MAINTENANCE/RELIABILITY SPECIALREPORT

Flow-induced fatigue failure

in tubular heat exchangers
Case histories describe a variety of failures and solutions
A. BABAKR, T. ASHIRU and C. WESTHUIZEN, SABIC R & T, Jubail, Saudi Arabia

D
ue to the combined actions of vibration with pitting cor-
rosion tube failure occurred by a mechanism known as
corrosion fatigue. Vibration on its own should not cause
any mechanical problems provided it is below the material fatigue
limit. Case histories are presented that describe a variety of flow-
induced vibration-related failures in tubular heat exchangers.
Introduction. Many types of heat exchanger failures are ran-
domly faced in the petrochemical, chemical, utility, engergy and
petroleum industries.1 Some common failures in heat exchangers
are: assembly errors, manufacturing defects, improper design,
pipe and tubing imperfections, welding,2 fabrication,3 improper
materials, improper operating conditions, pitting, stress-corrosion
cracking,4 corrosion fatigue, thermal fatigue,5 general corrosion,
crevice corrosion,6 design errors, fouling,7 selective leaching/
dealloying8 and erosion corrosion.9 This article will constrict
the readers to one failure phenomenon in heat exchangers that is
flow-induced fatigue.
were found to be leaking. The tube sections that had separated
were used to perform fractography.
The tubes were also split longitudinally in halves to view
the inside surfaces and to determine the extent of pitting dam-
age (Fig. 1). Visual observation of the broken piece revealed
small pits on the inside surface. Some pits were visible on the
outside surface as well. The tube exterior also had indicated
baffle marks as can be clearly seen in Fig. 2. A spark emission
spectrometer was used to identify the tube alloy composition
and it was found to conform to the SA 214 tube specification.
An optical macrograph of the inner surface revealed corrosion
in progress. Pits were clearly visible after cleaning the surface as
can be seen in Fig. 3.
Further observation of the fracture surface revealed two pits
that were found at the origin of a fatigue crack. Fig. 4 clearly
shows two macrographs showing two pits and the fracture beach
TABLE 1. Heat-exchanger data

Case 1. The cooler has been in service for at least six years. Shell side Tube side
The earliest leak was recorded after only two years in service Operating pressure, bar 4.5 37.7
and was plugged. The tube side did not reveal any signs of cor-
Operating temp., C 38/44 90/45
rosion. Shell-side inspection could not be performed due to the
fact that this is a fixed-head heat exchanger. Tube leakage was Material SA516-60 SA214 ERW tube
again suspected within three weeks after the repairs. Recently, Service fluid Fresh cooling water Hydrocarbons
it was noticed that there was a considerable rise in the cooling
water pipeline skin temperature connected to the cooler. Skin Tube O.D., mm 19.05
temperatures of both the inlet and outlet pipeline surfaces were Tube length, m 6.0
found to be the same. In addition, it was also observed that HE and tube configuration Horizontal and straight tubes
cooling water flow was blocked by increased hydrocarbon leak-
age into the shell side. During shutdown, the heat-exchanger
tubes were replaced with seamless SA 179 and baffle material
remained typical carbon steel. The inspection team managed
to perform magnetic flux leakage (MFL) on the heat-exchanger
tubing. Major affected tubes were located immediately at the
hydrocarbon inlet as can be seen from MFL results (Fig. 1). The
heat-exchanger operating parameters and relevant tube informa-
tion are provided in Table 1.

Investigation. Two tubes were received (each six meters long)

in addition to two small sections that broke off while being pulled FIG. 1 Photo macrographs of received tube sections showing
out of the tube bundle. Because of the length, the tubes were cut where they broke off while being pulled out. Also, adjacent
to three meters. The tubes were tested for leaks by means of pres- photo (b) shows the broken section inner surfaces with
surizing with air while submerging them in a water bath. None slight indication of corrosion pits.

HYDROCARBON PROCESSING MAY 2010

I 27
SPECIALREPORT MAINTENANCE/RELIABILITY

marks indicating fatigue. The pits did not appear to be deep. Fig.
5 shows optical micrographs in the etched condition. No trans-
granular, intergranular or grain abnormality can be observed.

Discussion. From what had been presented, it is possible to say

FIG. 2 Photo macrograph of the as-received tube showing rub
marks caused by movement against the baffle. The tube
location is immediately in front of the hydrocarbon inlet
just before the failure site.
that the failure occurred due to the combination of fatigue and
pitting corrosion. The synergistic action of both can be rational-
ized as follows:
Fatigue. The problem of fatigue seemed to develop from the
design. By looking at the tube/baffle interface, we noticed that
there is increasing evidence of rub marks as we move toward
the hydrocarbon inlet/water outlet. This is due to the baffle
fit-up. Toward the hydrocarbon inlet the tube has a longer
unsupported length. During normal operation, this region is
susceptible to the highest vibration amplitude. Tubes are very
well fixed into the tube sheet where it does not move. Hence,
the highest fatigue-induced stresses will be at the tube/tube
sheet interface.

FIG. 3 Optical micrograph showing fracture and inner surfaces.

Many pits and corrosion are shown on the inner surface FIG. 4 Two pits at the origin of the failure, 75 X.
after cleaning.

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SPECIALREPORT MAINTENANCE/RELIABILITY

fatigue crack, the mechanism that caused the failure is corrosion

FIG. 5 Optical micrograph showing a pit filed with iron oxide and
with no cracks, 200X.
Pitting. Pitting was observed at both the tube and shell sides
of the tubes. However, the pitting corrosion seems difficult to
comprehend because the factors that will normally initiate pitting
are not present in the media or, indeed, on the tube surface. It is
possible that pits had been initiated by factors or situations that
occurred during the past shutdown and consequently not available
for us to analyze.
Corrosion fatigue. Due to the presence of pits in the region
of the fatigue fracture face and also pits at one of the origins of a
fatigue. For this mechanism the time to failure will be far shorter
than fatigue or pitting by itself. In corrosion fatigue, there is
always a corrosive environment present during the fatigue cycles
and this combination makes the component fail earlier than it
would have if only fatigue was the cause.
There may even be combinations of the above-mentioned
mechanisms at work. If the pits were not present then the heat
exchanger would have lasted longer. On the other hand, if
vibration was not present, then the pits would have taken far
longer to cause tube perforation. Depending on the root cause
of pitting, these pits may self-heal and may not even propagate
further. Regular IRIS/MFL checks will clarify this issue.
By using the finite-element (FE) method, we were able to
predict the cause of the fatigue. Because of the tube length
between the hydrocarbon inlet tube sheet and the baffle at the
water outlet, high vibration was experienced due to the natural
frequency of the tubes. These vibration waves were magnified
as they approached the tube sheet. Continuous repetition of
this action produced the rubbing marks observed and the tubes
failed later due to fatigue. Now that a pit is present, it will act
as a stress raiser that will reduce fatigue life. The tubes on the
top (12 oclock position) of the heat exchanger suffered more
fatigue failure due to the described motion, while the tubes that
are located at the lower part of the heat exchanger did not suffer
similar failure because they were likely not subjected to vibration-
induced forces and the effect had subsided before reaching them.
The plausible explanation of this is that the tubes in the lower
position are held down by the weight of tubes at the top loca-

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FIG. 6 Finite-element analysis results showing baffle fit-ups and

the last section of the tube having the highest displacment
due to higher natural frequency.

tion; while the tubes at the upper location are not prevented from
vibration like the lower tubes. Fig. 6 shows a 3D image and FE
analysis to establish a rationale of the situation.
These findings presented were supported by the IRIS test
performed. Their conclusive finding was that the upper tubes
had suffered the most (Fig. 7). This, in itself, had supported the
FIG. 7 IRIS results showing the affected tube locations.
proposed finding of the failed tube locations. This investigation
instigated plant personnel to review the heat exchanger and ones
of similar design.
Due to process requirements, other than materials, the design was
Case 2. The heat exchanger in this case (Fig. 8) has gone through changed to being horizontal with duplex stainless-steel tube.
design changes since its commissioning 20 years ago, this is because Since the process is not corrosive, its inspection was set to low.
of plant expansion and increased process demands. Only six years Still, for the first time one of them was inspected and cleaned. The
ago, the heat exchanger was vertical with cupper nickel tubes. original standby was placed in service in its place. After being in

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SPECIALREPORT MAINTENANCE/RELIABILITY

service for about two years to date, it was taken out and cleaned
using a novel method of hydrokinetic hydrojetting. While per-
H2O Failed tube and H2O
location of failure forming the cleaning, the top row (fifth tube from the north) at
the gas inlet had leaked. Almost at the same time, other coolers
installed in other parts of the plant had also leaked. Cooler inspec-
tion indicated a leak from one tube, again in the top row, but this
time the fifth tube from the right in the top row. This tube was
Cycle plugged and seal welded at both ends and the cooler was placed
Cycle gas
gas back in service. The phenomenon is that both units failed in the
16.756 m
same locations; right beneath the second baffle plate.
Material: Tube: duplex (2205) SS-SA-789-S31803
Shell-baffels: Carbon steel
FIG. 8 Schematics of the heat exchanger in question showing the Process medium: Shell-water
location of failure.
Tube-cycle gas
Time-in-service: 20 yearsHE setup was vertical and the
tube material was cupper nickel. From
2000 to present, HE setup horizontal and
tube material is duplex SS-2205.
Shell: Carbon steel.
Setup/number of tubes/length: horizontal-one pass / 2.040
tubes, 1.6764 mm.

Investigation. The sample tube that was received did not

reveal any form of corrosion. In addition, there was no apparent
deposit. Internally, it was very clean when viewed from one end.
Baffle-plate markings were apparent, decreasing as we moved to
inspect the tube length working our way back from the gas outlet
to inlet. It was noticed that the failure location was precisely under
the regions where the cooling water entered. Thinning was clearly
FIG. 9 IRIS back-end view of the heat exchanger showing the
location of the failed tube in the top row, fifth tube from
right.

FIG. 10 Tube showing failure in the second baffle plate from the
cycle gas outlet.

FIG. 12 Photograph of the severed section of the tube below the

baffle plate showing severity of flow-induced vibration.
FIG. 11 Photograph showing clear space between the baffle plate Also, from the inside showing no sign of corrosion or any
and tubes. damage.

32
I MAY 2010 HYDROCARBON PROCESSING
 MAINTENANCE/RELIABILITY SPECIALREPORT

apparent in the region exactly under the second baffle plate. Figs.
9, 10 and 11 clearly show the phenomena. Fig. 12 shows photos
of the affected section and a view of the inner surface indicating
no sign of corrosion.
Discussion. There is no doubt that the failure was the result
of thinning induced by movement/vibration. The movement/
vibration was the result of the water inlet flow. A failure scenario
can be proposed:
Excessive inlet flow created movement of the upper-right
tubes. Tube movement was excited by the space that already exists
between the tubes and the baffle plate. The tube movement action
resulted in localized tube thinning. The reason why this particular
location was the most affected was because water was directed first
to these locations by the impingement plate.
This was not evident while in operation. The failure took place
when hydrokinetic hydrojetting was performed, that particular
location under the baffle plate was so thinned that it could not
handle the pressure during cleaning. Indicative of that is the
failure shape. The burst is to the outside rather than inside. Since
this is a flow-induced failure, the most affected tube sites will be
around the upper-right and left locations.
It seems that the plant(s) demand had increased accumulating
the load on these. The most evident approach to minimizing this
problem is by reducing cooling water flowrate. This in turn will
jeopardize plant demand. Hence, it is empirical to accommodate
this problem by unit redesign to minimize the effect of cooling
water inlet. It would be impractical to only address the space
preset in the baffle plate. To eliminate flow-induced vibration, a
reduction in the flow is vital for the current situation. In addition,
it would not be feasible to change tube metallurgy since the failure
is not related to material compatibility.
Al-Anizi, Erosion in the tube entrance region of an air-cooled heat exchanger,
International Journal of Impact Engineering, V. 32, n. 9, September 2006, p. 1440.
Dr. Ali Babakr has served as a Senior Corrosion Engineer cum
Failure Analysis Advisor for Saudi Basic Industries Corporation
(SABIC), Jubail, Saudi Arabia since 2008. Currently, he serves as a
Consultant for an Engineering firm in the USA. He holds PhD and
MS degrees in Metallurgy from the University of Idaho, and B.S.
Materials Chemistry from the Huston-Tillotson University, Austin, Texas. He also has
interest in semiconductors and magnetic materials manufacture and applications.
He has authored several papers to address the mitigation of corrosion and other
materials degradation problems. Email: alibabakr@yahoo.com
Toyin Ashiru obtained his Ph.D. in industrial metallurgy from
the University of Birmingham, UK; and B.Sc. (honors) in materials
science from the University of Sussex, UK. He has about 25 years
of teaching, research and industrial experiences in corrosion and
metallurgy. Currently, Dr. Ashiru is senior staff engineer in the mate-
rial and corrosion section of SABIC Technology Center, Jubail. Dr. Ashiru has patents
on processes he developed for mitigating corrosion-related problems. He published
more than 100 papers in learned journals and conference proceedings. Dr. Ashiru is
a member of various professional associations and has served as the editor-in-chief
or as an editorial board member of some technical journals.
Christian van der Westhuizen has more than 26 years of industrial experi-
ence mainly focused in the petrochemical industry. He managed his own metallurgical
consulting company in South Africa and afterwards worked for companies in Saudi
Arabia as well as the United Kingdom. Mr. van der Westhuizens experience lies mainly
in failure analysis, welding, corrosion mitigation and material selection. At present he is
the company metallurgist for Davy Process Technology in London and is a professionally
registered chartered engineer as well as chartered scientist in the UK. Mr. van der West-
huizen has written over 15 papers and presented them at various international confer-
ences and has been involved as chairman is several technology exchange meetings.

Tentative conclusions:
Thinning was the result of increased flowrates.
The failures were due to flow-induced vibration that led to MIST ELIMINATORSU

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LITERATURE CITED
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1 Metals handbok. Fatigue Failures, vol. 10, 8th ed., ASM International. 1975, RANDOM PACKINGSU>}iivVi`
>`>V}V`}i>i`}>`>``i
p. 95.
i>V>`>V>ii>>>>Liii
2
>vii}iVii`
Otegui, J. L. and P. G. Fazzini, Failure analysis of tubetubesheet welds in
cracked gas heat exchangers, Engineering Failure Analysis V. 11, n. 6, INTERNALSU
i]>>```>vv>]
L>}>}>`Li>iV>V}>`
December 2004, p. 903. Li`i >`>}ivVi>v`>]
3 Naumann, F. K. and F. Spies, Boiler tube cracked during bending, ASM >L>`ii>VLLiV


-v>LV>iiVi>>i>>V
failure analysis library, ASM International, Materials Park, Ohio (1996).
4 Pola, A., Gelfi, M., Depero, L. E. and R. Roberti, Study of annealing tem- STRUCTURED PACKINGSU
VVvii
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perature effect on stress-corrosion cracking of aluminum brass heat-exchang- 8]x9iV>`}V>>V-ii

-
iV>i}>i`V}]`>}]i>}>`V}
ers tubes by microdiffraction experiments, Engineering Failure Analysis, i/>i

-iVivviVii
V. 15, n. 1, January-March 2008, p. 54. v>

- 8}>i>`}ivvViVi>V}

>LiVi>}v>>v
5 Becker, W. T., Thermal fatigue in a vaporizer handbook of case histories, >V}ii>iVvi`>>t

Failure Analysis, vol. 2, ASM International, USA (1996), p. 111.

6 Rakesh Kaul, N. G., et al., Failure analysis of carbonate reboiler heat FRACTIONATION TRAYSU,`]iV>}>]vi`]
v>}>`V>}i`>i>]>`]vVi]LLLiV>]
exchangers, Engineering Failure Analysis, V. 2, n. 3, September 1995, ii]L>vvi>`>`iV>

-vvi>Viii
vVi>>
p. 165.
7 Radhakrishnan, V. R., et al., Heat exchanger fouling model and preven-
tive maintenance scheduling tool, Applied Thermal Engineering, v. 27, 17-18,
December 2007, p. 2791.
8 Malik, A. U., Kutty, P. C., Andijani, I. N. and S. A. Al-Fozan, Materials
performance and failure evaluation in SWCC MSF plants, Desalination,
V. 97, n. 1-3, August 1994, p. 171. TEL:

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9 Badr, H. M., Habib, M. A., Ben-Mansour, R., Said, S. A. M. and S. S.
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