Repair of Tube―Tubesheet Weld Cracks in a Cracked Gas/Steam Heat Exchanger

Serious cracks were found at tube-to-tubesheet welds during the start up operation of a cracked gas/steam heat exchanger in a gas plant. The cause of the failure has been analyzed, and the exchanger is repaired. The root cause of the cracks is mainly attributed to poor workshop in the tube-tubesheet...

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Bibliographic Details
Published in:Journal of failure analysis and prevention 2011-12, Vol.11 (6), p.611-617
Main Authors: ADULLAH, Shaker, EZUBER, Hosni M
Format: Article
Language:English
Subjects:
Applied sciences
Cracks
Devices using thermal energy
Energy
Energy. Thermal use of fuels
Exact sciences and technology
Exchange
Failure analysis
Fracture mechanics (crack, fatigue, damage...)
Fundamental areas of phenomenology (including applications)
Heat exchangers
Heat exchangers (included heat transformers, condensers, cooling towers)
Physics
Repair
Roots
Solid mechanics
Structural and continuum mechanics
Welded joints
Workshops
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Summary:Serious cracks were found at tube-to-tubesheet welds during the start up operation of a cracked gas/steam heat exchanger in a gas plant. The cause of the failure has been analyzed, and the exchanger is repaired. The root cause of the cracks is mainly attributed to poor workshop in the tube-tubesheet welds. Failure analysis and repair procedure were reported in the present article. Several months of operation after the repair confirmed that the repair was successful.[PUBLICATION ABSTRACT]
ISSN:1547-7029
1864-1245
DOI:10.1007/s11668-011-9482-8