Damage Mechanisms Archives - The Equity Engineering Group, Inc.

Damage Mechanisms Affecting Catalytic Reformer Units

Oct 25, 2024

Author: Chris Aguayo, Team Leader of Materials & Corrosion/Senior Engineer II, M&C

This article offers a detailed look at catalytic reformer units, highlighting key components and operations like octane improvement and hydrogen production. The discussion on damage mechanisms, from high-temperature hydrogen attack to chloride stress corrosion cracking, provides valuable insights and lessons learned from industry experience which address common operational challenges and failures.

Damage Review and Risk Assessment of Midstream Amine Processing Units

Sep 24, 2024

Authors: Brian McNeill, Staff Engineer II; Shane Kelliher, Staff Engineer I

For those who had the opportunity to watch last week’s webinar presented by Brian and Shane, this article expands on the benefits of risk-based inspection (RBI) for amine processing units and offers a multidisciplinary approach. It begins with an overview of the process and rich/lean amine loading, identifies key damage mechanisms and areas of concern, and proposes options for corrosion mitigation.

Effect of Sigma Phase on FCC internals

Aug 26, 2024

Authors: Nate Sutton, P.E., Senior Engineer II; Shane Kelliher, Staff Engineer I

Sigma phase embrittlement is a concern for austenitic stainless-steel components in FCC units and other internal welds in FCC regenerators. Prolonged exposure to high temperatures can lead to sigma phase formation, reducing toughness and ductility and increasing the risk of creep cracking. In this article, the authors explore preventive measures to mitigate sigma phase formation and the importance of weldability testing to increase the reliability of FCC units.

Understanding Damage Mechanisms in Industrial Gas Applications

Mar 26, 2024

Author: Phillip Prueter, Principal Engineer II

Metallurgy and corrosion experts a key to identifying damage mechanisms and predicting corrosion rates for equipment used in processes like steam methane reformers (SMRs) and air separation units (ASUs). In this article, you’ll read how important it is to recognize which damage mechanism can be reasonably captured with risk-based inspection (RBI) methods and which ones require more detailed analysis using FFS principles. In addition, you will also gain insights into how to create robust mechanical integrity programs for industrial gas production units.

Reliability Issues Associated with Brazed Aluminum Heat Exchangers

Sep 25, 2023

Author: Phillip E. Prueter, P.E., Senior Vice President of Consulting

Brazed aluminum heat exchangers (BAHXs) are distinctly prone to several damage mechanisms, including thermal fatigue, cracking, and corrosion. In this comprehensive article, Phil uses a 2016 BAHX failure to explain typical BAHX reliability and maintenance issues and provide an overview of practical damage mitigation techniques.

Leveraging Omega Creep Assessments to Extend Fired Heater Tube Remaining Life

Aug 29, 2023

Author: Lucas Baldesberger, Materials & Corrosion Engineer II

Creep, a common damage mechanism across the refining industry, is commonly often found in fired heaters and boilers. In this article, Lucas offers a detailed description of an Omega creep test and shares the benefits of performing this analysis to accurately diagnose current damage and extend the remaining life of a facility’s fired heater tubes.

Commentary on the High-Temperature Behavior of Welds

Aug 29, 2023

Author: Phillip E. Prueter, P.E.

Welds are often the weak links in pressure equipment and other structures, especially when operated at elevated operating temperatures. In this article, Phil highlights the importance of understanding the high-temperature behavior of welds, specifically in relation to creep response, and discusses how creep testing helps to predict remaining life.

Manage the Damage

Sep 28, 2022

Author: Paul J. Kowalski, Staff Engineer I

In this World Fertilizer article, Paul Kowalski explains that damage mechanism reviews (DMRs) are one of the first steps in developing many key process safety management (PSM), mechanical integrity (MI), and equipment reliability programmes in fertilizer processing units. Completing a DMR can help ensure long-term reliability of fixed equipment and piping, allow for quicker run, repair, and replace decisions to be made, and is a critical component for proper material selection.

Case Study: Creep Assessment of a Heater Tube Using SagePlus™

Nov 17, 2021

High operating temperatures can lead to a variety of damage, including creep. During the SagePlus™ User Group Meeting, Matt S. Schaser shared a case study that estimated the remaining life of heater tubes operating at temperatures in the creep range.

Converting Units to Process Renewable Feeds: Materials & Corrosion Concerns

Sep 28, 2021

Author: Nathaniel G. Sutton

In this article, Nathaniel Sutton examines the different metallurgical issues and corrosion challenges prevalent in the bio-oil and biomass oils markets and introduces several areas of consideration when converting a conventional petroleum processing unit over to renewable feeds.

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