Corrosion Rate and Remaining Lifetime Calculation of Shell and Tube Heat Exchanger XXX-E-XX Based on Eddy Current Test and Ultrasonic Thickness Measurement Inspection Methods in the Delayed Coker Unit Operation Area

Shell and tube heat exchangers play a vital role in refinery operations by ensuring efficient heat transfer. However, corrosion significantly impacts their performance, reliability, and lifespan, leading to potential operational risks. This study assesses the corrosion rate and remaining lifetime of the shell and tube heat exchanger XXX-E-XX using Eddy Current Testing (ECT) for tube bundles and Ultrasonic Thickness (UT) measurement for the shell. The objective is to evaluate the extent of material degradation and predict the remaining service life based on API standards. Corrosion rates are determined by analyzing thickness reduction from historical inspection data, covering the period from 2016 to 2020. The results indicate that the corrosion rate of tube bundles ranges from 0.105 to 0.21 mm/y, while the shell exhibits a wider corrosion rate variation of 0.095 to 0.535 mm/y. The estimated remaining lifetime for tube bundles is between 5.28 and 14.56 years, whereas the shell components range from 1.89 to 43.09 years. To enhance operational reliability, periodic inspections, predictive maintenance strategies, and material improvements are recommended. These findings provide valuable insights into maintenance planning and longevity assessment of heat exchangers in refinery applications.