PSI - Issue 68

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2025) 000–000 ScienceDirect Structural Integrity Procedia 00 (2025) 000–000

www.elsevier.com/locate/procedia

www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 68 (2025) 409–414

European Conference on Fracture 2024 Root Cause Failure Analysis of a 9Cr-1Mo tube in the CCR Unit of an Oil Refinery Reza Khadem Hosseini * Corrosion Research Group, Research Institute of Petroleum Industry (RIPI), Tehran, Iran Abstract A severe local failure of a 9Cr-1Mo heater tube in the Continuous Catalytic Reformer (CCR) unit of an oil refinery, below the skin thermocouple shield junction, has been investigated. For this, the optical microscope and scanning electron microscope (SEM) were carried out for microstructural observation, and the micro-hardness measurements were performed for metallurgical evaluation. In addition, the elemental composition of the failed surface was studied by using EDAX analysis. Based on the results, "carburization" and, "metal dusting" were identified as two damage mechanisms in this case. The microstructural evaluation showed metallurgical phase transformation which is in agreement with micro-hardness results. European Conference on Fracture 2024 Root Cause Failure Analysis of a 9Cr-1Mo tube in the CCR Unit of an Oil Refinery Reza Khadem Hosseini * Corrosion Research Group, Research Institute of Petroleum Industry (RIPI), Tehran, Iran Abstract A severe local failure of a 9Cr-1Mo heater tube in the Continuous Catalytic Reformer (CCR) unit of an oil refinery, below the skin thermocouple shield junction, has been investigated. For this, the optical microscope and scanning electron microscope (SEM) were carried out for microstructural observation, and the micro-hardness measurements were performed for metallurgical evaluation. In addition, the elemental composition of the failed surface was studied by using EDAX analysis. Based on the results, "carburization" and, "metal dusting" were identified as two damage mechanisms in this case. The microstructural evaluation showed metallurgical phase transformation which is in agreement with micro-hardness results. © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ECF24 organizers © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ECF24 organizers © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ECF24 organizers Keywords: 9Cr-1Mo; metal dusting; carburization. 1. Introduction It is known that continuous catalytic reforming (CCR) can convert refinery naphtha into a high-octane liquid product in refineries when appropriate conditions of temperature, pressure, and time are met. It consists primarily of heat exchangers, reforming furnaces, catalyst regenerators, and other auxiliary equipment. (Polovina et al., 2018; Wang et al., 2012 ) . 1. Introduction It is known that continuous catalytic reforming (CCR) can convert refinery naphtha into a high-octane liquid product in refineries when appropriate conditions of temperature, pressure, and time are met. It consists primarily of heat exchangers, reforming furnaces, catalyst regenerators, and other auxiliary equipment. (Polovina et al., 2018; Wang et al., 2012 ) . Keywords: 9Cr-1Mo; metal dusting; carburization.

* Corresponding author. Tel.: +9821 4825 5204 E-mail address: hosseinir@ripi.ir

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ECF24 organizers 2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ECF24 organizers * Corresponding author. Tel.: +9821 4825 5204 E-mail address: hosseinir@ripi.ir

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ECF24 organizers 10.1016/j.prostr.2025.06.074