Paper No. 13326 High Temperature Hydrogen Attack Life Assessment Modeling and Inspection James Johnson, Brian Olson, Michael Swindeman, Mark Carte Stress Engineering Services, Inc. 13800 Westfair East Dr. Houston, TX 77041 Jeffrey Browning Riccardelli Consulting Services, Inc. 3347 Mayflower Ave. Lehi, UT 84043 ABSTRACT Key elements of a technology initiative aimed at developing high temperature hydrogen attack (HTHA) assessment methodologies for equipment and piping operating in hot hydrogen service are presented. Two assessment methodologies have been developed: (1) a Screening Assessment and (2) an Advanced Assessment, both of which predict the development of HTHA damage with time. The HTHA assessment methodologies utilize fitness-for-service (FFS) frameworks and are in good agreement with reported HTHA incidents in API RP 941 and API TR 941 for carbon steel and C-0.5Mo materials. The Screening Assessment provides an improved decision basis by classifying and ranking equipment operating in hot hydrogen service. The Advanced Assessment predicts through-wall damage progression. An inspection philosophy and the use of inspection findings as a means of risk mitigation are also discussed. Application of the assessment methods and utilization of advanced inspection methods are reviewed through an illustrative case study. The developed methodologies provide an improved link between HTHA damage assessment and progression, inspection and detection limits, damage tolerance, and operation severity. Key words: high temperature hydrogen attack, HTHA, modeling, inspection, life assessment, FFS, MT, HSWFMT, PAUT, FMC, TOFD, AET INTRODUCTION High temperature hydrogen attack (HTHA) has been a challenging damage mechanism for the petroleum refining and petrochemical industry to address since the industry first became aware of it in the early 1900’s. The earliest attempts to design for HTHA relied on a time-independent basis commonly referred to as the Nelson Curves. 1 The Nelson curves are lines drawn below operating conditions (combination of temperature and hydrogen partial pressure) that caused an HTHA incident for a given material class, e.g. post-weld heat treated (PWHT) carbon steel, carbon-0.5 molybdenum (C-0.5Mo) steel, etc… Recent industry experiences with HTHA have ©2019 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole, must be in writing to NACE International, Publications Division, 15835 Park Ten Place, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of the author(s) and are not necessarily endorsed by the Association. 1 reduced acceptable temperature and hydrogen partial pressure combinations by removing the C-0.5Mo Nelson curve and the addition of an even lower non-PWHT carbon steel Nelson curve to the American Petroleum Institute (API) (1) Recommended Practice (RP) 941. 2, 3 LIFE ASSESSMENT METHODOLOGIES Several time-dependent HTHA models have been developed to provide an owner/user an improved understanding of their likelihood of HTHA damage and remaining life: 4-6 Model 1. Model 2. Model 3. Provides prioritization and likelihood of damage based on hot hydrogen exposure and material class. Provides through-wall volumetric HTHA damage progression by integrating Model 1 as a function of through-wall position and methane partial pressure. Provides through-wall HTHA crack growth by correlating the effect of methane pressure at a crack tip to crack growth. Model 1 is used in the Screening Assessments; while Models 2 and 3 are implemented in the Advanced Assessment methods. Screening Assessments Screening Assessments use Model 1 to calculate a Damage Index (DI) that represents a subject asset’s hot hydrogen exposure relative to the average hot hydrogen exposure for a specific material class that resulted in HTHA damage, as reported in API RP 941, API TR 941, and select literature. 3, 7 To prioritize equipment, a DI is calculated below. The DI at a given time, t, is calculated by integrating the damage rate, ππΜ, over the service history, s, as shown in Equation 1: π‘π‘ π·π·(π‘π‘) = οΏ½ ππΜ (ππππ) (1) 0 The modifications were influenced by a number of bubble nucleation and growth models. 8-18 Parthasarathy developed an expression that described grain boundary diffusion controlled void growth, which the authors have fitted into the modified Orr-Sherby-Dorn interpretation for Model 1 (Equation 2): ππΜ = π΅π΅ ππ οΏ½πππΆπΆπΆπΆ4 οΏ½ ππ (ππ⁄π π π π ) ππ (2) The Model 1 damage rate equation is considered to be an empirical expression with the B, n, and Q constants developed for each material class. The effect of methane pressure, PCH4, is assumed to be much larger than the effect of surface energy over most of the life. The sintering term of the nucleation and growth models has been neglected, similar to the procedure outlined in API Technical Resource (TR) 941 Annex G. 7 All of the other terms are assumed to be constant. 1 American Petroleum Institute, 1220 L Street, NW, Washington, DC, 20005. ©2019 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole, must be in writing to NACE International, Publications Division, 15835 Park Ten Place, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of the author(s) and are not necessarily endorsed by the Association. 2 The methane partial pressure is calculated using the procedure developed by Odette and Vagarali and is dependent on the hydrogen partial pressure and the temperature. 19 A smoothing function has been implemented to address the discontinuous nature of the C(T) function, which has been fitted to the original data. 6 Equation 2 was preliminarily validated against laboratory test data and appeared reasonable. 9, A representative validation case takes data from Weiner’s study that exposed tensile test specimens to hot hydrogen for various temperatures, hydrogen partial pressures, and times. The time to measurable ductility loss, as characterized by reduction in area, was labeled the incubation time and is plotted as a function of temperature in Figure 1a. For hydrogen partial pressures of 700 psi (4.83 MPa) and temperatures greater than 1000 °F (538 °C), the time to degraded mechanical properties increases with increasing temperature. 20-28 Model 1 can be presented in a form analogous to a Larson-miller creep formulation and fitted to the data. Figure 1b shows the test data set regressed using Model 1, which captures the incubation conditions resulting in an R2 value of 0.98. The diagram in Figure 1b can be nonintuitive as each axis is a function of multiple variables, as demonstrated in Figure 2a. Model 1 was then optimized to assess likelihood of HTHA damage for in-service equipment by fitting it to the API RP 941 incident data and select laboratory data already in API RP 941. Constants for the following material classes have been determined: • • • Carbon steel including base metal, PWHT, and non-PWHT material C-0.5Mo with low HTHA resistance, e.g. non-PWHT or annealed microstructures C-0.5Mo with high HTHA resistance, e.g. PWHT material and normalized microstructures Alternative models have been developed for modeling HTHA damage in low-alloy steels. These data sets include reported HTHA incidents that resulted in damage being found from inspection, leaks, ruptures, or fires. Application of Model 1 is relatively simple as factors such as applied loads are not considered at this stage. Stainless steel cladding/ weld overlay can reduce the effective hydrogen partial pressures and can be addressed by modeling a temperature dependent steady state hydrogen concentration profile. 29 Using this approach, a DI of 1 represents the average hot hydrogen exposure that resulted in damage in the incident data set. Margins on DI have been developed and are applied to set categories as outlined in Table 1. Application of the margins expressed graphically is shown in Figure 2b. DI categories have been linked to upper bound expected HTHA damage using full immersion literature data and the Advanced Assessment (higher level methods). The lower bound DI (0.1) is related to the initiation of HTHA damage in full immersion laboratory testing data. The upper bound DI (0.4) was set to mark the approximate start of the incident data for all material classes. ©2019 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole, must be in writing to NACE International, Publications Division, 15835 Park Ten Place, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of the author(s) and are not necessarily endorsed by the Association. 3 Advanced Assessments The Advanced Assessment is not a fitness-for-service (FFS) assessment in the truest sense per API 579-1/ASME (2) FFS-1 (API 579), as the current API 579 does not include HTHA damage assessment options. 30 However, it does use accepted FFS methods and principles to assist in understanding remaining life/likelihood of failure. Multiple FFS approaches have been considered for guidance in developing the Advanced Assessment. 30-33 Three methods to model through-wall damage progression are utilized: 1. Volumetric HTHA damage progression using Model 2, which is usually applicable to low or compressive stress conditions. 2. HTHA crack-growth using Model 3, appropriate for higher stress conditions, e.g. nonPWHT assets or assets with relatively low design margins. 3. Combined damage progression considering crack growth through volumetric HTHA damage. All procedures rely on the establishment of the minimum detection limit and the critical flaw size for the component, both of which are detailed in the following sections. A threshold for damaged material has been developed based on the through-wall mechanical properties of HTHA damaged components. 26, 34 Material considered to be "damaged” has a measurable loss in ductility and, for conservatism, is assumed to have no tearing resistance. This assumption appears consistent with the work from Dauskardt, Pendse, and Ritchie, which measured markedly reduced tearing resistance for even early stage damage. 35 Leak-beforebreak scenarios are not considered. Minimum Detection Limit The minimum detection limit is an estimate of the maximum flaw size that may go undetected in an inspection. This value depends on the type of flaw, the method of inspection, the geometry of the sample, and other factors. The recommended inspection intervals for a range of minimum detection limits can be generated and provides guidance for inspection planning activities. Critical Flaw Size The critical flaw size is established by use of either API 579-1/ASME FFS-1, June, 2016 Part 9 Level 2 or 3 assessments for a hypothetical flaw in the wall of the component or 50% of the wall thickness, whichever is less. Two important and conservative assumptions are used in establishing the critical flaw size: • • Bending stresses whether resulting from thermal expansion or sustained loads are treated as primary membrane stresses. The maximum stress is always used. The flaw length (2c) is assumed to be very long compared to its depth (a). The fracture toughness of the material ahead of the crack-tip is considered to be 100 ksi√in, which is the lower bound KIR curve for high-sulfur steels with unknown chemistry (see API 5791/ASME FFS-1 Annex 9F). Residual stress fields for PWHT and non-PWHT are estimated in accordance with API 579-1/ASME FFS-1 Annex 9D. 2 The American Society of Mechanical Engineers (ASME), Two Park Avenue, New York, NY, 10016. ©2019 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole, must be in writing to NACE International, Publications Division, 15835 Park Ten Place, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of the author(s) and are not necessarily endorsed by the Association. 4 Volumetric HTHA Damage Modelling Due to a through thickness hydrogen concentration gradient, damage is modeled initiating at or near the inner surface. At this location, the hydrogen concentration in the steel is expected to be the highest. This allows for the through-wall integration of Model 1 and results in an effective damage gradient from the inner surface (highest level of damage) to the outer surface (lowest level of damage). For the Advanced Assessment, the evolution of the damage gradient with time is considered to model volumetric or classical HTHA damage. The volumetric damage model (Model 2) is based on the observation that HTHA damage progression at any point through the thickness and at constant service conditions (temperature and hydrogen partial pressure) progresses linearly in time. Here we must be careful in regards to what the term “Damage” refers to. Recall that the DI determined in the Screening Assessment refers primarily to the relationship between the conditions seen in service and the known incident data such that a DI of 1 can be said to correspond to conditions that fall along the mean line of the incident data. For the level 2 assessment the calculated level of damage has been linked to a metallurgical interpretation of damage, as characterized by the percentage of damaged grain boundaries. A Damage Tolerance has been established, such that calculated damage less than the Damage Tolerance is considered to have no measureable loss of properties. Conversely, ductility is considered to be completely degraded if the calculated damage is greater than the Damage Tolerance. The depth of degraded material increases with hot hydrogen exposure time. HTHA Crack-Growth Modelling Model 3 is intended for establishing a reasonable inspection interval based on the time to grow a crack from a detection threshold to the critical flaw size. The crack growth rate has a form similar to Model 1, but incorporates the through-wall stress intensity and was fitted to data from Shewmon and Xue’s work. 25 Due to the limited HTHA crack growth data, an inherent HTHA resistance factor was applied to allow for consideration of alternative material classes. The differences between the Model 1 material classes were used to provide the inherent HTHA resistance factor for a given material class. Combined HTHA Damage Growth Approach Since the two damage growth approaches have different behaviors, the combined approach considered them each independently. Typically, volumetric damage progression initiates with a high growth rate, but slows with increasing amount of damaged wall fraction (damage depth). Conversely, crack growth initiates with a low growth rate and increases velocity with increasing crack size. INSPECTION PHILOSOPHY An inspection philosophy has been developed for HTHA damage that centers around progressive validation of damage. 5 Currently, industry does not have a singular, mature, and easily deployable non-destructive testing (NDT) technology that can detect all HTHA damage types with well-established minimum detection limits. As such, the authors have found utilization of multiple inspection techniques for the detection of HTHA damage to be beneficial. The main inspection methods utilized for the detection of HTHA damage are as follows: ©2019 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole, must be in writing to NACE International, Publications Division, 15835 Park Ten Place, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of the author(s) and are not necessarily endorsed by the Association. 5 • • • • • Acoustic emission testing (AET) pre-turnaround (either continuous monitoring or during shutdown) as a way to prioritize inspection locations and/or provide a layer of protection against an end of life type event Visual testing (VT) inspection of the internal surface for late stage HTHA damage (bulges and severe cracking) with oblique white lighting resulting in shadows from surface discontinuities High-sensitivity wet florescent magnetic particle testing (HSWFMT) optimized for the detection of HTHA damage Emerging advanced UT techniques: o Advanced methods of external time-of-flight diffraction (TOFD), o External phased array ultrasonic testing (PAUT) using full matrix capture (FMC) inspection with the total focusing method post-processing, o Beam forming PAUT Metallurgical extraction and examination (scoop sampling, boat sampling, full thickness sampling) to confirm the damage mechanism and validate NDT findings The first portion of the above inspection philosophy is centered around 1) high coverage NDT detection techniques, 2) sizing, and 3) validation with metallurgical examination. High coverage NDT techniques allow for inspection of a large percentage of the equipment and address the localized nature of the HTHA damage mechanism. Coverage extent is typically handled by qualitative discussions on risk and prioritizing high consequence locations (longitudinal welds) and high likelihood locations for vessels (nozzles, closure welds, weld repairs) and piping (flanges and highly stressed locations). If detected, indication depths are sized using FMC. Metallurgical extraction from the internal surface (scoop, boat, or full thickness window) is always recommended. If no damage is detected, metallurgical extraction and examination is still recommended and provides improved confidence that there is no damage in the equipment. If indications are detected, metallographic examination will confirm the damage mechanism and reduce the likelihood of a false positive. Additionally, the examination can qualify the sized FMC indications to a level of microstructural damage. Qualifying or bounding the edge of damage can be critical when trying to size damage as HTHA damage does not abruptly end, but rather gradually reduces in severity with volumetric damage or has discontinuous crack tips. HSWFMT for HTHA The authors’ experience and research performing WFMT for HTHA has determined surface preparation, application method, and interpretation are critical for delivering a HSWFMT inspection for HTHA. Surface preparation starts with abrasive blasting with garnet followed by smooth blending of welds, heat affected zone, and base material. Metal is then removed using rubber backed fiber discs with a final grind grit of 80 to 100. The surface roughness should not impair particle mobility. At minimum, 2 inches on either side of welds should be prepared. A depth of 0.030 inch (0.76 mm) to 0.090 inch (2.29 mm) of the wall thickness within the area to be inspected is removed during the surface preparations while ensuring the corrosion allowance is not exceeded. The final surface preparation step is to macro-etch the ground surfaces using three applications of 5% Nital in 3 minute intervals. Application of the HSWFMT method calls for extended durations of applied magnetic fluxes using an AC yoke and WFMT solution, typically 30 to 45 seconds. Multiple directions are utilized for both magnetic flux lines and WFMT solution flow. Non-aerosol based deployments of ©2019 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole, must be in writing to NACE International, Publications Division, 15835 Park Ten Place, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of the author(s) and are not necessarily endorsed by the Association. 6 HSWFMT solution as there is more particle control with the deployment. Prepared florescent particle to carrier solution ratios are in accordance with ASTM International (3) guidelines. It is important to ensure the ultraviolet (UV) light source intensity and wave length is correct. The background light limits should be checked and managed in the area of inspection. AC yoke strength should be checked frequently as long durations of use can cause overheating and lack of magnetic flux line strength. Finally, acute vision is essential for this inspection as indications can often be relatively fine. The inspector should be mindful of the clarity of their personal protective equipment (PPE) as smudged or dirty glasses and face masks can hinder visual detection of fine indications. The last portion of a HSWFMT inspection is interpretation and is considered to be the most challenging. HSWFMT indications can appear as indications consistent with macro-cracking. However, they can also appear as clusters of very fine indications with indication density and shape varying from cluster to cluster. Fine indication clusters have been detected in base metal, heat affected zones, and weld metal. Often, these indications appear as linear clusters in the heat affected zone adjacent to welds. Fine indication clusters should be verified with multiple HSWFMT solution flow directions. Indications should be removed between each solution flow direction application. CASE STUDY In 2016, a refinery from the Western US initiated a revamp of their HTHA program and began re-assessing the potential for HTHA damage in all of their assets. The process started with a review of equipment using process flow diagrams (PFD) and piping and instrumentation diagrams (P&ID) to identify carbon steel and C-0.5Mo steel equipment in hydrogen service. Maximum operating temperatures and maximum hydrogen partial pressures were determined. The beneficial effects of cladding were not considered. If the maximum temperature and maximum hydrogen partial pressure were within 100 °F (56 °C) of the appropriate carbon steel API RP 941 curve, the equipment priority was elevated and a Screening Assessment was performed. Hydrocracker Feed-Effluent Exchanger Background The review identified a Hydrocracker feed-effluent exchanger that operated as shown in Figure 3. The exchanger was PWHT C-0.5Mo steel with no cladding, which was in-service since 1966. In 2011 it was inspected using multiple NDT inspection techniques including: external advanced ultrasonic backscatter and spectrum analysis (AUBT/ABSA), external conventional PAUT, and internal WFMT. No damage was detected in the exchanger. Screening Assessment The Screening Assessment’s Model 1 was integrated using a Robinson rule approach over the exchanger’s shell side outlet (reactor feed inlet) operating conditions (Figure 3). The Instantaneous DI rate and cumulative DI are graphed over the provided data and the entire service in Figures 4 and 5. The average damage rate calculated over the data was then extrapolated over the service history resulting in a calculated DI of 5.4. The effective conditions are plotted relative to the C-0.5Mo PWHT HTHA incident data set in Figure 6a. Given the calculated DI was relatively high; it was considered that the equipment had a high likelihood of HTHA damage. 3 ASTM International, 100 Barr Harbor Drive, PO Box C700 West Conshococken, PA, 19328. ©2019 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole, must be in writing to NACE International, Publications Division, 15835 Park Ten Place, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of the author(s) and are not necessarily endorsed by the Association. 7 Advanced Assessment An Advanced Assessment of the vessel was performed to determine the degree of damage progression since the last inspection. HTHA crack growth based on a minimum detection limit of 20% of the wall to the critical flaw size is shown in Figure 6b. A preliminary critical flaw size of 0.78 inches (19.8 mm) was determined based on internal pressure in a cylindrical geometry with a long longitudinal crack. Sensitivity analyses using the most optimistic material properties (slowest crack growth) resulted in potential crack growth from below the detection limit to critical flaw size within 5 years – with a maximum recommend inspection interval of 2.5 years. To demonstrate continued safe operation of the equipment, on-line AET was immediately applied. AET detected signals on the long seam and inlet nozzle that were near or below typical minimum signal thresholds. No other reportable signals were detected. All detected signals were relatively low energy and were not consistent with a near end of life type scenario. On-line AET was then applied for the remaining 4 months until the next scheduled shutdown. HTHA Inspection Results and Exchanger Path Forward An extensive HTHA inspection was performed in 2017 on the exchanger and included the inspection techniques summarized in Table 2. NDT techniques that detected indications were the on-line AET, internal HSWFMT, FMC, and metallurgical extraction via scoop sampling. Initial inspections with AUBT/ABSA, conventional PAUT, and WFMT did not detect HTHA damage. The high-sensitive WFMT inspection detected indications on the long seam, multiple circumferential welds, inlet nozzle, and outlet nozzle. Indications appeared random along the long seam welds and almost continuous around the outlet nozzle. Indications were sized using FMC to be up to 0.5 inch (6.4 mm) deep on both the long seam and inlet nozzle. FMC screen capture of the long seam is shown in Figure 7. To confirm the damage mechanism and qualify the degree of damage relative to the output FMC signal, metal scoop sampling was performed. Scoop sampling involves removing a lens shaped volume of metal from the wall. API 579-1/ASME FFS-1 Part 4 local thin area (LTA) calculations were performed to determine acceptable scoop sampling depths that would not need to be repaired. Metallographic examination of the scoop samples confirmed the presence of HTHA damage in the long seam (Figure 8) and outlet nozzle (Figure 9). The long seam exhibited decarburization, grain boundary fissuring, and was relatively uniform in appearance for a given depth. This form of HTHA damage is considered to be volumetric HTHA damage. The nozzle damage exhibited crack-like HTHA damage that was dominated by fissuring, and cracking in the weld metal and heat affected zone (HAZ). Isolated slight decarburization was also observed. Cracking could be described as aligned fissures, branched cracking, and discontinuous in nature. An API 579-1/ASME FFS-1 Part 9 Level 3 was performed on the damage at the outlet nozzle. The damage was modeled as 0.5 inch (12.7 mm) deep cracking completely around the nozzle. The size of damage was larger than the critical flaw size and the vessel was retired from service. ©2019 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole, must be in writing to NACE International, Publications Division, 15835 Park Ten Place, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of the author(s) and are not necessarily endorsed by the Association. 8 SUMMARY Two assessment methodologies have been developed and provide owner/user’s a more detailed understanding of likelihood of HTHA damage and remaining life: 1) the Screening Assessment to determine the potential for HTHA damage based on equipment life cycle; and 2) the Advanced Assessment to better predict damage depth, damage manifestation type (crack versus volumetric), and rate of damage propagation. These methodologies address the time and stress dependency of HTHA damage, which are currently not explicitly addressed in API RP 941. Due to the historic challenges in detecting HTHA damage, the authors advocate utilization of multiple high-sensitivity inspection techniques to provide improved detection of HTHA damage. (a) (b) Figure 1: Graph (a) is reproduced from Weiner’s study and shows the effect of temperature on the incubation time, which represents the hot hydrogen exposure time to degraded mechanical properties. 2 Graph (b) plots the data from Figure 1a regressed using Model 1. (a) (b) Figure 2: Model 1 (a) assessment variables affect plotted points. Example graph (b) shows a new hypothetical component (red circle) with a DI < 0.0001. The red arrow indicates direction the equipment will follow as time increases at a constant temperature and hydrogen partial pressure. ©2019 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole, must be in writing to NACE International, Publications Division, 15835 Park Ten Place, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of the author(s) and are not necessarily endorsed by the Association. 9 Table 1 HTHA Damage Index Categories Category A B C D Damage Index Upper Bound HTHA Stage Description D=1 • Average hot hydrogen exposure that resulted in damage. D > 0.4 • Advanced HTHA damage progression has likely occurred. • Detection using advanced ultrasonic techniques is possible. • Component load carrying capacity has likely reduced and maximum potential depth of embrittled wall fraction has increased. 0.25 < D < 0.4 • Significant HTHA damage progression may have occurred. • Detection using advanced ultrasonic techniques is possible. • Component load carrying capacity may be reduced and inner surface likely embrittled. 0.1 < D < 0.25 • HTHA damage progression has occurred. • Detection using advanced ultrasonic techniques may be possible. • Component load carrying capacity may have been reduced and inner surface likely embrittled. D < 0.1 • Aligns well with full hydrogen emersion incubation testing data. • Single-sided HTHA damage initiation near the ID surface and may have caused inner surface to become embrittled. • Component load carrying capacity is essentially unaffected. Figure 3: Feed-Effluent Exchanger daily average temperature and hydrogen partial pressures for all retrievable dates in the distributed control system (DCS). Figure 4: Feed-Effluent Exchanger instantaneous DI rate is shown for the provided data. ©2019 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole, must be in writing to NACE International, Publications Division, 15835 Park Ten Place, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of the author(s) and are not necessarily endorsed by the Association. 10 Figure 5: Feed-Effluent Exchanger cumulative DI is shown from start of in-service. (a) (b) Figure 6: Effective conditions (red circle), based on provided temperature and hydrogen partial pressures for the hydrocracker feed-effluent exchanger plotted (a) relative to the timedependent PWHT C-0.5Mo data set. HTHA crack growth (b) from the minimum detection limit to the critical flaw size. Table 2 2017 Hydrocracker Feed-Effluent Exchanger Inspection Summary Applied NDT Technique AUBT/ABSA WFMT Conventional PAUT HSWFMT FMC Scoop Sampling Inspection Results No findings. No findings. No findings. Indications detected on long seams, multiple circumferential welds, inlet nozzle, and outlet nozzle. Indications detected on long seams, multiple circumferential welds, inlet nozzle, and outlet nozzle. Metallurgical examination confirmed that the detected HSWFMT and FMC indications were HTHA damage. ©2019 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole, must be in writing to NACE International, Publications Division, 15835 Park Ten Place, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of the author(s) and are not necessarily endorsed by the Association. 11 Figure 7: FMC screen capture showing the deepest damage on a long seam weld. Base metal near ID surface; Original magnification: 500X. Base metal 0.25 inch from ID surface; Original magnification: 1000X. Base metal near ID surface; Original magnification: 200X. Figure 8: Micrographs adjacent to the shell long seam showing volumetric HTHA damage with fissuring and decarburization in the base metal. Etchant: 2% nital. ©2019 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole, must be in writing to NACE International, Publications Division, 15835 Park Ten Place, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of the author(s) and are not necessarily endorsed by the Association. 12 Original magnification: 50X. Cracking in weld metal/HAZ. Original magnification: 200X. Cracking in weld metal/HAZ. Original magnification: 200X. Decarburization and fissures in HAZ. Original magnification: 1000X. Figure 9: Micrographs from the outlet nozzle-to-shell weld showing crack-like HTHA damage in the C-0.5Mo weld metal and HAZ. Etchant: 2% nital. ©2019 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole, must be in writing to NACE International, Publications Division, 15835 Park Ten Place, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of the author(s) and are not necessarily endorsed by the Association. 13 REFERENCES 1. G. Nelson, "Hydrogenation Plant Steels," in API 1949 Proceedings, Washington DC, 1949. 2. 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