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Corrosion Resistant Alloys (CRAs) are routinely utilized to mitigate against the complex damage mechanisms encountered in refining operations that carbon and low alloy steels are highly susceptible to. However CRA materials can suffer similar corrosion damage when improperly manufactured or exposed to aggressive environments. In this paper three modes of CRA failure observed at a client’s site were analysed in a lab and mitigation strategies proposed.Tower trays near the top of a crude tower made of 410S martensitic stainless steel failed as a result of localized undersalt corrosion due to formation of amine hydrochloride salts. Appropriate crude pre-treatment was implemented to mitigate this corrosion mechanism.Inconel 625 flexible hoses located at the inlet of a reformer in a hydrogen plant failed upon start-up during a turnaround. It was found that these materials were heavily sensitized with embrittling phases present at the austenite grain boundaries. Improper annealing processes at the manufacturing plant likely caused the sensitization of the microstructure.Downstream of the reformers 304L SS tube ends of the boiler feed water (BFW) heat exchanger underwent a failure. The tube to fixed tube sheet seal weld failed as a result of fatigue cracking originating at a lack of weld deposit location. Ensuring a proper weld profile in compliance with the weld procedure would reduce such stress riser concentrations.
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Both cast (UNS N08151) and wrought (UNS N08810/N08811) metallurgies have been used for outlet components. The microstructural features responsible for material performance, the various microstructural alterations occurring in service are reviewed as are the impact on serviceability and on, repair weldability and examples of failures.