This paper explains the cause of the failures, the follow up incident investigation and the actions taken to prevent recurrence of a similar failure. This case study details the failure of recently replaced inlet pigtail pipes for a hydrogen reformer furnace. The pigtail connection to the catalyst tube consisted of a ASME A-335 P22 pipe welded to an Incoloy 800HT weldolet. The weldolet was joined to the catalyst tube, which was an HP Modified. By Manikandan Palanisamy, Lead Engineer - Asset Integrity at OQ Base Industries, Ali Al Zawamri, Asset Integrity Manager at OQ Base Industries, and Abdullah Al Balushi, Asset Integrity Engineer at OQ Base Industries. A welded manifold pipe in a primary steam reformer used to transport hydrogen gas at about 873°C developed leakage in the weld fusion zone after about 22,000 h of operation. Agrium's Ammonia Plant #2 is located near Redwater, Alberta, Canada and the plant produces about 680 KMT per year of ammonia that is used to produce. The nipping of the pigtails is exercised and performed under slightly reduced plant load. Certain routines were established to do the nipping exercise in the safest way, having no leakages to the surroundings, nor endangering the people involved. However during one nipping exercise an outlet. Bulk hydrogen production in a petroleum refinery by steam–methane reforming (SMR) utilizes high temperatures, moderate pressures and catalyst – filled tubes which generate high tube temperatures of up to 920 °C [1,690 °F ]. Creep and pressure / temperature cycling imposes severe loading on the.