Reformer Tube Failures Explained: A Practical Guide for Engineers

 Identifying, Preventing, and Overcoming the Most Common Reformer Tube Challenges in Industrial Plants

In industrial environments like petrochemical refineries, DRI plants, ethylene crackers, and fertilizer units, reformer tubes work relentlessly under extreme thermal and mechanical loads. Operating beyond 800°C with fluctuating pressures, these tubes are critical to the success of high-temperature reforming processes. But when they fail, it’s more than downtime—it’s a direct hit to safety, efficiency, and profitability.

Illustration showing carburization and oxide layer formation in reformer tubes under extreme conditions.

In this guide, we explore the top reformer tube failure modes, how to spot them early, and the proven preventive measures trusted by industry leaders.

1. Creep Damage

• Visual clue: Gradual deformation over time.

• Why it matters: At extreme temperatures, alloy microstructures deteriorate, causing elongation, wall thinning, and cracks.

• Prevention tip: Monitor tube ovality and bulging using dimensional gauges during shutdowns.

2. Carburization

• Visual clue: Surface hardening, brittleness, and internal spalling.

• Why it matters: Carbon-rich gases penetrate the alloy, reducing ductility and initiating cracks.

• Prevention tip: Use alloys with carburization resistance and perform periodic hardness checks.

3. Hot Spots

• Visual clue: Localized discoloration and pitting.

• Why it matters: Uneven heating accelerates creep damage even if average temperatures seem safe.

• Prevention tip: Employ infrared thermography to detect burner issues early.

4. Bulging & Ovality

• Visual clue: Distorted tube profiles—either bloated or oval.

• Why it matters: Often signals internal overpressure or advanced creep.

• Prevention tip: Track profile changes with digital scanning tools.

5. Oxidation & Surface Scaling

• Visual clue: Flaky oxide layers and rough surfaces.

• Why it matters: Erodes protective alloy layers, reducing service life.

• Prevention tip: Select high-chromium alloys for better oxidation resistance.

6. Weld Failures

• Visual clue: Cracks at weld seams.

• Why it matters: Poor welding or dissimilar metals accelerate failures.

• Prevention tip: Perform ultrasonic or dye penetrant testing during shutdown inspections.

Best Practices for Prevention

• Choose high-performance alloys with improved creep and carburization resistance.

• Use digital twins and predictive analytics for early degradation detection.

• Conduct visual & NDT inspections at every shutdown.

• Implement root cause failure analysis (RCFA) to guide future design and operations.

Visible crack on reformer tube surface caused by creep and thermal stress over prolonged operation.

Uni Abex – Your Reformer Tube Reliability Partner

At Uni Abex Alloy Products Limited, we deliver centrifugally cast reformer tubes engineered for the harshest operating conditions. Backed by decades of metallurgical expertise and stringent QA/QC processes, our solutions are built to last longer and perform better.

If your plant is facing premature tube failures or you’re planning an upgrade, our experts can decode, diagnose, and design for durability. Learn more about our proven capabilities here:
🔗 www.uniabex.com