Help. I bought a new home 14.5 years ago. Since then, I've had 6
(electric) water heater failures. My early heaters would leak at the
top. Lately, the failures start with "brown water" thru the house at
each hot water outlet which progressively gets darker. After replacing
the heater, the water is clear. I've purchased quality name brand
units with dual heating elements and even increased the total gallon
capacity (now 80gal). I have a water softener ahead of the unit as
well as a hot water recirculating pump (on a timer) to circulate the
hot water through the long runs in the house. I drain the water heater
once a year and flush it as well as remove and clean the heating
elements. I started to do this around failure #4. I'm now getting
light brown water at the taps so I know I'm facing #7 real soon! By
the way, my neighbors to each side and across the street don't
experience this problem.

My first guess would be a water quality problem. Water Softeners
generally just neutralize the minerals in the water. You could still have
really acidic water which could be corroding your water heaters and
plumbing.

You may also have lots of rust and/or sediment in your water. I recommend
you install a whole house water filter on your cold water supply.

Maybe you have some kind of bacterial or other contamination. Your water
softener company should be able to test for this, or your local health
department could test your water as well.

What kind of piping is in your house? Copper, CPVC, PEX, Galvanized? My
in-laws had terrible water quality because of their old galvanized
piping. After I replaced their piping, their water runs clear and fresh.

Have you inspected the anode rods of the water heaters when you replace
them? They're supposed to reduce tank corrosion by sacrificing themselves
instead of the tank.

You may want to search for a tank with a liner that can handle harsh
water conditions. They usually cost more, but should be cheaper than
replacing your tank every couple of years.

One last thought, though I'm not sure if it would affect the tank or
water. Check to make sure your water heater is grounded to the electrical
system.

Good luck!

Anthony