High Temperature Assessments
High and normal operating temperatures can degrade metallurgical properties and produce damage not seen at lower temperatures. The design codes for components in this temperature range only provide basic design requirements, but actual component behavior is strongly dependent on the existing operating conditions and service environment. To prevent both under-utilization and failure of equipment, the challenge for owner-users is to accurately predict remaining life, prevent unnecessary repairs or replacements, and extend equipment life and availability,
E2G has in-depth experience in evaluating the suitability for service of components operating in the high temperature range and subject to a variety of damage mechanisms. Our membership and support of joint industry programs sponsored by the Materials Properties Council (MPC) Project Omega for creep damage evaluation and MolyHy for assessment of High Temperature Hydrogen Attack (HTHA) gives us special expertise in state-of-the-art technologies for equipment assessment.
E2G’s David Osage and Gerrit Buchheim are recognized high temperature experts:
- Drafted creep life assessment rules for Part 10 in API 579-1/ASME FFS-1
- Authored Appendix F of API 579-1/ASME FFS-1
- Active members of MPC Project Omega since its inception in 1984
- Created VCESage remaining life assessment module
- Active members of MPC MolyHy program
We can help you understand – and deal with – the various ways high temperatures can impact your equipment and the interactions between mechanical, metallurgical, and environmental causes of high temperature damage mechanisms.
Practical Advice for a Complicated Problem
E2G's close working relationship with MPC provides us access to extensive materials property information, and insight into innovative analytic methodologies. MPC's Project Omega methodology can be used to accurately determine the remaining life of aging equipment not only by providing materials properties that are the best in the industry, but also through a procedure for conducting creep strain rate tests from the assessment day forward, thereby avoiding the need for a precise past pressure and temperature operating history. The methodology has been validated through experience and is published in API 579. Most of the major integrated oil companies are using this technology with great success.
E2G uses a phased approach to help you mitigate and manage the damage mechanisms that most often cause costly failure: creep, high temperature hydrogen attack, metallurgical embrittlement, and thermal stresses/fatigue. This approach saves time and money by giving you the ability to stop applying technology as soon as the essential need is satisfied.
- Phase 1 – Preliminary calculations based on previous industry inspections and nominal operating conditions
- Phase 2 – More sophisticated stress analysis and better understanding of the materials involved; possibly some chemical analysis
- Phase 3 – Creep testing through one of the most respected labs in the country
- Phase 4 – Remaining life calculations
- Phase 5 – Probabilistic assessments
This working process assures that you won't get caught in a consulting quagmire of doing unnecessary work that yields marginal value. Our goal is to give you practical advice.
Beyond Heater Tubes: Help with Other At-Risk Components
E2G has performed hundreds of heater tube assessments, using VCESage software plus the API 530 design code for heaters and the API 579-1/ASME FFS-1 FFS Standard. However, many components require more sophisticated analysis, including vessels, piping, and other heater components.
E2G performs finite element stress analysis to simulate temperature and structural response of complex components and loading conditions. We are one of the few firms to commonly employ advanced stress analysis techniques in conjunction with the MPC material models (that is, advanced non-linear inelastic stress analysis combined with an understanding of metallurgical properties) to simulate high temperature response and characterize creep damage.
This multifaceted approach can be beneficial in assessing high temperature damage in the following:
- Process heaters (coke heaters, cat reformers, steam/ammonia reformer heaters
- Heater components (tube sheets, hangers, ducts, headers)
- Hot piping and valves
- FCCU reactor and regenerator components
- Reactor health/remaining life
- Thermal diffusion calculations for start-up and shutdown; safe envelopes
- PWHT simulations to advise on difficult applications
- Hot-tap analysis
E2G performs these state-of-the-art assessments quickly, to help you make informed decisions in a timely manner.
