Proceedings of the ASME 2009 Pressure Vessels and Piping Division Conference

Proceedings of PVP2009
PVP2009
2009 ASME Pressure Vessels and Piping
July 26-30, 2009, Division Conferen0
Prague, Czech Republic
July 26-30, 2009, Prague, Czech Republic

PVP2009-77076

Leakage Detection Problems on Bottom Tubesheets of Vertically

Positioned HP Exchangers An Experience with a Urea Stripper

Pervez Fateh
Inspection Manager, Fauji Fertilizer Company
Sadiqabad, Pakistan
Email: pervezfateh@ffc.com.pk

Muhammad Hussain
Staff Engineer-Inspection, Fauji Fertilizer Company
Sadiqabad, Pakistan
Email: mhussain@ffc.com.pk

Omer Akhtar
Staff Engineer-Inspection, Fauji Fertilizer Company
Sadiqabad, Pakistan
Email: omerakhtar@ffc.com.pk

ABSTRACT
The exchanger under consideration is a bimetallic
urea stripper, a high pressure heat exchanger used for stripping
urea from carbamate solution at urea fertilizer plants. Its
typical orientation with respect to ground is vertical, medium
pressure steam being used as the shell side fluid. The paper
provides an account of problems related to detecting tube
leakage(s) at the bottom tube sheet of a urea stripper, primarily
because of its positioning and presence of shell side
condensate. This caused water to be retained in the tube to
tubesheet annular spaces, hence forming a water seal and
creating a barrier for the pressurization gas preventing it to
pass through the leakage path towards the tube side.
In order to save valuable time during a plant
shutdown, a new technique of carrying out a helium-ammonia
leak test was indigenously developed, tested and applied.
However, despite the application of well developed and time-
tested techniques of helium and ammonia testing, leakage
location could not be ascertained and the tests remained
largely inconclusive causing unnecessary delay and anxiety.
The only real clue during inspection was a few droplets
emerging from one of the tubes and the health of remaining
2387 tubes could not be reliably established.
The paper opens with a brief discussion outlining the
urea synthesis process along with the technical data specific to
the urea stripper under discussion. The focus of the paper,
however, remains at sharing with the reader; problems
experienced during its leak testing and further recommend
possible measures to tackle these problems in order to achieve
improved testing effectiveness.
FOREWORD
Urea, an inorganic nitrogenous fertilizer is arguably
the most widely used fertilizer across todays world. One of
the methods for urea manufacturing is introduction of excess
ammonia together with carbon dioxide in a synthesis reactor at
a pressure and temperature of ~ 150 kg /cm2 and 205oC
respectively. The process initially results in the formation of
ammonium carbamate according to the reaction:

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 2NH3 + CO2 = NH2COONH4 Seven years down the line since project inauguration
and after successful rehabilitation of three strippers (two
Dehydration of ammonium carbamate thus formed
bimetallic and one titanium), one carbamate condenser and
results in the formation of urea according to the following
one BFW pre-heater, FFC is poised to extend its expertise to
equilibrium reaction:
the industry, in-country and abroad (Fig. 2.)
NH2COONH4 = NH2CONH2 + H2O
The reaction product consists essentially of a solution
comprising urea, water, un-converted ammonia and
ammonium carbamate. The stripping of urea along with the
decomposition of ammonium carbamate from this solution is
achieved in a urea stripper. The process however, is
exceptionally corrosive due to extreme operating conditions
and hence urea strippers are traditionally built from state of
the art corrosion resistant materials. Urea strippers are falling
film, fixed tube-sheet, shell and tube heat exchangers installed
vertically in high pressure sections of urea plants.
Initially constructed with special urea grade
materials, urea strippers advanced to the use of titanium as the
material of choice. Titanium has excellent corrosion resistant
properties; however, further improvement was introduced in Fig. 2. NEW HP EQUIPMENT REHABILITATION
the form of a bi-metallic tube consisting of a 25Cr-22Ni-2Mo FACILITY AT FFC - NEARING COMPLETION
external shell housing a thin Zirconium liner drawn internally
with a certain interference, primarily to withstand corrosion
EQUIPMENT HISTORY AND DESIGN DATA
and erosion. Hence a mechanical bond existed between the
The bimetallic urea stripper, E-4101 was installed in
inner and outer tubes. Such strippers were brought in service
service in the year 1996 at FFC-I in place of a titanium
with the turn of the 90s.
stripper. Eight years later, the stripper was removed from
service and rehabilitated at FFC workshops by shortening its
COMPANY BRIEF AND REHABILITATION OF HIGH
tubes from bottom side and re-welding with an increased tube
PRESSURE EQUIPMENT
protrusion from the tubesheet, i.e., 17mm. The reason of this
Fauji Fertilizer Company (FFC) owns and operates
modification was to reduce or minimize the dis-bonding effect
three ammonia and urea plants in Pakistan. The company
(between the two layers of bimetallic tube) by moving the tube
produces ~ 7000MTPD of Urea with a service and capacity
ends away from the heat affected zone (HAZ) induced during
factor of 99% and 140% of the name plate respectively, during
tube to tube sheet welding. Welding of the tube ends was
the year 2008. After a thorough evaluation of available
performed by outside resources. The stripper was then
resources and expertise, the company embarked upon an
installed and taken in service at FFC-II during plant
ambitious project of urea stripper rehabilitation in 2001.
turnaround in the year 2006.
Hence, the first rehabilitated stripper (titanium) rolled out of
workshops in the year 2003 and is delivering satisfactory After two years of reliable and smooth service, leakage was
service at FFC-III, Mirpur Mathelo (Fig. 1.) reported through the tubes of the stripper.
Equipment design along with various specifications is detailed
as follows (Fig. 3):
Construction ASME VIII-Div. 2, TEMA Class R,
Type BEM Special-Falling Film,
straight tube with fixed tube sheets
Service 08 years/ In-service
Weight (dry) 74000 Kg
Length 12008 mm
Shell:
Material ASME SA516-70
Diameter 1730 mm

Fig. 1. A STRIPPER ROLLING OUT OF FFC HP

EQUIPMENT SHOP AFTER REHABILITATION
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 Channel Heads: applied on the suspected area which changes color at the
Material ASME SA508 Cl.3 with 5mm lining location of leakage. The biggest drawback however is the
soaking time and ammonias intrinsic
25Cr-22Ni-2Mo+3 mm weld overlay
affinity for water which if present
Tube sheets: would tend to dissolve ammonia
Material ASME SA508 Cl.3 instead of allowing it to exit through
Thicknesses 310mm + 10mm weld overlay the leaking point.
with 25-22-2 Exclusively for the reasons
Tubes: (or limitations) of ammonia test
Material Bimetallic, Outer: 25-22-2 Cr-Ni-Mo mentioned above and in a bid to
& Inner: Zirconium B-253 effectively utilize the soaking time, a
No. of Tubes: 2388 new testing technique was developed
Dimensions: Outer Dia.: 25.4 mm by FFC inspection engineers (namely
Thickness Outer: 2 mm Mr. Ahmed Raza, Faran Hussain &
Thickness Inner: 0.7 mm Omer Javed Khan), and applied on
Length: 6000 mm the subject stripper for leakage
Design Parameters: detection i.e., the helium-ammonia
test. Principally, the test is a modified
SHELL SIDE TUBE SIDE
version of helium sniffer test whereby
Fluid circulated Vapor/ Steam Urea solution helium is mixed with ammonia
instead of air. Helium being inert is
Pressure 28 Kg/cm2 165 Kg/cm2 non-reactive with ammonia and its
Temperature 235 C 225 C superior penetrating nature allows it
to travel through the leaking point(s)
Hydro-test pressure 38.8 Kg/cm2 206.3 Kg/cm2 far ahead of ammonia.
Testing the Test
Operating Parameters:
The efficacy of the newly
Pressure 26.5 Kg/cm2 148 Kg/cm2 developed test procedure required to
Inlet Temperature 226 C 203 C be tested practically on a mock-up
prior to its application in the actual
situation. A mock-up cylinder with a
DEVELOPMENT OF TESTING PROCEDURE perforated plate at its one end was
The leakage was indicated as an increase in stripper prepared. A permeable membrane (of
shell side steam condensate conductivity. It was however, of a neoprene) was placed in front of the
minor magnitude i.e., of the order of 11 S/cm against a Fig. 3. UREA plate and the cylinder was pressurized
normal of 6~8 S/cm. STRIPPER-TYPICAL from the other end. The idea of using
the membrane was to replicate the
The conductivity eventually increased to 60S/cm.
leakage scenario as close to the actual as possible.
This value still indicated a minor leakage raising doubts with
regards to its detection by conventional methods of soap film Following step-wise procedure was adopted:
test or ammonia test. Nevertheless, due to the risk of damage
i. Cylinder was pressurized with pure helium up to 1kg/cm2.
to carbon steel tubesheet by leaking corrosive carbamate, it
was decided to shutdown the plant for rectification. ii. Soaking (waiting) time of about one hour was allowed.
The Helium-Ammonia Test iii. Minute leakage was picked up by the helium leak
detector.
The conventional method of leakage detection
associated with tubular heat exchangers is the soap film test or iv. Ammonia gas was then admitted to the cylinder and the
where greater sensitivity is required e.g., detection of trace or helium-ammonia mixture was pressurized to 2.5 kg/cm2.
minute leakages, helium test [1] or ammonia test is utilized.
v. Soaking time of about 20 minutes was allowed.
Being highly sensitive, ammonia test is used as a
standard on high pressure equipments at fertilizer plants. The vi. Helium leak detector picked up the helium trace with
equipment to be tested is pressurized with ammonia and after satisfactory sensitivity i.e., leakage rate of the same order
allowing 8-10 hours of waiting or soaking time, an ammonia as was detected in step no. iii (10-5 atm-cc/s.)
sensitive medium in the form of a paper, paste or spray is

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 It was concluded from above that ammonia did not mask
helium or adversely affected test sensitivity.
PROBLEMS IN LEAKAGE DETECTION
After plant shutdown, stripper shell side was purged,
pressurized with helium up to 1.5 kg/ cm2 and then ammonia
to reach final pressure of 2.5 kg/ cm2. First entry was made
from bottom channel head and following observations were
recorded [2]:
Helium test was performed but it remained inconclusive.
However, during this activity, few droplets emerging
from inside the zirconium liner and stainless steel tube
interface in one of the tubes were observed.
Strips of ammonia sensitive paper were placed on the
suspected tube and leakage indication was confirmed.
Ammonia test was carried out, but it remained
inconclusive. Several false indications on the ammonia
sensitive paper (Fig. 4) were recorded.
Fig. 4. NH3 PAPER - INDICATIONS
FROM TUBE AND LINER INTERFACE
At this point, the test results achieved so far were
confusing and the leaking points in the exchanger could
not be reliably established.
In a further attempt, shell pressure was increased and a
second ammonia test at bottom tubesheet was carried out.
Three additional tubes were indicated for leakage in the
second ammonia test. These indications were confirmed
by ammonia spray however ammonia sensitive paste did
not confirm them due to their minute nature.
In the final decision, only one tube, the one identified in
the beginning during the helium test, could be declared as
confirmed leaking and was plugged for rectification.
Three other tubes identified in the second ammonia test
were also plugged preventively.
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Leakage Mechanism and Analysis
The ineffectiveness of the tests caused unplanned
delay and anxiety, as every passing moment was production
lost. Evidently, the problem was caused by the level of
condensate in stripper shell which could not be completely
removed and created a water seal in the tube to tubesheet
annular spaces. This prevented shell side helium-ammonia
mixture from passing through the leakage path. The sole
leakage trace during inspection was a few droplets emerging
from one of the tubes and the reliability of remaining tubes
still remained suspected.
The most probable path of carbamate solution
leakage (on the basis of observations made during the leak
test) is shown in Fig. 5. This can be attributed to stainless steel
tube deterioration during tube to tube sheet seal welding. The
deterioration may be related to high (higher than normal) heat
input during welding of first pass, thereby initiating liner to
tube detachment along the length of 17mm protrusion. This in
Zirconium Zirconium
Leakage Path
`\Tube sheet
25-22-2
(Cr-Ni-Mo)
Deteriorated area due to
excessive weld heat
(HAZ)
Fig. 5. BLUE LINE INDICATES LEAKAGE
TRAVEL PATH
turn allowed the carbamate solution to enter the interface and
come in contact with the heat affected zone (HAZ) of the tube
to tube sheet welding, a weak area in terms of its resistance
against corrosion [3]. The solution corroded the already
weakened HAZ and made way through the tube wall,
eventually emerging as leakage on the shell side.
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 POST SHUTDOWN EXPERIMENTATION
After plant start-up, a number of tests were performed
with an objective to investigate and identify the reasons of the
problems experienced in leak testing of stripper. For the
purpose, a test apparatus consisting of a single or mono tube
exchanger was fabricated (Fig. 6.) A leakage was then created
in this exchanger that simulated the original leakage
experienced at the urea stripper in the field. Leak testing of
this mono-tube exchanger was then performed with various
sets of conditions which alongwith the respective findings are
detailed as follows:
- Scenario 1: Mixture of ammonia and air in the
exchanger shell side with water present in the annular
tube to tube sheet space thereby forming a water seal in
the leakage channel.
Findings: Ammonia was absorbed in the water due to
its natural affinity for the later. After saturation of
water, some ammonia did eventually emerge on the
tube side through the leakage path, however in tiny
quantities. Further, the stream of ammonia received was
not continuous. This finding confirmed our actual
experience at the stripper whereby the reliability of
ammonia teat was compromised due to the intermittent
pick-up of ammonia from the presumed leakage spot.
- Scenario 2: Mixture of helium and air in the exchanger
shell side with water present in the annular tube to tube
sheet space thereby forming a water seal in the leakage
channel.
Findings: Helium was obstructed by water and it did
not travel through the leakage channel. Hence the
sniffer trying to pick-up a helium trace on the other end
of leakage picked up nothing. In such a case, the only
way for helium to communicate through the leakage
channel is to physically displace the water in the
channel and force its way through to the other side
(tube side), a feat which is unlikely to achieve for the
gas even at higher pressures (within the safe pressure
limit of the shell).
- Scenario 3: Mixture of helium and ammonia in the
exchanger shell side with dry shell side conditions.
Findings: Both gases were detected from the tube side
without any difficulty, hence confirming the validity of
helium ammonia test.
CONCLUSIONS
There are a number of measures that should be taken to
bring about conclusive results while testing bottom tube sheets
of vertically positioned exchangers for leakage detection.
Listed hereunder are recommendations in the anticipation to
outline better work or procedural practices adaptable in such
scenarios;
- A moisture free shell side would be the ideal solution
to the problem. One suggestion to achieve quick shell
side drying is to circulate once-through hot air
stream. Another suggestion is to shutdown the plant
in a way that the shell side drying activity is timed to
commence at the highest ambient temperature in the
day.
- Detection of leakage was quite difficult due to its
minute nature. It gets easier to detect and locate as it
increases in magnitude.
- It would always be advisable to make a quick bottom
entry in the equipment after its shutdown (as soon as
the internal conditions conform to the confined space
entry requirements) in order to pick-up maximum
visual observations, including any dripping which
might still be present from the leakage spot.
ACKNOWLEDGEMENTS
We are deeply indebted to Mr. Tahir Javed, General
Manager (M&O), Mr. Najeeb Afzal, Sr. Technical Services
Manager FFC-GM, and Mr. Asif Jamal, Sr. Technical
Services Manager FFC-MM, for the inspiration and guidance
in writing this paper.
REFERENCES
1. Nondestructive Testing Handbook, Volume One, Leak
Testing- American Society for Nondestructive Testing,
American Society for Metals.
2. E-4101, Urea Stripper Shutdown Inspection Report # IR-
180-80 issued by Inspection Department, Fauji Fertilizer
Company.
3. Tubular Heat Exchanger-Operation and Repair by Carl
F. Andreone & Stanley Yokell.

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