An early corrosion failure of the piping system of a gas heater was reported by a gas complex company. Local corrosion rates of 0.90 and 0.66 mm/year were observed in the heater piping system. An investigation including visual examination, macrostructure, microstructure (SEM, EDS and XRD), thickness gauging, chemical analysis, and mechanical testing, was performed. The results showed that corrosion damage occurred on the external surface of the pipes. Corrosion occurred at the cold sides of the pipes and elbows. The corrosion pattern is broad and shallow pitting. Some elbows showed an early stage of carbide spheroidization and pearlite decomposition. The EDS microanalysis revealed that the level of sulfur, chlorine, and nitrogen was substantially high in the rust samples. The XRD of the corrosion products showed that the main oxyhydroxide was Akaganeite. The analysis of results showed that the flue gas dew point corrosion was the mechanism of damage, and the root cause was the operation of the heater at low temperatures and the frequent outings of service, combined with evident material drawbacks including low levels of Si, Cu, Ni, Cr, and Mo. These elements should be at their maximum allowable limits of the SA 105 and SA 106 to improve the corrosion resistance of the steel piping components.
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