INVESTIGATIONS ON THE FAILURE OF AL-WAJH MULTIEFFECT DESAL CONDENSER TUBES1

T.L.Prakash and Anees U.Malik Research & Development Center Saline Water Conversion Corporation P.O.Box: 8328, Al-Jubail 31951, Kingdom of Saudi Arabia ABSTRACT Amongst the SWCC seawater desalination plants, Al-Wajh desalination plant at the west coast is unique in the sense that it is the only plant that operates on multieffect evaporation principle. This plant has been in operation for more than 14 years. This paper covers the results of two case studies regarding the desal effect tube failures in the plant. Case - I The Aluminum Brass tubes of the first and second rows of the tube bundle of the 2nd effect chamber were found leaking. In all 31 numbers of tubes had failed and the R&D Center received two failed tubes for investigation. The outer surface of the tubes contained patches of visually thick scales and pits. Both the tube surfaces contained small and big size (approx. 15 mm dia) holes. Substantial thinning of the metal near the edges of the holes was noticed. The results of the investigation pointed out that tubes had failed mainly due to erosion corrosion. The erosion - corrosion occurred when gases, vapors or liquid impinge on metal surface at higher velocities. Non uniform spray distribution of seawater on the tubes was found responsible for the observed localized perforation of the tubes. It was recommended that during plant maintenance, thorough cleaning of seawater distribution trays including holes and nozzles should be carried out in order to ensure uniform spray pattern on the tubes during operation. Case - II The investigation on the failure of Aluminum Brass tubes of reheat type desal unit D-03 and D04 was carried out at R&D Center. The tube of D-03 was located on top few rows below the distribution tray, whereas the tube of desal D-04 was situated at the bottom most row and the

Presented in Second Acquired Experience Symposium on Desalination Plants O&M, SWCC, Al-Jubail, Sept.29-Oct.3, 1997.

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failed region was facing the bottom of evaporator. The tube of desal unit D-03 contained a relatively large perforation at the center and that of D-04 had a long rupture initiated from one end. The results of the investigation indicated that basically both the tubes were failed by erosion - corrosion although mode of failures were different. In D-03 tube, the failure was ascribed to liquid impingement attack. The desal D-04 failure occurred due to erosion corrosion attack carried out effectively by non condensable gases or vapor pocket at the bottom section of the evaporator chamber. It was recommended that in order to avoid impingement corrosion attack, the existing tubes be replaced with impingement resistant compatible tubes 90/10 Cu Ni or Fe/Mn modified Cupronickel tubes. Improving the venting system of the flash chamber could control the erosion - corrosion of bottom row tubes.

INTRODUCTION
Saline Water Conversion Corporation (SWCC) desalination plant at Al-Wajh produces potable water from seawater through multieffect evaporator modules. This plant is operating successfully since 14 years. The condenser tubes of this plant were constructed out of aluminum brass alloy. It is a cost effective material generally recommended for use in multieffect desalination plant. This alloy known to exhibit good seawater corrosion resistance due to the development of a protective oxide layer. Unfortunately, its application is limited by the velocity of liquid impinging on it. The impingement corrosion is normally expected when the velocity of falling seawater exceeds 2 m/sec [1]. When the velocity exceeds 2 m/sec, the protective oxide layer on the surface of the alloy is disrupted and carried away by the high velocity water, thus exposing metal for localized attack. The nature of the protective oxide deposits play an important role. If humid condition exists during outage of the plants, the protective oxide deposits shall be of hydrated copper oxide [2] which is less adherent than the unhydrated copper oxide and could be easily disrupted even if the flow velocity is far less than 2 m/s. Another factor that has to be taken into account while using this alloy for such application is its susceptibility to erosion corrosion. The erosion corrosion occurs when gases, vapors or liquids impinge on metal surface. In most of the cases it is found that seawater containing small percentage of sulfur compounds [3], dissolved ammonia or chlorides attack the metal surface and locally removes the protective films thereby contributing to the formation of concentration cell and localized pitting of anodic sites.

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This paper presents two interesting case studies carried out at SWCC Research and Development Center, Al-Jubail on the failure of multieffect condenser tubes of Al-Wajh desalination plant.

1.

CASE I

1.1.

BACKGROUND

The failed tubes of the Desal unit were located at the first and second row of the tube bundle of the 2nd effect chamber. In all 31 numbers of tubes have failed during service. These tubes were just below the seawater distribution trays and were in service since inception. The unit was manufactured by M/S Sasakura Engineering Company Ltd. Japan. 1.2. PHYSICAL INSPECTION

The tubes were of size 19 mm OD x 1.0 mm thickness. The outer surface of the tubes contained patches of visibly thick scales and pits. Both the tube's surfaces contained small and big size (approximately 15 mm dia) holes (Fig. 1). The big size holes were characterized by undercut groves with directional pattern moving away from the center of the holes. Substantial thinning of the metal near the edges of the holes were seen indicating erosion corrosion of the metal occurred from the top surface during service. Plenty of surface pits were also noticed on the tubes. The inner portion of tube surface contained uniform layer of greenish colored scale deposits and were free from pitting. 1.3. CHEMICAL COMPOSITION

The tube samples were analyzed for the chemical composition by X-ray Fluorescence apparatus (Outokumpu model X-MET 880) and wet chemical methods. The chemical compositions of the tube samples were found as: Zn-20.2, Al-2.2, As-0.005 and Cu-Bal. The result of the analysis indicates that the material of the tube belonged to aluminum brass category that is designated by ASTM B 111 (UNS C 68700).

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1.4.

METALLOGRAPHY

The samples for metallography were prepared from the area where samples surface contained pits. The general microstructure of the tubes as observed in the metallography of the transverse sample showed recrystallized alloy structure. The microstructure revealed a typical single alpha phase alloy structure of aluminum brass and had an average grain size of 25 m. The surface of the tube had revealed uneven depressions caused due to pitting. 1.5. SCANNING ELECTRON MICROSCOPY (SEM)

The surface areas containing large hole and areas containing scale deposits have been examined by SEM. Outer scale deposits near the holes have been analyzed by Energy Dispersive X-ray Analysis (EDAX) technique during SEM. The deposits were found to be consisted of S, Cl, Mg, Ca and O2 indicating the presence of sulfides, chlorides and oxides. The SEM of the inner surface deposits have revealed mainly oxides of copper in EDAX analysis (Fig. 2). The inner surface scale deposits were uniformly thick. The outer scale deposits were nonuniform in thickness, discontinuous and wavy in nature (Fig. 3), suggesting aggravated corrosion of the surface. It is therefore thought that the gradual thinning and subsequent perforation of the tubes have taken place mainly due to metal corrosion from the outer surface agents during service. 1.6. DISCUSSION

All the evidences gathered in the course of this investigation suggest that the tubes have failed mainly due to erosion corrosion. The pits and the leak spots observed on the tube surface were characterized typically of erosion corrosion. In multieffect horizontal falling film desalination process, the velocity of seawater falling on aluminum brass tubes may not exceed 2 m/s since it is gravity fed through spray distribution trays. The leak spots localized to 1st and 2nd row of tubes below spray distribution tray suggest that nonuniform distribution pattern of spray on the tubes might have been occurring due to clogging of holes in the distribution tray. The non uniformity in spray may have an effect on the velocity and thereby causing erosion corrosion of the tubes. Another factor that aggravated the erosion corrosion is the nature of protective film developed during outages. The development of less adherent hydrated copper oxide film

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deposits was also responsible for the increased corrosion rate. This could be avoided by keeping the environment clean and non-humid during outages. 1.7. i) ii) CONCLUSIONS The failure of tubes was most likely due to erosion corrosion. Non-uniform spray distribution pattern of seawater on the tubes was responsible for the observed localized perforation of tubes. iii) Development of non adherent protective oxide film during outages might have also been responsible for the premature failure of the tubes.

1.8. i)

RECOMMENDATIONS Regular cleaning of the seawater distribution trays, holes/nozzles of trays and ensuring uniform spray pattern on the tubes would help in limiting the erosion corrosion.

ii)

During outages, the environment should be dry in the effect chamber in order to develop non hydrated copper oxide which is more protective film than other forms of copper oxides on the tube surface.

CASE II

2.1.

BACKGROUND

The failed tubes were a part of the condenser tubes used in the reheat type multieffect desal units namely D-03 and D-04. The tube of desal D-03 was located on top row below the distributor tray, whereas, the tube of desal D-04 was situated at the bottom most row and the failed region was facing the bottom of the evaporator. 2.2 PHYSICAL INSPECTION

The cut portions of failed tubes were inspected visually on receipt. The desal unit D-03 tube was of size 25 mm outer dia, 82 mm length and 1 mm thickness. At the center it had contained

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a perforation of approximately 18 mm length and 10 mm width. Few perforations of small diameter were also noticed along the line near the main perforation. The desal D-04 unit tube was of size 35 mm outer dia, 720 mm length and 1 mm thickness. One end of the tube was ruptured and the cracked length of the rupture was of approximately 360 mm. The photographs of the close-up view of tube failures were shown in Figure 4. The D-03 tube had a uniform dark yellow color external appearance with a rough surface. The internal surface appearance was brownish yellow and had fairly smooth surface. Both external and internal surfaces were free from corrosion deposits. The thickness of the tube was almost constant all along the length of the tube except at the place near perforation. Few depressions on the surface were also noticed near the perforation at the center portion of the tube (Fig. 4a). Tube D-04 had brownish yellow external appearance. The external surface was smooth unlike tube D-03, the internal surface appearance was similar to the external surface and were devoid of any corrosion deposits. The ruptured edges were considerably thin and ragged because of the tearing of wasted zone as shown in Figure 4b. 2.3. CHEMICAL COMPOSITION

The tube samples were analyzed for the chemical composition by wet chemical method and Energy Dispersion Spectroscopy. The chemical compositions of the tube materials were : Tube D-03 : Zn-19.8, Al-2.3, Fe-0.02, As-0.04 and Cu-Bal., Tube D-04 : Zn-19.6, Al-2.3, Fe0.02, As-0.04 and Cu-Bal. The results of the analysis indicate that the material of the tubes belonged to aluminum brass class of alloy designated by ASTM B 111 (UNS C 68700). 2.4. METALLOGRAPHY

The metallography of the tubes were carried out on the cut cross section of the tubes. Standard metallographical procedures have been adopted for the purpose. The microstructure showed fine grained structure for D-04 tube when compared to D-03 tube. The microstructures were of the type typical of a single phase recrystallized alloy with twining inside the grain boundaries. The grain size of D-03 tube sample was approximately 15 m where as it was around 10 m for D-04 tube sample (Fig. 5). 2.5. SCANNING ELECTRON MICROSCOPY (SEM)

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The SEM examination at the failed portion of the D-03 tube revealed material loss regions due to liquid impingement. The surface of the material was uneven and contained oxides layer network at the troughs of the surface irregularity. These oxide particles were seen as bright spots (Fig. 6a) in the SEM fractograph. These particles were analyzed by EDAX attachment of SEM and they found to be the oxides of copper. The SEM examination around perforation showed deep pit marks those were responsible for perforation (Fig. 6b). The pit surface wall was examined by EDAX and found that it contained no corrosion products, thus indicating that the pitting was caused mainly due to impingement of the falling liquid. The D-04 tube fracture surface exhibited material wasting at the ruptured place and it was devoid of any corrosion products. The edges of fracture surfaces were thin and striated grooves have been seen pointing towards the rupture edge and decorated with oxide particles. The erosion marks noticed at the place near the rupture were responsible for material thinning (Fig. 7). 2.6. DISCUSSION

The observations made in this investigation suggest that the failure of both tubes were characterized typically of erosion/impingement corrosion. It is particularly severe when they were in the zone of top two rows of the evaporation chamber [4]. The D-03 tube, in fact, was below the spray distribution trays of the evaporation chamber and one can therefore expect impingement corrosion occurring from the falling seawater. The force of impingement might have been enhanced due to increased velocity of flow resulting from reduction in the cross section area of distribution tray nozzle openings. This is possible due to local obstruction by foreign particles. The surface of the failed tube had also contained much surface depression along the straight line containing the perforation which were presumably below distribution tray nozzle. As this tube (failed D-03 tube) was in the top row, it confronts higher impingement effect of liquid when compared to the one at the bottom and hence lead to perforation. In the case of D-04 tube, the fracture contained thin rupture lip unlike D-03 tube failure. The failure area of the tube was facing the bottom of the evaporator. The examination carried out on the rupture area indicated that the material wastage at the failure area had lead to failure of the tube. Rupture edges were thin and ragged because of the wasted material. The wastage appears to be the effect of erosion corrosion. The erosion corrosion of copper alloys can occur due to interaction of noncondensable gases, vapors or liquids pockets present in the bottom vapor space of the chamber. These vapors attack copper alloy tubes and remove locally the protection

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film [5,6]. They contribute to the formation of concentration cell and subsequent corrosion of anodic sites resulting in material wastage (thinning) or erosion corrosion. A good venting system obviously would minimize such erosion corrosion problem of the tubes arising from noncondensable gases accumulated at the vapor space of the evaporator chamber. 2.7 CONCLUSIONS

Desal D-03 Tube: i). The failure of the tube was due to impingement attack of sea water on the tube surface. ii). Perforation of tubes was due to material loss by pitting preceded by liquid impingement. iii). The impingement attack might have enhanced due to increased velocity of flow of liquid from the distribution tray. It is likely that flow passage of the distribution tray might have clogged or obstructed by foreign particles present in the liquid. Desal D-04 Tube: i). The failure of tube was most likely due to erosion corrosion. ii). The erosive thinning of material had led to rupture of tube. iii). The erosion-corrosion might have resulted from the reaction of metal with noncondensable gas or vapor pockets present at the bottom most section of the evaporator chamber. 2.8 RECOMMENDATIONS

i) To avoid impingement corrosion failure on the top row tubes, the top two to three rows of the existing tubes may be replaced with impingement resistant compatible tubes viz. 90/10 copper nickel tubes (UNS C 70610) or iron or manganese modified copper-nickel tubes (UNS 671640 or C 71630). These tubes have adequate impingement corrosion resistance. ii) Alternatively, reduction in the liquid impingement attack can also be accomplished by increasing the cross-section of flow passages of distribution tray. Increasing the crosssection of flow passage will reduce the flow velocity, thus reducing the intensity of impingement attack. iii) The erosion corrosion of bottom row tubes can be controlled by improving the venting system of the evaporation chamber. The pockets of non-vented non-condensable

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vapors/gases which were responsible for erosion corrosion should be avoided by redesigning the venting ports.

REFERENCES 1. Tuthill, A.H., Guidelines for the use of copper alloys in seawater, Material Performance, Sept. 1987, PP 12-22. 2. North,R.F and M.J.Prayor, Corr. Sci.,10,1970, p-297. 3. Davis,J.R., J.D.Destafani and G.M. Crankovic, Eds., Metals Hand Book, Vol. 13, 9th Edition, 1987, Metals Park, Ohio, PP 7-37. 4. Narain, S and S.Asad, Corrosion Problems in Low Temperature Desalination Units, Acom, Avesta Sheffield, Sweden,2,1993, p-4. 5. Desalination Technology, King Abdulaziz University, Jeddah, Short Course, 18-30 March 1980, p-48. 6. Al-Sum, E.A., S.Aziz,. A. Al-Radif, M. Samir, and O. Heikal, Vapor side corrosion of copper base condenser tubes of MSF desalination plants of Abu Dhabi, Desalination, 97, 1994 , PP 109-119.

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Figure 1. Photographs of the failed portions of condenser tubes in the as received condition.

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Figure 4. Close up view of failed portions of the evaporator tubes. a) Tube D-03 showing few surface depression marks. b) Tube D-04 showing rupture edges due to erosive thinning.

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Figure 5. Photomicrographs of failed condenser tubes a) Microstructure of tube D-03, 200 X. b) Microstructure of tube D-04, 200 X.

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Figure 6. SEM Photomicrographs of failed portion of condenser tube D-03. a) Note the decoration of oxide particlea at the surface irregularities. b) Photomicrograph at the perforation region.

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Figure 7. SEM Photomicrograph near the fracture edge of evaporator tube D-04 showing erosion marks pointing towards the rupture edge.

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