Investigation Analysis of Crude Distillation Unit (CDU) Fired Heater’s Tubes Thinning

Hydrocarbon leak from fired heaters tube while in operation in petroleum refining and petrochemical plants is a safety concern and cause economic impactImpact of operating plant due to unplanned shutdown. Fired heaters tubes leak or rupture can be caused by several factors. One of the causes of fired heater tube leaks is due erosion that will cause tube thinning and subsequently leak while in operation. The tube thinning also will expedite the tube leak which operating in normally operating and creep region. This concern can be avoided by designing out the erosion flow region during design and conduct scheduled thickness inspection at concerned location during shutdown as a preventive measure. This paper is to share actual experience of thinning tubes at CrudeCrude Distillation Unit (CDU) Fired heaters tubes after years of operation when the plant inspection team conducted thickness checking and found several localized thinning at a few locations.