Journal of Failure Analysis and Prevention

, Volume 11, Issue 6, pp 611–617 | Cite as

Repair of Tube–Tubesheet Weld Cracks in a Cracked Gas/Steam Heat Exchanger

  • Shaker Adullah
  • Hosni M. Ezuber
Case History---Peer-Reviewed


Serious cracks were found at tube-to-tubesheet welds during the start up operation of a cracked gas/steam heat exchanger in a gas plant. The cause of the failure has been analyzed, and the exchanger is repaired. The root cause of the cracks is mainly attributed to poor workshop in the tube–tubesheet welds. Failure analysis and repair procedure were reported in the present article. Several months of operation after the repair confirmed that the repair was successful.


Heat exchanger failures Tube-to-tube joints Weld cracks 


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Copyright information

© ASM International 2011

Authors and Affiliations

  1. 1.Ramsis Engineering East RiffaBahrain
  2. 2.College of EngineeringUniversity of BahrainIsa TownBahrain

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