Heat Exchanger Failure, Boiler Failure, Tube Sheet Failure

Heat Exchanger Failure, Boiler Failure, Tube Sheet Failure

 Heaters, Boilers, Tube Sheet and Heat Exchanger Failures

Heaters, Boilers, Heat Exchanger and associated piping operate under various kinds of static and dynamic stresses, both thermal and mechanical. In addition to this the type of fluid plays an important role in analyzing such failures. The fluids flow at high velocity and many a times under turbulent conditions. Induced thermal stresses and vibrations demand careful selection of material and design. Failure in such equipment can occur due to both manufacturing deficiencies and operational mistakes among other factors. ITS metallurgists and engineers have hands on experience in refineries and petrochemicals and understand exactly how the equipment operates under normal and abnormal conditions. ITS failure analysts have top-notch expertise in analysis of heaters, boilers, heat exchangers, pressure vessels, reactors, drums, storage tanks and other ancilliary equipment. ITS personel have analyzed failures due to creep, fatigue, corrosion, hydrogen damage, stress corrosion cracking, wear etc. for refineries, research outfits, and chemical companies. ITS investigation on Heaters, Boilers and Heat Exchanger and associated piping involves detailed analysis of the various parameters that may have led to the failure of the equipment. Our approach for failure analysis may include

  • The study of design parameters
  • Chemical analysis of the material of construction
  • Process by which equipment was made
  • Operation parameters at which equipment was been used and how long
  • Visual examination/fractography
  • Dimensional measurements
  • Microscopic examination of material samples
  • Mechanical Tests
  • Scanning Electron Microscopy and Energy Dispersive Spectroscopy

Based on all our observations and analysis, the client is provided with the detailed report that is conclusive, accurate and well illustrated for technical and non technical readers.

Some of the recent failures analyzed were:

  • Failure of a green house boiler that failed due to fabrication mistakes
  • An eleven section residential boiler that failed because of water starvation
  • Floating head bolts of eight heat exchangers that failed soon after chemical cleaning
  • An oil pump that failed due to wear by solid contaminants
  • A critical pipe line reducer that failed from excessive flow velocities.


Heat Exchanger Failure, Boiler Failure, Tube Sheet Failure

A tubular reactor that failed in service by hydrogen attack. Wrong material of construction was found to be the primary cause of failure