PPCHEM HINTS FROM THE EXPERTS

HINTS FROM THE EXPERTS

Why Do Sample Coolers Fail? Aditya Sanjay Kanetkar

ISOLATION VALVES
ASME B16.34

SAMPLE NOZZLE
ASTM D1066 INTRODUCTION
FIELD PIPING
In steam and water analysis sys­
PRIMARY RACK BULKHEAD UNION
BLOW DOWN
tems (SWAS), the sample cooler
ISOLATION VALVES PG
ASME B16.34 VALVES TG is one of the most important com­
ASME B16.34
BLOWDOWN (FLUSH) HEADER ponents. The main function of the
FS COOLING WATER OULET sample cooler is to reduce the tem­
perature of high-temperature sam­
PRIMARY SAMPLE ples from elevated temperatures to
COOLER PG TG
ASME SECTION VIII the temperature required for ana­
COOLING WATER INLET
lyser sensors. In the case of steam
PRIMARY RACK sampling, the steam samples are
FIELD PIPING not just cooled, but are condensed
to water (phase change).
FIELD PIPING
SWAS SYSTEM BULKHEAD UNION Helical coil sample coolers are
ISOLATION VALVE generally used in SWAS packages,
SAMPLE FILTER PG where the very hot high-pressure
TG
ROD IN TUBE PRESSURE REDUCER sample (like superheated steam
ASME PTC19.11 & SECTION VIII
FS CHILLED WATER OULET
of pressures > 250 bar and tem­
peratures > 600 °C) flows inside the
SECONDARY helical coil tube, while the cooling
SAMPLE COOLER PG TG
ASME SECTION VIII water flows around the coil in the
shell (~ 35 °C).
CHILLED WATER INLET
TG The sample cooler may be the only
THERMAL SHUT OFF VALVE heat exchanger in the entire power
PG ASME PTC19.11 & SECTION VIII
AL HIGH PRESSURE SAMPLE PARTS plant which is exposed to such
extreme conditions. Thus, sample
FICV coolers in SWAS packages must be
designed considering:
BPR 1. Sample temperature
FICV FICV FICV

2. Sample pressure
3. Sample flow rate and
4. Cooling water conditions
CE CE CE pHE DOE
Any failure of the sample cooler
WASTE DRAIN HDR in a SWAS leads to failure of
the downstream sampling com­
pHT DOT
ponents and instruments (see
Figure 1 for an overview of a typical
Figure 1: SWAS). In fact, most of the issues
P&I diagram of a sampling system showing locations of primary and secondary in these packages start with failure
sample coolers. of the sample cooler.

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 HINTS FROM THE EXPERTS PPCHEM

THREE COMMON FAILURES, THEIR ROOT

CAUSES AND SOLUTIONS
Cracking or Pin Hole Failure of Sample Cooler
Tubes near the Entry Point
Symptoms This type of failure is observed
mainly in sample coolers used to condense
steam samples. The sample cooler coil fails
near the entry point with pin holes or cracks,
and leakage mainly occurs near the first turn of
the coil (see Figure 2). These failures are char­
acterized by a thick wall, brittle type crack and
may be found at locations of higher external Figure 2:
stresses, such as near attachments. In many Photograph of a damaged sample cooler coil showing cracks which de-
cases there is no heavy scaling inside the cool­ veloped on the surface.
ing water shells with such tube failures.
Root Cause We have investigated numerous
cases where sample coolers from various rep­
utable manufacturers have been sent to us for
root cause analysis. These types of coil failures
are quite common when sample coolers are
supplied with coils made of stainless steel (UNS
S31600 / UNS S31603). From the cross sections of
the failed sample cooler coils it can be seen that
the crack propagation often starts from the outer
surface of the coil tube, which is in contact with
the cooling water (Figure 3). In many cases, even
Figure 3:
multiple cracks develop from the outer surface Microstructural analysis of a failed sample cooler showing crack prop-
(Figure 4). When the cooling water is analysed in agation.
the laboratory, it usually indicates a higher level
of chloride ranging from 50 mg⋅L–1 to 500 mg⋅L–1.
These types of sample cooler coil failures are
identified as stress corrosion cracking (SCC). If
the chloride content of the cooling water is higher
than 40 mg⋅L–1, cooler coil tubes made of stainless
steel (UNS S31600 / UNS S31603) can fail. This is
mainly due to the sample steam entering at higher
temperatures and pressures, and in such cases,
the coil tube may be subject to intergranular
corrosion, resulting in SCC. Generally, SCC due
to chloride is observed at high-temperature and
-pressure (stress) conditions. Thus, sample cool­ Figure 4:
ers in sampling lines with temperatures higher Microstructural analysis of a failed sample cooler showing
than 120 °C fail first. SCC is most commonly asso­ crack propagation.
ciated with austenitic (stainless steel) superheater
material and can lead to either transgranular or
intergranular crack propagation in the tube wall.
This occurs where a combination of high-tensile
stresses and a corrosive fluid is present.
Solution The most simple way to solve this
issue is to upgrade the cooler coils to INCONEL®
625 (UNS N06625). Inconel is a nickel alloy which
provides excellent corrosion resistance to high
chloride content in cooling water.

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 PPCHEM HINTS FROM THE EXPERTS

Blocking of Cooler and Reduced Heat Transfer Such issues are mainly observed for the follow­
(Insufficient Cooling) ing reasons:
Symptoms There is scaling and sludge for­ ◾ High amount of suspended impurities
mation on the cooling water side of the sam­
◾ Biofouling inside the sample cooler shell
ple cooler (see Figure 5). The loss of sample
cooler efficiency causes higher sample tem­ ◾ High degree of hardness
peratures at the outlet of the sample cooler. As sample coolers are used to condense
steam, cooling water temperatures rise as high
Root Cause These issues are mainly observed
as 50–60 °C, reducing the solubility of hard­
in SWAS packages supplied to industrial boilers
ness-causing salts.
or small power plants where open circuit cool­
ing water is used. This results in hard scale formation on the sam­
ple cooler coils. This directly impacts the heat
transfer, reducing heat transfer efficiency.
Solution Even the use of special materials can­
not prevent issues related to scaling in sample
coolers or any other heat exchangers. Sample
coolers must be designed with removable shells
and replaceable coils in order to allow easy
inspection and maintenance (cleaning). The best
solution for scaling issues is to switch from open
circuit cooling water to closed circuit cooling for
the primary sample cooler. As a source, either
demineralized water or well-filtered softened
water may be used. In many cases, the users
cannot provide high-purity water continuously.
In such cases, demineralized water can be stored
in a storage tank and can be circulated in the pri­
mary cooler. This demineralized water needs to
Figure 5:
be cooled down again using an open circuit cool­
Sample cooler shell blocked
by hard scales and suspend- ing water system. Many sampling system man­
ed impurities in the cooling ufacturers also provide cooling water separation
water. skids for these applications (see Figure 6).

Figure 6:
P&I diagram of a typical cooling water separation skid by Forbes Marshall.

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 HINTS FROM THE EXPERTS PPCHEM

Insufficient Sample Cooling and High Sample

Temperatures
Symptoms Typical symptoms of this issue are:
◾ High sample outlet temperatures
◾ High cooling water return temperatures
◾ Frequent tripping of thermal shut-off valves
Root Cause These issues point towards either
design or operational issues such as:
PPCHEM AG
◾ Design Issues
▪S
 ample coolers have not been selected is a service provider
considering heat load
▪ I
ssues in closed circuit cooling water based in Switzerland that aims
piping design
• High pressure drops on the cooling to serve all users in
water side to handle the required cool­
ing water flows the power market. To best
• Back pressures in the cooling water
return lines pursue this objective and fit the
• Insufficient capacity of the cooling
towers and cooling water pumps
different needs, PPCHEM AG
◾ Operational Issues offers the different
▪E
 xcess sample flows through the sample
cooler services of
▪ Insufficient or throttled down cooling wa­
ter flows
Solution Operators should not encounter
this kind of issue with a well-designed SWAS ◾ PUBLISHING
package. The sample cooler must be selected
properly taking into consideration the heat ◾ CONFERENCES & SEMINARS
load anticipated in the sample cooler. Also, the
cooling water system must be designed to pro­ ◾ CONSULTING & TRAINING
vide the required cooling water to the primary
coolers.

HINTS FROM
THE EXPERTS
CONTACT
Forbes Marshall Pvt. Ltd.
Aditya Sanjay Kanetkar
PL – Integrated Solution (Sampling Solutions)
A34/35 MIDC Pimpri H Block
Pune 411018
India
E-mail: akanetkar@forbesmarshall.com

PPCHEM AG
CH-8340 Hinwil | Switzerland
info@ppchem.com | www.ppchem.com

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