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This paper discusses reactors in hydrocarbon service that experienced numerous cracking problems over a 8-year period, where cracks were confined to the welded zones. The material is TP347 stainless steel, welded with E347-16 consumables.
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Degradation mechanisms experienced by a refinery’s RFCC catalyst cooler aeration piping system. Analysis of the most recent and a past failure determined the metallurgical and mechanical degradation mechanism(s) that led to these failures.
Up until the 1940s, typical furnace tube materials consisted of wrought chromium steels and austenitic stainless steels. But the low carbon content led to increased creep.
During plant shutdown maintenance, some components cannot be removed out of service immediately for metallurgical examination due to high cost involved and loss of production hours. The best alternative is to replicate the lab based metallography work under the field conditions. Field Metallography and Replication (FMR) also known as in-situ metallography is a powerful non-destructive test (NDT) tool used to examine the microstructure of the component when it is still in service. Moreover, FMR is also used to study the microstructural alterations for the fitness for service assessment.
This paper provides case studies of materials in Natural Gas Processing facility where FMR was used as an NDT tool without sectioning the component. This paper discusses the damage mechanisms such as sigma phase embrittlement, stress relaxation cracking and creep.
Stress relaxation cracking (SRC) is a failure mechanism known to occur in austenitic stainless steels and nickel alloys operating at moderate to high temperatures.
Typically, SRC failures tend to occur under the following conditions: 1-6 1. Susceptible material: 800H, 347H, 617, etc. (typically materials with low creep ductility) 2. High residual stresses: Hardness > 200 HV (welded thick section) 3. Specific temperature range: usually between 500 °C (932 °F) and 750 °C (1382 °F).
Under these conditions, component stresses are relieved by time dependent inelastic deformation.3 In susceptible materials, this process occurs by intergranular cracking and is essentially a creep mechanism.2-6 In this respect, materials with low creep ductility tend to be prone to this type of damage mechanism. On the other hand, materials that have good creep ductility can tolerate the inelastic strains due to relaxation without cracking.3