Just to start supporting your idea, petrochemical plants are sitting on massive amounts of operational data… but only a small fraction is actually converted into actionable predictive reliability or integrity intelligence.
Most sites still operate in a “reactive + preventive” mode:
Alarm happens ...

This is required to be connected with defining & reporting exceedances in integrity operating windows, as you clearly mentioned.
IOWs are recognized to ensure integrity of the equipment, and there has to be a review process through which they must be added /modified as needed.
I understand that not ...

Do you have any reference of performing sleeving for finfan tubes upon corrosion?
I understand if damage is uniform and spread at a larger area, sleeving may not be appropriate.

arcpro,
What are the conditions which could lead to internal corrosion, and are there are repair methodology once tube leaks /ruptures are identified?

Thanks luca

luca wrote: 09 May 2026, 08:16 Published in AICHE, back in 2012.

I would recommend that you consider the following before modifying line size:
Map exact blockage locations
Perform IR thermal survey during operation
Review minimum-flow cases
Verify steam trap functionality
Check slopes and pockets
Calculate velocity before/after upsizing
Run hydraulic + thermal ...

Let me just add here "like-to-like" assumptions of many of our colleagues.
This is one of the classic weakness which Operations engineers can catch as something labeled “replacement in kind” may still introduce:
Different vibration characteristics
Altered control response
Different dead volume ...

I was just thinking about badd transmitters which can indirectly create vibration through faulty flow indication, incorrect level, bad pressure reading, and drifting temperature sensor.
Operators then unknowingly push machine into low-flow region, cavitation, surge margin loss, and unstable ...

What are the most common failure modes observed in air cooled fin fan heat exchangers in hydrocarbon service?

A gradual rise in differential pressure is one of the best early indicators.
Deposits reduce flow area:
tube-side fouling leads to higher tube velocity resulting in ΔP rises
shell-side fouling leads to shell restriction increases
Sometimes duty still appears acceptable because operators compensate ...