Session: MF-20-02 Material Quality and Failure Analysis-2

Paper Number: 125453

125453 - Analyses, Mitigations and Reflections From Hydrogen Embrittlement Failure of a Duplex Stainless Steel Reactor Effluent Air Cooler (Reac) in Hydrocracker Service 

During the start up following an outage for a major turnaround, there was a leak that occurred on a Duplex Stainless Steel Reactor Effluent Air Cooler. This air cooler was on a hot high pressure separation circuit in a refinery hydrocracker unit.  Following the leak, there was a detailed failure investigation that was conducted. The failure investigation revealed that the leak had occurred as a result of hydrogen embrittlement cracking. While the susceptibility of duplex stainless steel Reactor Effluent Air Coolers to hydrogen embrittlement has been previously attributed to certain specific features from manufacturing among others, over the past few years there has been emerging knowledge in the oil refining industry of duplex material with hydrogen embrittlement damage, despite their having the controls in place during manufacturing stages. This paper will discuss the case history of the leak on the duplex stainless steel Reactor Effluent Air Cooler, including the details of the failure analyses and the engineering evaluation conducted on the duplex stainless steel. This paper will also discuss some of the mitigations that were put in place and as well as provide reflections on the mode and mechanism of hydrogen embrittlement damage observed in the duplex stainless steel material. 

Presenting Author: Allie Hosack Shell Canada Ltd.

Presenting Author Biography: Allie started with Shell in 2017 as an intern, and came back full time in 2019 following her graduation from university. Allie is part of the pressure equipment integrity team, in the materials and corrosion discipline. She graduated from the University of Alberta in 2019 with a Bachelor of Science in Materials Engineering Degree.

Authors:

Allie Hosack Shell Canada Ltd.
Oluwaseun Idowu Shell Canada Ltd
Jordan Barrass Shell Canada Ltd
Jorge Penso Shell Global Solution (US) Inc.
Wesley Pudwill Shell Global Solution (US) Inc.
Mitul Dalal Shell Global Solution (US) Inc.