{"id":1051,"date":"2019-01-22T22:44:49","date_gmt":"2019-01-22T22:44:49","guid":{"rendered":"http:\/\/johnbrear-plantintegrity.com\/?page_id=1051"},"modified":"2019-01-22T22:47:27","modified_gmt":"2019-01-22T22:47:27","slug":"failure-of-an-hk40-heater-support-system","status":"publish","type":"page","link":"https:\/\/johnbrear-plantintegrity.com\/?page_id=1051","title":{"rendered":"Failure of an HK40 heater support system"},"content":{"rendered":"<p>&#160;<figure id=\"attachment_1052\" aria-describedby=\"caption-attachment-1052\" style=\"width: 425px\" class=\"wp-caption alignright\"><img fetchpriority=\"high\" decoding=\"async\" src=\"http:\/\/johnbrear-plantintegrity.com\/wp-content\/uploads\/2019\/01\/Heater-supports-PM.jpg\" alt=\"\" width=\"425\" height=\"305\" class=\"size-full wp-image-1052\" srcset=\"https:\/\/johnbrear-plantintegrity.com\/wp-content\/uploads\/2019\/01\/Heater-supports-PM.jpg 529w, https:\/\/johnbrear-plantintegrity.com\/wp-content\/uploads\/2019\/01\/Heater-supports-PM-300x216.jpg 300w\" sizes=\"(max-width: 425px) 100vw, 425px\" \/><figcaption id=\"caption-attachment-1052\" class=\"wp-caption-text\">HK40 tube support<\/figcaption><\/figure><\/p>\r\n<p><strong>Item:<\/strong><\/p>\r\n<ul>\r\n    <li>HK40 support system in a catalytic reformer heater at a UK refinery<\/li>\r\n<\/ul>\r\n<p><strong>Problem: <\/strong><\/p>\r\n<ul>\r\n    <li>Two of the eight high temperature (980\u00b0C) radiant section supports had failed, leaving the remaining six to support the full load<\/li>\r\n    <li>Supply of replacement HK40 material has a lead time of two months<\/li>\r\n<\/ul>\r\n<p><strong>Objective:<\/strong><\/p>\r\n<ul>\r\n    <li>Fitness for service and remaining life assessment to consider whether the surviving supports could sustain the load until a convenient time for replacement<\/li>\r\n<\/ul>\r\n<p><strong>Approach:<\/strong><\/p>\r\n<ul>\r\n    <li>Removal of failed supports from operating heater<\/li>\r\n    <li>Metallographic examination revealed failure to be by creep<\/li>\r\n    <li>Creep life assessment predicted that the remaining life of the current supports, subjected to the higher support loads, to be a matter of days, or even hours<\/li>\r\n<\/ul>\r\n<p><strong>Solution: <\/strong><\/p>\r\n<ul>\r\n    <li>24 hour monitoring of remaining supports instigated<\/li>\r\n    <li>Plant immediately put into condition for most economic safe shutdown<\/li>\r\n    <li>An alternative material to HK40 proposed for support replacement and new supports constructed in days<\/li>\r\n<\/ul>\r\n<p><strong>Outcome:<\/strong><\/p>\r\n<ul>\r\n    <li>Failure of third support two days later<\/li>\r\n    <li>Heater immediately shut down safely<\/li>\r\n<\/ul>\r\n<p><strong>Benefits:<\/strong><\/p>\r\n<ul>\r\n    <li>Catastrophic failure of heater, with associated consequential loss, avoided<\/li>\r\n    <li>Alternative solution to existing long lead time material procurement<\/li>\r\n    <li>Safe shutdown and monitoring processes identified and implemented<\/li>\r\n<\/ul>","protected":false},"excerpt":{"rendered":"<p>&#160; Item: HK40 support system in a catalytic reformer heater at a UK refinery Problem: Two of the eight high temperature (980\u00b0C) radiant section supports had failed, leaving the remaining six to support the full load Supply of replacement HK40 material has a lead time of two months Objective: Fitness for service and remaining life &hellip; <a href=\"https:\/\/johnbrear-plantintegrity.com\/?page_id=1051\" class=\"more-link\">Continue reading <span class=\"screen-reader-text\">Failure of an HK40 heater support system<\/span> <span class=\"meta-nav\">&rarr;<\/span><\/a><\/p>\n","protected":false},"author":1,"featured_media":0,"parent":155,"menu_order":5,"comment_status":"closed","ping_status":"closed","template":"","meta":{"footnotes":""},"class_list":["post-1051","page","type-page","status-publish","hentry"],"_links":{"self":[{"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/pages\/1051","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=1051"}],"version-history":[{"count":3,"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/pages\/1051\/revisions"}],"predecessor-version":[{"id":1055,"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/pages\/1051\/revisions\/1055"}],"up":[{"embeddable":true,"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/pages\/155"}],"wp:attachment":[{"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=1051"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}