If the reactor electric heater leaks, what are the causes? Today, we will analyze the reasons in detail. For the electric reactor heater, this can also serve as a reference. The analysis is as follows:
Leakage in the reactor electric heater mainly manifests in two aspects: tube port leakage and tube body leakage.
1.Tube Port Leakage
Cause 1: Excessive Thermal Stress
During the start-up and shutdown of the reactor electric heater, if the temperature rise and drop rates exceed the specified range, the thermal stress on the tubes and plates increases, causing damage to the welds or expanded joints, leading to port leakage.
Cause 2: Tube Sheet Deformation
If the tube sheet deforms, leakage may occur when it connects with the tubes. Insufficient tube sheet thickness is one of the causes of deformation.
Cause 3: Improper Tube Plugging Process
Generally, conical plugs are welded to block tubes. When driving in the conical plug, the force should be moderate; excessive force can deform the tube hole. During welding, improper operation or incorrect position/size can also damage the connection between the tube and tube sheet.
2.Tube Body Leakage
Cause 1: Erosion
When the steam flow velocity is high and the steam contains large-diameter water droplets, the outer wall of the tube is subjected to steam-water two-phase flow erosion, causing the tube wall to thin, perforate, or rupture under water pressure.
If the material and fixing method of the impingement plate are not reasonable, it may break or fall off under the impact of steam or condensate, losing its protective function. Insufficient area of the impingement plate and too small a distance between the shell and tube bundle are also causes.
Cause 2: Tube Vibration
When the tube bundle vibrates, if the vibration frequency or its multiples coincide with the frequency of the excitation force, resonance occurs, increasing the amplitude and ultimately damaging the connection between the tube and tube sheet.
Cause 3: Corrosion
When the tube material of the reactor electric heater is copper, if the pH value is too high, the copper tubes may corrode, leading to leakage.
Cause 4: Poor Material or Process
This includes poor tube material, uneven tube wall thickness, tube defects, and over-expansion at the expanded joint. These are all manifestations of poor material or process. Once the reactor electric heater encounters abnormal conditions, the tubes are easily damaged, causing leakage.
