Experimental in-situ metallographic investigations of industrial hydrocarbon processed fired heater tubes

Abstract

In the present investigations, the coker unit heater tube has been evaluated using in-situ metallography, after an exposure at a temperature of 615 °C for around 52 000 h. The heater tubes in petroleum industries are mostly damaged by creep failures; hence metallography assessments are conducted for safe operation of industrial units. The primary material of construction for fired heater tubes is ASTM A213 GrT9 chromium molybdenum ferritic steel and maximum primary creep strains are estimated as 11.2761 × 10−2 and 11.2802 × 10−2 for temperature 888 and 923 K, respectively. In-situ metallography test was conducted at finish pass surface on one butt weld joint section of two different passes (pass I and pass II) of heater tubes. Hardness is within limit and chemical composition stands confirmed within material standards. A heater tube weld joint comprising weldment metal, heat affected zone and base metal were found in good condition, and no indications of creep were observed. Tempered martensite is observed only in weld metal and heat affected zone which aids in high temperature creep strength of metal at weld joint and heat affected zone. No martensitic structure was observed on the base metal; however base metal creep strength was ascertained by fine precipitated alloy carbides within the ferritic matrix base metal structure. Recommendations were further provided to monitor the performance of heater tubes and for an early prediction of secondary creep.