Failure analysis of corroded heat exchanger CuNi tubes from a geothermal plant

This study examined the premature failure of cupronickel (CuNi10Fe) tubes in a shell-and-tube heat exchanger after five months of service. An investigation to identify the root cause of the tube burst was carried out using macroscopic and microscopic inspection, chemical analysis, and mechanical analysis. The optical microscopy (OM) and scanning electron microscopy (SEM) evaluation revealed crack propagation characterized by pits and inclusions at the tube surface. This was due to the diffusion of hydrogen ions into the material from the hydrogen sulfide (H2S) rich geothermal environment. Furthermore, high tensile residual stresses of 172 MPa were recorded in the failed tube, leading to stress cracking in hydrogen-containing material. Additionally, the high sulfide content in corroded water and condensate samples suggests that the leading cause of tube rupture was through hydrogen embrittlement and sulfide stress cracking mechanism in the presence of hydrogen sulfide. Therefore, the use of laser cladding to protect tubes using functionally graded materials is recommended to mitigate degradation in aggressive environments, through careful material selection and additional water treatment to eliminate the contaminants.