Failure analysis of air pre-heater tubes of a petrochemicals plant

Heat resistant alloy tubes used in the higher temperature range of 1150–1273 K depends on the protective scale integrity for prevention of corrosion induced premature failures in a mixed gas environment with potential corrodents for oxidation, carburization and sulphidation attack. Cast HK40+Nb alloy tubes of an air pre-heater unit of a petrochemical industry failed prematurely after 13,000 h in service. The unit used smoke gas containing gaseous corrodents that could cause oxidation/sulphidation/carburization type of attack. Failed parts showed crack/punctures below the corrosion product filled pits. The crack occurred in the fully carburized zone present at the thinned out centre of the pit. Factors like excessive temperature cycling, overheating, presence of impurities either in the pre-heating gas mixture or that got introduced while in operation were found to be the reasons for breach of protective scale integrity leading to unwarranted corrosion attack resulting in thinning of tube material and internal corrosion penetration which finally led to premature failure.