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Journal of Failure Analysis and Prevention
Published in: Journal of Failure Analysis and Prevention 3/2017

01-06-2017 | Case History---Peer-Reviewed

Metal Dusting of Process Gas Heater Convection Tubes

Authors: Abdulaziz Al-Meshari, Gys van Zyl, Mazin Al-Musharraf

Published in: Journal of Failure Analysis and Prevention | Issue 3/2017

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Abstract

An investigation was conducted into a failure of convection section tubes in a process gas heater in a steel-making company. Thorough study using various characterisation techniques showed that the failure of the tubes, which were made of low-alloyed steel ASTM A335 P22, was attributed to metal dusting. The attack was accelerated because of the use of incompatible tube material for the intended operating conditions. Moreover, thermal fatigue cracks were discovered on the tube surfaces. Such cracks might have been caused by the high number of plant start-ups and shutdowns. Failure contributing factors and recommendations to avoid similar failure are discussed in this article.
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Literature
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B.A. Baker, G.D. Smith, Metal Dusting Behaviour of High Temperature Alloys, NACE International, Corrosion 99, Paper No. 54
2.
H.J. Grabke, M. Spiegel, Occurrence of metal dusting-referring to failures cases. Mater. Corros. 54(10), 799–804 (2003)CrossRef
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J. Kelly, J. Wilson, D. Wachowiak, Metal Dusting a.k.a Carbon Rot in the Heat Treat Industry, 50 years (2004)
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R.T. Jones, K.L. Baumert, Metal Dusting-An Overview of Current Literature, NACE International, Corrosion 2001, Paper No. 01372
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H. J. Grabke, Metal Dusting, Materials and Corrosion 2003, 54, No. 10
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M.H. Ravestein, Metal Dusting in Catalytic Reforming Furnace Tubes, NACE International, Corrosion 97, Paper No. 496
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R. Kirchheiner, J.L. Jimenez Solar, Correlation of Oxidation, Carburisation and Metal Dusting; “Controlling Corrosion by Corrosion”, NACE International, Corrosion 2001, Paper No. 01374
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P. Szakalos, Mechanisms of Metal Dusting, Doctoral Thesis, Department of Material Science and Engineering, Division of Corrosion Science, Royal Institute of Technology, Sweden AND Swedish Institute for Metals Research, Sweden (2004)
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H.J. Grabke, E.M. Muller-Lorenz, S. Strauss, E. Pippel, J. Woltersdorf, Effects of grain size, cold working, and surface finish on the metal dusting resistance of steels. Oxid Met 50(3/4) (1998)
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H.J. Grabke, E.M. Muller-Lorenz, A. Schneider, Review-carburisation and metal dusting on iron. ISIJ Int. 41(Suppl), S1–S8 (2001)CrossRef
Metadata
Title
Metal Dusting of Process Gas Heater Convection Tubes
Authors
Abdulaziz Al-Meshari
Gys van Zyl
Mazin Al-Musharraf
Publication date
01-06-2017
Publisher
Springer US
Published in
Journal of Failure Analysis and Prevention / Issue 3/2017
Print ISSN: 1547-7029
Electronic ISSN: 1864-1245
DOI
https://doi.org/10.1007/s11668-017-0241-3

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