The 7 Shutdown Checks Your Reformer Tubes Must Pass

 A Practical Guide for Maintenance, Reliability, and Operations Teams by Uni Abex

In high-temperature industrial systems like Steam Methane Reforming (SMR), Direct Reduced Iron (DRI), and ethylene cracking, reformer tubes are the lifeblood of the operation. But even the most robust components demand attention—especially during a planned shutdown.

So, the critical question is: Are your reformer tubes ready for another operating cycle?

Shutdowns offer a rare opportunity to identify potential threats before they become failures. This guide outlines 7 essential checks every plant team must conduct:

Cross-section showing carburized, oxidized, and healthy sections of a reformer tube during shutdown inspection.

1. Visual Inspection for External Defects

Begin with high-powered lighting and borescopes to spot:

• Discoloration indicating hot spots

• Swelling, bulging, or deformation

• Visible cracks near welds

👉 Tip: Log visual findings with photos for comparative monitoring.

2. Dimensional Checks for Bulging or Ovality

Use calibrated tools or lasers to detect loss of circularity. Bulging often means internal pressure buildup or metal creep.

Best practice: Compare with past records to track acceleration.

3. Hardness Testing (Surface & Through-Wall)

Helps identify:

• Carbon migration

• Flame-zone embrittlement

Test zones: Tube bends, radiant sections, high-heat zones.

4. Infrared Thermography

Use IR cameras to spot temperature irregularities and flame impingement zones. Residual discoloration often matches thermal stress patterns.

5. Ultrasonic Thickness Gauging (UTG)

Detect mid-wall corrosion and oxidation:

• Uneven thinning

• Thinning near burners or welds

Track thickness trends to forecast remaining tube life.

6. Weld Zone Inspection

Welds are stress points—look for:

• Microcracks from thermal fatigue

• Metallurgical mismatches

Test methods: Dye Penetrant (DPT), UT, and visual inspection.

7. Internal Oxide Scaling or Spalling

Internal inspections may reveal:

• Dusty flakes

• Dislodged metal

• Roughened inner surfaces

These signs point to compromised metallurgy and contamination risks.

Why Prevention Is Cheaper Than Repairs

Even high-grade alloys can deteriorate under changing conditions or if early signs are ignored. These inspections are critical—not just for compliance—but for plant longevity, safety, and cost-efficiency.

At Uni Abex, we specialize in cast components tailored for high-performance environments. Our Reformer Tubes & Catalyst Tubes are engineered for maximum durability, reliability, and serviceability.

If your plant faces recurring tube failures or you're planning a revamp, we’re here to support your mission with technical insight and engineering precision.

Common reformer tube defects: surface cracks, oxide scaling, and bulging with heat-induced discoloration.

🛠️ Downtime is costly. Missing early warnings is costlier.

Now is the time to build a detailed inspection record for every reformer tube—because metallurgy always leaves clues. You just need to know where to look.

Stay ahead. Stay reliable. Choose Uni Abex.