Abstract
Waste heat boilers are widely used in the petroleum refining industry to improve energy efficiency. However, improper design, operation or maintenance of these boilers may result in costly failures. Cracking was found repeatedly at the same location on a circumferential weld of a certain waste heat boiler in CPC refinery. Hence a special designed fixture was used to avoid crack extension. Root cause mainly due to improper arrangement of internal tubes and external piping was then mainly found by thermal stress analysis. Recommendations was proposed to shut down the boiler immediately and to rearrange the tubes and piping without changing basic design of the waste heat boiler.
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