Failure Analysis of α-MDEA Air-Cooled Heat Exchanger of CO2 Removal Unit Based on the Semiquantitative Risk-Based Inspection Method

Risk-based inspection program (RBI) is a decision making techniques for providing refineries and petrochemical plants with an effective and appropriate inspection planning. The aim of the present study is to analyze failure behavior and risk ranking of α-MDEA fin/fan cooler of CO2 removal unit based on API 581 in order to find out the reason(s) of tubes failure. According to previous experience in similar plant, risk calculation results and conducted inspection activity by using RFT eddy current technique, CO2 corrosion damage mechanism was identified as a main reason of tubes failure. In next step, process key variable, prevention/mitigation methods and inspection planning programs were determined so as to minimize the similar failure behavior in the rest of the lean amine air-cooled heat exchangers of CO2 removal unit.