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Investigation of Platformer Reactor Nozzle Cracking

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This paper details with the unexpected cracking encountered in the outlet nozzles of all three reactors for Platformer unit, during a scheduled shutdown. The unit was commissioned in 1957 and the reactors metallurgy is as per withdrawn ASTM standard, A301 Gr. B (1Cr-1/2Mo). The isolated cracks were located at the upstream edge of the inset nozzle and running vertically down. The cracking in the high-pressure fixed bed reactor outlet nozzles was successfully repaired in-situ. This paper reviews the circumstances which led to these failures and highlights the lessons learned from each failure.

Product Number: MPWT19-15243
Author: Pranav Agrawal, Abdulla Ali Juma
Publication Date: 2019
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Weld Jointing Influence on Boiler Tube Sheet Integrity

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SRU Reaction Furnace Waste Heat Boiler Tube Failure Causing Unscheduled Shutdown

Product Number: MPWT19-14391
Author: Qasem J. Al-Hassan, Iyad A. Al-Buraiki
Publication Date: 2019
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A sulfur recovery unit (SRU) train in a gas processing facility went under an emergency shutdown due to the failure of a reaction furnace waste heat boiler (WHB) tube. The failed tube had been in service for approximately 18 years. The failed tube was subjected to a number of metallurgical laboratory examinations in order to determine the damage mechanism and root cause(s) of the failure. Examinations included visual inspection, scale analysis, chemical analysis, metallographic examination and mechanical testing. The examination revealed internal corrosion thinning in the tube which led to rupture since the tube could no longer withstand the pressure. Metallographic examination revealed spheroidized microstructure indicating that the tube experienced high metal temperature. This is suggesting that something was impeding heat transfer between the tube and water. Scale analysis results from a sample collected from the tube internal surface indicated the presence of iron sulfide corrosion products. Based on the aforementioned findings, it was concluded that the corrosion thinning was caused by sulfidation. Sulfidation is one of the potential damage mechanisms in WHB tubes and is caused by reactive sulfur species as a result of the thermal decomposition of sulfur compounds at high temperatures (above 500oF). Failure contributing factors as well as corrective actions to prevent recurrence of such failure are discussed in this paper.
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08458 Thermal Fatigue in a De-Superheater Induced by Thermal Loads

Product Number: 51300-08458-SG
ISBN: 08458 2008 CP
Author: Bakheet Al-Yami
Publication Date: 2008
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