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Uncertainty in Damage Assessment and Remaining Life Prediction of Engineering Materials Used In Petrochemical Industry | OMICS International | Abstract

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Research Article

Uncertainty in Damage Assessment and Remaining Life Prediction of Engineering Materials Used In Petrochemical Industry

Ray AK1*, Roy N1, Raj A2, Matwa M3, Davuluri A3, Kumari A4, Kumar P5, Mundhada D6, Kaushal V3 and Roy BN7
1Materials Science and Technology Division, CSIR-NML(National Metallurgical Laboratory) PO-Burmamines, Jamshedpur-831007, India
2R.V.S. College of Engineering and Technology, Jamshedpur-831012, India
3Indian Institute of Technology, Kharagpur-721302, India
4Indian Institute of Technology, (BHU) Varanasi-221005, India
5National Institute of Technology, Rourkela-769008, India
6National Institute of Technology, Warangal-506004, India
7Bihar Institute of Technology, Sindri-828123, India
Corresponding Author : Dr. Ashok Kumar Ray
Chief Scientist and GL/ Head of Materials Testing and Evaluation Section (Creep, Fatigue & Fracture)
Materials Science and Technology Division
CSIR-NML(National Metallurgical Laboratory) PO-Burmamines, Jamshedpur-831007, India
Fax: 91-657-2345213
E-mail: [email protected]
Received June 06, 2014; Accepted July 22, 2014; Published July 30, 2014
Citation: Ray AK, Roy N, Raj A, Matwa M, Davuluri A, et al. (2014) Uncertainty in Damage Assessment and Remaining Life Prediction of Engineering Materials Used In Petrochemical Industry. J Pet Environ Biotechnol 5:181. doi:10.4172/2157-7463.1000181
Copyright: © 2014 Ray AK, et al. This is an open-access article distributed under the terms of the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited.


In this paper creep damage assessment of about 11 years’ service exposed HP-40 grade of steel used in hydrogen reformer of a petrochemical industry has been carried out in terms of a discontinuous Markov process. Experimentally determined conventional creep data under identical testing condition were used in the present investigation. Scatter and damage accumulation due to creep deformation were evaluated through microstructural assessment using light optical microscope and scanning electron microscope. Quantification of creep damage was made from replicated creep data in terms of two damage parameters A and A*. Statistical analysis of void area fraction has been carried out extensively for the both top and bottom portions of the reformer tube at 870 o C in the stress range of 52-68 MPa. In addition, the proposed probabilistic model has been compared with the Kachanav’s Continuum Damage Mechanics (CDM) model. Both the approaches displayed quantitative experimental support. A residual life of ⟩ 10 years is estimated at 870 o C/ operating stress. For 55 years’ service exposed Catalytic Cold Cracking (CCU) reactor vessel and Feed Processing Unit (FPU) distillation column materials of a petrochemical industry remnant life assessment studies were estimated by incorporating the uncertainty involved in calculation of LMP (Larson Miller Parameter) values and from extrapolation of stress vs. LMP plot. Variability of normalized creep damage for reactor and column materials is well approximated with the aid of Weibull distribution. As expected, it is observed that the distributions shift towards the higher range of damage with increase in service exposure time.


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