International Journal of Automation and Safety
Volume 4, Numéro 1, Pages 17-25
2026-07-23

Implementation Of Risk-based Inspection Approach On Catalytic Reformer Heater Tubes



Authors : Dib Khawla . Zennir Youcef . Bounezour Hichem . Berri Islem .

Abstract

This paper presents a case study on reformer heater tubes in a refinery using a Risk-Based Inspection (RBI) methodology to optimize inspection planning according to the probability and consequences of failure. The study aims to evaluate the integrity and reliability of the heater tubes by identifying the most critical degradation mechanisms affecting their performance under severe operating conditions. The assessment focused on radiant tubes exposed to high temperatures, internal pressure, cyclic thermal loading, and corrosive environments. Several damage mechanisms were analyzed, including wall thinning caused by oxidation and corrosion, thermal fatigue resulting from repeated heating and cooling cycles, and creep deformation due to long-term exposure to elevated temperatures. These degradation processes significantly affect the structural integrity and remaining life of the tubes. The RBI analysis showed that radiant tubes are subjected to high-risk damage parameters, making them highly susceptible to failure. Among the identified mechanisms, creep and thermal fatigue found to be the most critical factors influencing tube deterioration and operational risk. The calculated risk levels indicated that extending the inspection interval to 36 months would not ensure adequate safety and reliability. Based on the obtained results, an optimized inspection interval of approximately 1.41 years recommended allowing early detection of degradation and reducing the risk of unexpected failures. The proposed RBI-based strategy improves maintenance efficiency by prioritizing inspections on critical components while minimizing unnecessary inspection activities. Overall, the study demonstrates that the implementation of RBI methodology enhances refinery safety, equipment reliability, and asset integrity management. In addition, it contributes to reducing unplanned shutdowns, maintenance costs, and operational risks, ensuring safer and more efficient refinery operation

Keywords

Risk based inspection ; damage mechanism ; failure ; heater tubes ; API 580.

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