Materials & Corrosion Archives - The Equity Engineering Group, Inc.

Boilers and Common Damage Mechanisms with Real-World Case Studies

Mar 25, 2025

Boilers are essential for industrial steam generation, but corrosion issues can disrupt operations, making prevention and mitigation critical. In this article, Nate and Luke explore common damage mechanisms, discuss effective prevention strategies, and share recent case studies demonstrating the value of expert analysis in maintaining reliability. Read the full article to learn how to keep your systems running smoothly.

Damage Mechanisms Affecting Catalytic Reformer Units

Oct 25, 2024

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.

Effect of Sigma Phase on FCC internals

Aug 26, 2024

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.

Materials & Corrosion Considerations for Ammonia, Urea, Nitric Acid, & UAN Units

Apr 30, 2024

Over the past 20 years, the fertilizer industry has experienced several metallurgical and operational advancements for process equipment. In this article, Raj and Phil discuss the ongoing challenge of damage mechanisms and corrosion-related issues in fertilizer plants and highlight the critical role of materials selection and process monitoring in managing equipment degradation rates. Read more and learn how to achieve long-term equipment reliability and maintain a robust mechanical integrity program through the routine collaboration between materials/corrosion, mechanical, and process engineering subject matter experts and inspection specialists.

Understanding Damage Mechanisms in Industrial Gas Applications

Mar 26, 2024

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.

Case Studies of Failures in Crude / Vacuum Units

Feb 27, 2024

The contaminants found within crude oil can lead to numerous types of damage mechanisms that impact the crude unit. Unfortunately, multiple damage mechanisms can be the cause of an in-service failure. In this article, two case studies discuss the need to conduct in-service failure analyses for uncovering the root causes and developing practical risk mitigation strategies.

Hot Tap Evaluations and Practical Guidance for In-Service Repair Welding

Nov 1, 2023

In-service welding as part of a maintenance program is a practical and economical way to address leak repairs or new nozzle installations; however, it does come with a few risks, including burn-through and hydrogen-induced cracking. In this article, Raj will discuss the risks involved with in-service welding, thermal analysis to quantify the risks, and practical in-service welding considerations to ensure safe and successful hot tap connections.

Reliability Issues Associated with Brazed Aluminum Heat Exchangers

Sep 25, 2023

Brazed aluminum heat exchangers (BAHXs) are distinctly prone to several damage mechanisms, including thermal fatigue, cracking, and corrosion. In this comprehensive article, the author 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

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

Welds are often the weak links in pressure equipment and other structures, especially when operated at elevated operating temperatures. This article 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.

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