A great number of heavy wall hydroprocessing reactors for oil refining processes have been installed in the refineries all over the world in the past 50 years. These reactors are made from heavy wall Cr-Mo steel with stainless steel weld overlay cladding and are suitable for high pressure/high temperature hydrogen services. During past half century, manufacturing technologies such as those for design, materials, welding and NDE have seen remarkable advances based on feed back from operational experience. This paper summarizes the generation changes of manufacturing technologies and considerations for appropriate maintenance and inspection in order to provide for the safe operation of heavy wall hydroprocessing reactors.

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