Rahmadani, Ricky (2026) Analisa Penyebab Kegagalan Pada Evaporator Tube Heat Recovery Steam Generator (HRSG) Di Fasilitas Enhance Oil Recovery Dengan Kapasitas 10.000 BCWPD. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Heat Recovery Steam Generator (HRSG) berperan vital pada fasilitas Enhanced Oil Recovery (EOR) steamflood. Namun, evaporator tube HRSG mengalami kebocoran berulang (pinhole) pada sambungan las elbow 180° sisi hilir, yang menyebabkan unplanned shutdown dan kerugian ekonomi signifikan. Penelitian ini bertujuan mengidentifikasi mekanisme kegagalan dan merumuskan langkah mitigasi melalui analisis kualitas air umpan, pemeriksaan visual, SEM/EDS, metalografi, serta simulasi CFD multifasa menggunakan ANSYS Fluent dengan Discrete Phase Model. Material teridentifikasi sebagai baja karbon ASTM A53 Grade B berstruktur ferit–perlit tanpa kandungan kromium, sehingga inheren rentan terhadap Flow-Accelerated Corrosion (FAC). Analisis air umpan mengungkap penyimpangan serius dari standar, meliputi total dissolved solids yang tinggi, klorida (737–993 mg/L), dan pH (8,51–8,95) yang berada di bawah rentang stabilitas magnetit. Permukaan menunjukkan morfologi khas berupa "kulit jeruk" (orange-peel)/scallop, sementara hasil EDS didominasi Fe–O disertai jejak klorida. Metalografi mengonfirmasi struktur ferit–perlit normal tanpa sferoidisasi, sehingga menyingkirkan degradasi termal. Simulasi CFD mengonfirmasi percepatan aliran hingga 4,8 m/s pada elbow yang melampaui kecepatan kritis erosi–korosi baja karbon (3 m/s), dengan erosi teramplifikasi hingga 3,3 kali pada area cacat lasan. Disimpulkan bahwa kegagalan didominasi oleh FAC yang bersinergi dengan erosion-corrosion, diperparah oleh klorida agresif dan partikel tersuspensi, dengan cacat lasan yang melokalisasi terjadinya perforasi atau degradasi. Penelitian ini merekomendasikan perbaikan kualitas air umpan (Cl⁻ < 10 ppm, pH 9,0–9,5), penerapan long-radius elbow, serta peningkatan material dengan kandungan kromium > 0,5 wt%.
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The Heat Recovery Steam Generator (HRSG) is vital in Enhanced Oil Recovery (EOR) steamflood facilities. However, the evaporator tube of HRSG suffered recurring pinhole leaks at the downstream weld joint of a 180° elbow, causing unplanned shutdowns and significant economic losses. This study aims to identify the failure mechanism and formulate mitigation measures through feedwater quality analysis, visual examination, SEM/EDS, metallography, and multiphase CFD simulation using ANSYS Fluent with the Discrete Phase Model.The material was identified as ASTM A53 Grade B carbon steel with a ferrite–pearlite microstructure and no chromium, rendering it inherently susceptible to Flow-Accelerated Corrosion (FAC). Feedwater analysis revealed severe deviations from standards, including high total dissolved solids, chloride (737–993 mg/L), and a pH (8.51–8.95) below the magnetite stability range. The surface exhibited a characteristic "orange-peel"/scallop morphology, while EDS was dominated by Fe–O with chloride traces. Metallography confirmed a normal ferrite–pearlite structure without spheroidization, ruling out thermal degradation. CFD confirmed flow acceleration up to 4,8 m/s at the elbow exceeding the critical erosion–corrosion velocity of carbon steel (3 m/s) with erosion amplified up to 3.3 times at the weld defect. It is concluded that the failure was dominated by FAC acting in synergy with erosion–corrosion, aggravated by aggressive chloride and suspended particles, with the weld defect localizing the perforation. This study recommends improving feedwater quality (Cl⁻ < 10 ppm, pH 9.0–9.5), adopting a long-radius elbow, and upgrading to chromium > 0.5 wt.%.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | Flow-Accelerated Corrosion, Erosion-corrosion, HRSG, Evaporator tube, Analisis kegagalan, Flow Accelerated Corrosion, erosion-corrosion, HRSG, Evaporator tube, Failure Analysis. |
| Subjects: | T Technology > TA Engineering (General). Civil engineering (General) > TA169.5 Failure analysis T Technology > TJ Mechanical engineering and machinery > TJ263.5 Boilers (general) T Technology > TJ Mechanical engineering and machinery > TJ935 Pipe--Fluid dynamics. Tubes--Fluid dynamics |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21101-(S2) Master Thesis |
| Depositing User: | Ricky Rahmadani |
| Date Deposited: | 30 Jul 2026 06:55 |
| Last Modified: | 30 Jul 2026 06:55 |
| URI: | http://repository.its.ac.id/id/eprint/141134 |
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