All six installed reduction reactors showed the same failure pattern, which can be attributed to inadequate original design, material degradation due to service conditions and improper maintenance activities. Service is typically low frequency fatigue load conditions with changes of pressure, temperature and batch load. All revealed defects severely affected the integrity of the pressure envelope and vessels were classified for major repair work with subsequent in situ monitoring program. The justification for such extensive and costly repair required a positive evaluation of the current condition of equipment. After complete study, a report was prepared which included the fitness for purpose evaluation, remaining life assessment and recommendation for future field inspections. All reactors were found to be suitable for repair. Within the scope of repair a number of critical elements were redesigned and replaced. The repair was successful and all reactors were put back into operation. Unique expertise was obtained regarding setting the parameters of dehydrogenation in reference to the heavy wall items. Taking replicas and surface sampling appeared to be very reliable and simple tools in monitoring the condition of pressure envelope. For the purpose of future inspection shutdowns specific inspection requirements were put in place to ensure continuous monitoring of the vessel integrity.