure drop of conical spiral tube bundle are proposed both in laminar and turbulent fluid flow.On the based of the field synergy principle,the synergy of four vectors,the velocity,the velocity gradient,the temperature gradient and the pressure gradient,are calculated and discussed via the user defined function（UDF） program.The synergy angles β and θ,which respectively denote the performance of heat transfer enhancement and pressure drop of the conical spiral tube bundle,are analyzed.Finally,the comprehensive performance of the conical spiral tube is evaluated by the synergy angle γ and all of the three synergy angles of conical spiral tube bundle are compared to both bare tube and thin cylinder-interpolated tube.The analysis of the synergy angles shows that the heat transfer enhancement and pressure drop of conical spiral tube bundle are smaller than that of the thin cylinder-interpolated tube,while the comprehensive performance of conical spiral tube bundle is greater.The analysis of the heat transfer and pressure drop of conical spiral tube is valuable and instructional on the design and optimum of conical spiral tube bundle heat exchangers.

Experimental Study on Cross-Flow Induced Vibrations in Heat Exchanger Tube Bundle

Vibration in heat exchangers is one of the main problems that the industry has faced over last few decades. Vibration phenomenon in heat exchangers is of major concern for designers and process engineers since it can lead to the tube damage, tube leakage, baffle damage, tube collision damage, fatigue, creep etc. In the present study, vibration response is analyzed on single tube located in the centre of the tube bundle having parallel triangular arrangement （60-） with P/D ratio of 1.44. The experiment is performed for two different flow conditions. This kind of experiment has not been reported in the literature. Under the first condition, the tube vibration response is analyzed when there is no internal flow in the tube and under the second condition, the response is analyzed when the internal tube flow is maintained at a constant value of 0.1 rn/s. The free stream shell side velocity ranges from 0.8 rn/s to 1.3 m/s, the reduced gap velocity varies from 1,80 to 2.66 and the Reynolds number varies from 44500 to 66000. It is observed that the internal tube flow results in larger vibration amplitudes for the tube than that without internal tube flow. It is also established that over the current range of shell side flow velocity, the turbulence is the dominant excitation mechanism for producing vibration in the tube since the amplitude varies directly with the increase in the shell side velocity. Damping has no significant effect on the vibration behavior of the tube for the current velocity range.