e°0e° eran J Ladd lad ced ad ed ded lade ee eerie crip eiee BRC-CORP 37-74.F st secu 13,_CREEP_RUFIUKE Definition of the Problen Creep is time-dependent strain occurring at elevated tenperature under the influence of stress. The rate at which a material will creep ie dependent upon ite etrength, the stress imposed, and the temperature. ‘The magnitude of creep incurred, therefore, depends upon the length of time in which the material was creeping. When a material is subjected to a constant stress at an elevated temperature, the resulting strain occurs initially at a decelerating rate; this 1s designated "first stage creep". Subsequently, when the creep rate becones essentially constant, it is referred to as “second stage creep". Finally the creep rate begins to accelerate (third stage creep) and, if the process 16 not interrupted, rupture occurs. The three stages of creep are represented graphically in Figure 13-1. When metal equipment is designed for elevated temperature operation, a stress level is chosen which will permit an arbitrary amount of creep to occur. Although common design criteria are "stress to produce 1% creep in 100,000 hours" and “stress to produce rupture. in 100,000 hours", other values may be employed. Ideally, this approach for equipment design should not cause difficulties. However, in operation, conditions may exist for a short or long period of time which place the component at higher-than-design stress and temperature levels, Such conditions may promote excessive creep and premature rupture, Creep rupture failures are most frequently encountered in tubes in process heaters, boilers, steam superheatere, steam reformers, and pyrolysis heaters. However, any application in which the metal is operated in the creep range (temperature range in which metal under stress deforms with time) and is stressed continuously must be regarded as possible location for eventual creep failure. A typical creep rupture failure in a steel heater tube is show in Figure 13-2. Metallographic features characteristic of creep rupture failure are shown in Figure 19-3. The region around tne fracture exnabite extensive intergranular tearing. In a more brittle material, auch ax alloy HKA4O used for pyrolyste tubes and catalyst tubes in stean reformer heaters, rupture failures are accompanied by only moderate over-all deformation and extensive internal cracking (Figure 13-4). Methods of Checking for the Problem vecermining 4f creep of an item of equipment nas occurred 18 most effectively accomplished by visual examination and direct measurement for most materials. For example, heater tubes may be calipered during each maintenance chutdewn of the unt. Again, however, dn the cace of brittle materials such as HK-40, the onset of third stage creep can occur52 BRC-CORP 97-74.F aU 0.5 to 1.0% diamecrie giowel, and fLeld weasurewents of Lube diaueter may be insufficiently sensitive to reveal creep. Creep damage of such tubes (empty of catalyst) can usually be detected by means of radiography, in-place metallographic examination, or ultrasonic testing. Methods of Eliminating the Problem Creep can be controlled or eliminated by proper choice of materials for high temperature applications and by operating the equipment at or below design conditions at all times. Pitfalls After a design condition for a high temperature application, such as a process heater tube, has been chosen and the equipment is placed in service, performance may be totally satisfactory. However, if the stream being heated is capable of depositing coke or other solid matter on the inside wall of the tube, heat transfer can decrease and an overheated condition can result. The higher tube wall temperature in turn can promote increased deposition and if the process continues, the ‘ube will rupture. If che foregoing sequence occurs rapidly, a “short time" (non-creep) rupture will result, Short time ruptures usually are accompanied by considerable bulging and localized plastic deformation in the fracture zone, wheraae oreep rupture failure exhibit more apparent brittleness in the fracture and less bulging. In some cases, conditions which lead to the failure are varied and complex and indications of both creep and short time ruptures are observed. An accurate diagnosis requires not only a thorough examination of the failure but also careful consider~ ation of information available concerning design, operation, and previous history of the equipment in question. ecece cocesceete Ri veccccccccccccs 8.BRC-CORP 37-74-F Second-stage creep % Vlongation. —» S EAccelerated creep and final fracture Creep data useful in engineering design Initial strain Time —» Figure 13-1 ‘Typical Creep Behavior Showing the Relation of the Useful Portion of a Creep Curve to the Eventual Fracture of the Allov FaFigure 132 Twoical Cream Runture of a Carhon Steel Tube Magnification: | 14X. BRCCORP 37-74.F a Seco ce ccc ecccebcccsacce cceccestuee.