Monitoring and Replacing IN 519 Catalyst

Tubes of Steam Reformer

After 11 years of efficiënt operation, the steam reformer had to be s hut down
completely. This article discusses its maintenance history as well as lessons learned
from its shutdown and replacement problems.

Mahmoud M. Hamza
Abu Qir Fertilizer and Chemical Industries, Alexandria, Egypt

INTRODUCTION: OPERATION IS TO USE THE EQUIPMENT AS

IN 519 CATALYST TUBES OF STEAM REFOR- LONG AS THEIR MATERIALS REMAIN SERV-

MER H A V E BEEN USED IN OUR PLANT SINCE ICEABLE.

1979 EFFICENTLY FOR ABOUT 11 YEARS. WE REPLACED THE CATALYST TUBES BY A

THE REFORMER IS UHDE DESIGN TOP FIRED NEW SET OF UP GRADED MATERIAL 36X FOR

HAS 288 TUBES ARRANGED -6 ROWS EACH ECONOMIC CONSIDERATIONS WHICH W I L L BE

OF 48 TUBES. NO FAILURES HAVE BEEN DISCUSSED IN DETAIL.

DETECTED IN ANY OF THE TUBES D U R I N G THE SCHEDULED REPLACEMENT WAS CARRIED

THE S E R V I C E LIFE. PROCESS PARAMETERS OUT W I T H I N 15 DAYS I N C L U D I N G LIFTING

PLAYED AN IMPORTANT ROLE IN PROTECT- OLD ONES INSTALLING THE NEW TUBES,

ING THE TUBES AGAINST FAILURES. GOOD WELDING INSPECTION F I L L I N G THE CATAL-

CONTROL FOR THE TEMPERATURE INSIDE YST.

THE FIRE BOX. THE CATALYST IS REGULA- LESSONS LEARNED FROM SUCH EXPERINCE

R L Y CHANGED EVERY 2 - 3 YEARS. WILL BE SUMMERIZED.

M I N I M I Z I N G THE N U M B E R & SEVERITY OF
THERMAL CYCLING. DETAILED DESCRIPTION OF THE PRIMARY

ALTHOUGH THE RECENT TREND OF PLANT REFORMER:

36
THE PRIMARY REFORMER IS DESIGNED AS * FEED STOCK NATURAL GAS AND STEAM

A BOX TYPE FURANCE WITH 6 VERTICAL * ENGINEER OF PLANT UHDE, W. GERMANY

ROWS OF 48 TUBES EACH.

* DESIGN OF THE REFORMER
TO INSURE A UNIFORM HEATING OF THE
A- ONE FIRE B O X .
REFORMER TUBES A TOTAL OF 120 FORCED
B- BURNERS L O C A T E D IN THE TOP (DOWN
DRAUGHT B U R N E R S ARE ARRANGED IN THE
FIRING T Y P E ) , 7 ROWS BETWEEN EACH
REFORMER C E I L L I N G IN 7 ROWS.
OF 6 ROWS OF TUBES.
THE BURNER FLAMES ARE VERTICAL AND
C- FUEL: NATURAL G A S .
BURN DOWNWARDS. FLUE GAS DUCTS ARE
* ARRANGEMENT OF THE T U B E S :
A R R A N G E D BETWEEN THE TUBE ROWS ON
6 ROWS, EACH W I T H 48 TUBES OF T O T A L
THE R E F O R M E R BOTTOM.
THE FLUE GASES ARE WITHDRAWN THROUGH 288 TUBES. PROCESS FLOW FORM THE

TOP TO THE B O T T O M .
SLOTS IN THE SIDE WALLS OF THE DUCTS
AND FED TO THE WASTE HEAT R E C O V E R Y * MATERIALS AND DIMENSIONS:

SYSTEM. MATERIAL 24 CR 24 NI Nb

THE R E F O R M E R TUBES ARE C E N T R I F U G A L L Y SUPPLIER FAM

CAST FROM AN ALLOY IN 519 CONTAINING ID 110 - 0.5

24 CR%, 24 NI, 0.3 %C & 1.5 Nb. THE OD 114 1.5 MM

FEED STOCK ENTERS THE CATALYST FILLED WALL THICKNESS 17 MM, IN SIDE
TUBE THROUGH THE INLET PIGTAIL WHICH MACHINED 12 RMS
IS WELDED DIRECTLY TO THE REFORMER HEATED LENGTH 10 METERS = 10,000 MM
TUBE BLIND FLANGE.
THE HIGH ALLOY REFORMER TUBE AND THE B- PROCESS AND OPERATION CONDITIONS:

HEADER ARE INTERCONNECTED BY MEANS OF * TUBE SKIN TEMPERATURE 910

AN INTERMEDIATE PIECE MADE OF CARBON °C DEPENDING ON THE LOAD
MOLYBDENUM STEEL (15 M 03) AND WHICH * GAS OUTLET 860 °C TO 780 °C MAX DEPEND-
IS WELDED TO THE REFORMER TUBE BY IN ON THE LOAD
MANUFACTURER. * INSIDE PRESSURE 34 BAR
A- PROCESS AND E N G I N E E R I N G DATA: * NUMBER OF SHUT DOWN 91 DURING 11 YEARS
* END PRODUCT AMMONIA SYNTHESIS GAS SERVICE LIFE.

37
 THE TUBE, INDICATES CREEP PHENOMENA.
MEASURMENTS OF ALL 288 REFORMER TUBES
THE PLANT WAS ON STREAM SINCE MAY
WERE TAKEN IN 3 DIFFERENT LEVELS.
1979. DURING STARTING UP PERIOD MORE
ACCORDING TO THE MANUFACTURER DRAW-
SHUT DOWNS WERE RECORDED. ENOUGH
ING THE O.D OF THE TUBE SHOULD BE
DATA ABOUT THE REAL LIFE CONDITION
144.5 MM t 1.5 MM MEANS.
OF IN 519 (14/24 Nb) TUBES WERE NOT
CIRCUMFERENCE 454.5 MM MIN. TO
A V A I L A B L E AS WE HAVE FOR HK 40
459.5 MM MAX.
(25/20).
FOR BETTER COMPARISON PURPOSE 6 NEW
SO FOR FURTHER COMPARISON WE NEED
SPARE TUBES FROM THE O R I G I N A L DELIV-
THIS DATA WHICH WAS COLLECTED BY
ERY WERE CHECKED AND ITS READINGS
INTENSIVE INSPECTION METHODS.
WERE M I N . 455.5 MM TO 460 MM MAX.
METALLOGRAPHIC E X A M I N A T I O N FROM THE
THIS CONFIRMS THAT NEW TUBES ARE
MACRO-STRUCTURE IN "AS CAST" CONDI-
EXACT WITHIN THE POSSIBLE SCATTER
TION OF A LOT OF TUBE ELEMENTS WAS
CORRESPONDING TO DRAWINGS AND DIMEN-
PERFORMED BY THE SUPPLIER D U R I N G THE
SIONAL TOLERANCES POSSIBLE IN THE
FINAL INSPECTION OF THOSE TUBE
PRODUCTION OF CENTRIFUGALLY CAST
ELEMENTS.
TUBES.
INSPECTION:
C I R C U M F E R E N C I A L MEASURMENTS WERE
THE FIRST TUBE INSPECTION WAS CARR-
CARRIED OUT AT 1980, 1981, 1982,
IED OUT IN SEP. 1980, CIRCUMFERENC-
1983, 1985, 1986 AND 1988. BEFORE
IAL - MEASURMENTS WERE USED AS A
REPLACING THE REFORMER TUBES IN 1990
BASIC METHOD.
SOME CRITICAL TUBES SHOWS HIGH CREEP
SPECIAL C I R C U M F E R E N C I A L MEASURMENT
TENDENCY WERE MEASURED AND RECORDED.
TAPE WAS USED WHICH ALLOWS VARIAT-
THE DATAS OBTAINED TABULATED IN
IONS OF ONLY i 0.5 MM.
TABLE (D , THE MEAN VALUES OF THE
NORMALLY ON REFORMER TUBES WITH REL-
REFORMER ROWS TABULATED IN TABLE (2)
ATIVLY HIGH INSIDE PRESSURE OF 35
AND THE MEAN VALUES OF 288 REFORMER
BAR, EVERY DIMENTIONAL CHANGE, LIKE
TUBES BLOTTED IN TABLE (3).
C I R C U M F E R E N C I A L , LENGTH EXTENSION OF

38
iVALyTigN_gF_THE_DATAS_OBTAINED:
WERE BESIDE FURNACE WALL) SIGNALE

- 1980 MEASURMENTS INDICATES NO REAL SPRING HANGERS WERE INSTALLED TO SUP-

MEASURABLE CREEP AFTER ONE YEAR OF PORT THE TUBE AND MINIMISE THE BOWING

THE TUBE LIFE, THESE READINGS CAN TENDENCY.

BE CONSIDERED AS BASIC VALUES FOR

FURTHER FUTURE INVESTIGATION.
SINCE PLANT START UP TILL THE TUBE
- 1981 THE OBSERVED TENDENCY FOR THE
REPLACEMENT THE SKIN TEMPERATURE WAS
MOST STRESSED TUBE AREA ARE 3-4 M
CONTROLLED AT A MAX. RANGE 880 -
A B O V E THE COFFIN TOP PLATFORM ALSO
890 °C THE TEMPERATURE EXCEEDED 900°C
NO CLEAR TENDENCY CAN BE MEASURED
FOR FEW HOURS SOME TIMES, THE MAX.
ON TUBES WHICH WERE INDICATED AS
TEMPERATURE WAS REALIZED M A I N L Y ON
HOT TUBES COMPARED TO THE OTHER
ROW "F". THE M I N . TEMPERATURE WAS
TUBES. GENERALLY THERE WERE MORE
ABOUT 830 - 400 °C IN ROW "A", SOME-
HOTE TUBES IN ROW "C" THAN IN ALL
TIMES IT REACHES LOWER TEMPERATURE
THE OTHER ROWS.
ABOUT 815 °C FOR A SHORT PERIOD.
- 1982 MEASURMENTS INDICATES AN INC-
(SEE FIGURE 4) .
REASE IN C I R C U M F E R E N T I A L LENGTH OF
119 TUBES WITHIN A RANGE 1 TO 2.5
MM. THESE TUBES INDICATE THE BEGE-
D U R I N G THE START UP PERIOD THE PLANT
NING " CREEPSTRESS ".
HAD BEEN OPERATED WITH 22 SHUT DOWN
- 1983, 1985, 1986 AND 1988 :
(1979).
THE LEVEL OF INCREASE IN CIRCUMFE-
AT 1980 SEVEN SHUT DOWNS WERE RECOR-
RENTIAL LENGTHS OF MOST TUBES 1 TO
DED.
2 MM. BUT NO FAILURE WAS DETECTED
AT 1981 SIX SHUT DOWNS WERE RECORDED.
IN TUBES INSIDE THE FIRE BOX DURING
COMPLETE SHUT DOWNS WERE MINIMIZED
THE TUBES SERVICE LIFE.
UPTO AN ACCEPTABLE NUMBER A YEAR
THE TENDENCY OF TUBE BOWING APPEARED THIS IS ATTRIBUTED TO EXPERINCE GAI-
IN THE TUBES SUFFERING FROM IRREGUL- NED BY PLANT OPERATORS AND STABLE
ARITIES AND INHOMOGENITIES IN THE CONDITION OF OPERATING PARAMETERS.
TEMPERATURE PROFILE (THE MAJORITY (SEE TABLE 5).

39
IT IS ALSO KNOWN THAT: SINCE THE NEW TRENDS NOW IN STEAM

A- NUMBER OF SHUT DOWN CYCLES HAVE A REFORMING UNITS IS TO INCREASE OPER-

HEGATIVE IMPACTION TO TUBE LIFE. ATION TEMPERATURES AND/OR PRESSURES

B- IT IS RECOMENDED THAT SPECIAL AND ALSO TO LIMIT THE CATALYST TUBE

ATTENTIQN SHOULD BE PAID FOR START WALL THICKNESS TO LESS THAN 16 MM TO

UP AND SHUT DOWN OPERATION TO A V O I D EXCESSIVE THERMAL STRESSES,

PROLONG THE TUBE LIFE. TWO COUNTER MEASURES ARE TAKEN. THE

C- THE TEMPERATURE GRADIENTS FOR FIRST IS TO REMOVE UNSOUND INSIDE

START UP AND SHUT DOWN PROCEDURES LAYER OF THE TUBE. THE SECOND IS TO

ARE AN IMPORTANT FACTOR AFFECTING USE ALLOYS OF HIGHER GREEP REPTURE

THE TUBE LIFE. STRENGTH AND DUCTILITY.

THERE IS A GROWING NEED FOR MORE
ALL TEMPERATURE GRADIENTS OVER 60 -
STRONGER MATERIALS WHICH ARE F A V O U R -
80 °C PER/H WERE CONSIDERED AS THE-
RMAL SHOCK FOR THE TUBES AND SHOULD ABLE FROM THE VIEWPOINT OF SAFETY
BE AVOIDED. AND ECONOMY.
E M P L O Y I N G HIGH STRENGTH MATERIAL
REFORMER TUBE MATERIAL: WITH REDUCED WALL THICKNESS DECREA-
IN 519 ALLOYS ARE SUSCEPTIBLE TO SES THE THERMAL STRESSES WHICH IS
EMBITTLEMENT BY THE HARD SIGMA PHASE BETTER FROM ECONOMIC POINT OF VIEW
WHICH IS FORMED AT HIGHER TEMPERATU- SINCE THE LIFE OF THE TUBE CAN BE
RES DURING SERVICE THIS EMBRITTLEMENT INCREASED AND THE COMBUSTION TEMPE-
CAN BE ELIMINATED BY DEPRESSING THE RATURE CAN BE LOWERED.
FORMATION OF SIGMA PHASE VIA GOOD
CONTROLLING THE ALLOY COMPOSITION.

SIGMA PHASE PROMOTING ELEMENTS SUCH ALLOY 36X WHICH IS 35 NI 25 CR + Nb

AS SI, CR, W AND MO SHOULD BE MINIM- WILL OFFER A BIGGER ADVANTAGES COM-

IZED IN THE ALLOY COMPOSITION - INC- PARED TO 24/24 Nb MATERIAL. BESIDE

RESING NI AND C CONTENT SHOULD BE ITS HIGH CREEP STRENGTH. THE EXPEC-

CONSIDERED SINCE THEY SUPRESS SIGMA TED LIFE OF 36X TUBES WILL BE LONGER.

PHASE FORMATION. THIS ALLOY HAS A HIGHER DUCTILITY

40
WHICH GIVES LESS SENSITIVITY AGAINST TEMPERATURE PROFILE. SO ACTIVE CATA-
THERMO CYCLES AND THERMOCHOCK COND- LYST PROLONG TUBE LIFE
ITIONS E.G. IN CASE OF TEMPERATURE DUE TO THE FACT THE CATALYST PRICE
CHANGES AND NUMBER OF INTERRUPTIONS IS NEARLY 1/10 OF THAT FOR TUBE IT
AS WELL AS UNEXPECTED SHUT DOWNS IS ECONOMIC TO AN EXTENT THAT THE
CAUSED BY POWER FAILURES. CATALYST SACRIFAY THE TUBES. ACOMPR-
IT CAN WITHSTAND UNEXPECTED HIGHER OMISE BETWEEN THIS FACT AND SLIGHT
TUBE SKIN, TEMPERATURE RESULTING EXCESS FOR STEAM GAS RATIO, FUEL

FROM CATALYST AGEING OR OTHER PRICE IS NECESSARY. IN THIS PARTICU-

CATALYST PROBLEMS, AND BAD ADJUSTING LAR CASE 3 YEARS LOOK THE BEST

OF THE BURNERS, WHICH CAN ALSO CAUSE CHOICE.

LOCAL OVER HEATING ON THE TUBES

* THE APPROACH &T
(HOTSPOTS). SO 36X ALLOY GIVES A
WHERE AT = TA ~ T£
CERTAIN HIGHER TEMPERATURE SAFETY.

36X TUBES WILL HAVE A SMALLER WALL IS ALWAYS POSITIVE IN CASE OF METH-
THICKNESS WHICH WILL REDUCE THE TEM- ANE OR NAPHTHA R E F O R M I N G , LOW VALUES
PERATURE GRADIANT ACROSS THE TUBE OF AT (BELOW 20 °C) CORRESPOND HGIH
WALL. IN ADDITION SMALLER THICKNESS CATALYST ACTIVITY THE APPROACH IS
WILL LOWER TUBE WEIGHT AND CONSEQUE- AFFECTED BY SPACE VELOCITY, STEAM
NTLY THE PRICE. IN COMPARISON WITH RATIO, TEMPERATURE AND PRESSURE FOR
IN 519 (24/23 Nb) TUBES. REFORMING TEMPERATURE UP TO 800 °C
AND PRESSURES UP TO 33 BAR, THE CAT-
PdILQSgPHY_QF_CATALYST_REPLACEMENT:
ALYST IN PRIMARY REFORMER GIVES AN
CATALYST USED IS (ICI 57-3 SUPPORTED
APPROACH OF 10 - 15 °C & SLIGHTLY
NICKEL OXIDE) ON A L U M I N A , LOW SILICA
ABOVE 20 °C JUST BEFORE REPLACEMENT.
CONTENT (LESS THAN 0.2% WT). POOR

CATALYST ACTIVITY IS ONE OF THE MOST BiE9BMER_CATALYST_TUBES_REPLACEMNT

IMPORTANT FACTORS WHICH SHORTEN THE PROCEDURE:

TUBE LIFE SHARPLY. 1- SPARE PARTS PROCUREMENT PROGRAM

IT CAUSE HOT SPOTS HOT BANDS AND BAD 45 CATALYST TUBES IN 519 WERE IN

41
 STOCK SINCE PLANT START UP 1979. 2.2. WELDING OF INCOLOY 800 TUBE

150 TUBES MANAURITY 36X WERE PUR- OUTLET NOZZLES.

CHASED STEP WISE AND KEPT IN AS A SECOND STEP THE INCOLOY 800
STOCK AT 1986. OUTLET NOZZLES WERE WELDED AND

110 TUBES G 4852 WERE PURCHASED CHECKED BY DYE PENTERANT CHECK.

DELIVERED AT AUGUST 1990. PREFABRICATED INSULATING RINGS

THE TUBES WERE STORED UNDER GOOD WERE INSERTED ARROUND IT.

CONDITIONS TO PROTECT IT FROM BAD NOW THE CATALYST TUBE IS READY

E N V I R O N M E N T A L EFFECTS AND CORROS- FOR REPLACEMENT.

ION ATTACK. 3- DISTRIBUTION OF DIFFERENT TUBE

2- PRE PREPERATION OF NEW TUBES FOR DELIVERIES INSIDE THE REFORMER

REPLACEMENT: BOX.

THE WHOLE TUBES WERE TRANSFERRED THE SELECTION OF TUBE DISTRIBUTION

TO OPEN YARD ADJACENT TO REFORMER INSIDE THE FIRE BOX IS BASED ON

AREA. THE EXPERIENCE OF THE ACTUAL TEM-

2.1 INSPECTION: PERATURE AT DIFFERENT LOCATIONS.

THE TUBES WERE SUBJECTED TO A CON- THE ROW WHICH HAS THE LOWEST TEM-

DENSED AND THROUGH INSPECTION PRO- PERATURE WERE SELECTED FOR IN 519

GRAM. TO BE SURE THAT STORAGE TIME (ROW B).

AND CONDITIONS H A V E NO N E G A T I V E THE TUBES IS AS FOLLOWS:

EFFECTS ON IT. ROW "A" 48 TUBES 36X OLD DELIVERIES

DYE PENETRANT CHECK AND WELDSEEMS ROW "B" 45 TUBES IN 519 + (3) 36X

RADIOGRAPHY. OLD D E L I V E R I E S .

WERE MADE WITH GOOD RESULTS. NO ROW "C" 48 TUBES 36X OLD DELIVERIES.

DEFECTS WERE DETECTED. ROW "D" 48 TUBES 36X OLD DELIVERIES.

ALSO TUBE C I R C U M F E R E N C E WAS MEASU- ROW "E" 48 TUBES G 4852 NEW DELIVERIES

RED AT 3 LEVELS AS USUAL. ROW "F" 48 TUBES G 4852 "

THE OBTAINED DATA WILL BE CONSIDE- 4- MANPOWER AND TOOLS NEEDED:

RED AS A BASE DATA FOR FUTURE 4.1 MANPOWER 4 TIG W E L D E R S

MEASUREMENTS. TESTED & GUARANTED

42
 4 ARC MELDERS THE REFORMER BOX IN A LOCATION TO

TESTED & GUARANTED COVER AND CARRY OUT ALL THE 6

2 PIPE FITTERS HEADERS AND ALLOMS FOR HIGHTS

2 HAND GRINDERS MAKE THE LIFTING OF THE TUBES

2 THERMAL INSULATION TECH- FREELY MITHOUT ANY DIFFICULTY.

NICIANS. THIS LOCATION MAS AS A RESULT OF

6 HELPERS & SCAFFOLDING A GOOD STUDY AND THE ATTACHED

PEOPLE. SKETCHS INDICATES CLEARLY THIS

4.2 TOOLS SITUATION (FIG. 10 , 11).

8 MELDING MACHINES. 5- FILLER METAL AND M E L D I N G ELECTR-

4 PORTABLE G R I N D I N G MACHI- ODES:

NES. FOR ROOT TIG MELDING GRIDUCT T-3

8 HAND G R I N D I N G MACHINES. " X 1000 FILLER METAL MAS USED.

10 CHAIN M A N U A L LIFTING FOR OTHER COVER PASSES ELECTRODE

CRANES. ARE M E L D I N G MAS USED AND ELECTR-

AS MELL AS THE NECESSARY ODES OF THE TYPE.

SCAFFOLDING TO COVER ALL GRITHERM 2 0 2.5 x 350 E 8013-A1

THE ACTIVITIES ARROUND THE & GRITHERM 2 0 3.25 x 350 E 8018-A1

6 HEADERS (6 ROWS) WERE USED.

4.3 LIFTING CRANES AND RELATED 6- SEQUENCE OF TUBE REPLACEMENT:

FACILITIES: THE F O L L O M I N G SEQUENCE WAS FOLLO-

ONE 250 TON MOBILE LIFTING CRANE. MED D U R I N G THE TUBE REPLACEMENT

MITH 10 TONS MOBILE CRANE AS MELL INCLUDING CUTTING OF OLD TUBES,

AS TMO FORK LIFTS 5 TON EACH. ALL LIFTING IT AND INSERTING THE NEM

THE LIFTING EQUIPMENT USED HAS ITS ONES AFTER THE NECESSARY MELD PR-

SKILLED OPERATORS MHO H A V E GOOD EPERATIONS AND FINALLY MELDING.

TRAINING TO CARRY OUT VERY DIFFIC- STARTING MITH ROM "F" FOLLOMED BY

ULT JOBS. ROM "D" THEN "A", "C", "E" AND

THE GIANT CRANE MAS LOCATED ASIDE FINALLY "B" ADJUSTING THE TUBE

43
 VERTICALLITY IS ONE IMPORTANT JOB INSPITE OF THE FACT THAT THE REPLAC-

BEFORE WELDING. EMENT DECISION WAS TAKEN WHILE NO

7- INSPECTION ACTIVITIES: SINGLE TUBE FAILURE WAS REPORTED

INSPECTION ACTIVITIES CARRIED OUT BECAUSE THE COMPANY POLICY CONCERN-

THROUGH THE REPLACEMENT SCHEDULE ING THE SPARE PARTS PERMIT ACCUMULA-

IN TIME NOT HINDERING WORK PROGR- TION OF THE CATALYST TUBE SET AT

ESS. 100% RADIOGRAPHY FOR THE THAT DATE, CATALYST REPLACEMENT WAS

FIELD WELD JOINTS. DUE TIME INTERVAL BETWEEN THE PLANT

8- COMPLETION OF OTHER MECHANICAL T U R N A R O U N D 2 YEARS.

ACTIVITIES: UN CERTAINTY TOWARDS CONTINUITY TRO-

AFTER FINISHING THE WELDING ACTI- UBLE FREE OPERATION DUE TO TUBE FAI-

VITIES, OTHER M E C H A N I C A L WORKS LURE FOR ANOTHER COUPLE OF YEAR

WHICH COMPLETES THE JOB SUCH AS WHILE THE SPARE TUBES WERE A V A I L A B L E .

ERECTING THE COMPENSATOR, BECTING WE ARE GOING TO EVALUATE THE POSSI-

REFORMER ROOF, CLOSING THE UPPER BLE N E G A T I V E EFFECT ON THE TUBES DUE

FLANGES AND ERECTING THE INSULA- TO LONG STORA6E PERIOD.

TION OF THE TOP FLANGES WAS CARR- IN THE SAME TIME WE DIDN'T RECOMMEND

IED OUT, AT THE SAME TIME PROCESS SUCH SPARE PARTS POLICY IT IS PREFE-

SIDE STARTED TO FILL THE CATALYST RABLE TO HAVE IN STOCK FEW NUMBER

AND PRÉPARÉ THE REFORMER TO START TUBES, AND THE I N Q U I R Y FOR THE WHOLE

UP. SET SHOULD COMMENCED AFTER THE FIRST

CONCLUSIQN: TUBE FAILURE.

IN 519 REFORMER TUBES PERFORMS WELL WE BEHAVE THAT THE ECONOMIC OPTIMIZ-

FOR MORE THAN 100,000 HR SERVICE LIFE ATION FOR REFORMER OPERATION (STEAM/

ATTRIBUTED TO GOOD MONITORING, MINI- GAS RATION, CATALYST REPLACEMENT,

MUM TEMPERATURE CYCLING AND SHUT FUEL CONSUMPTION) SHOULD NOT IGNOR

DOWNS. THE LONG TERM IMPACTS, LIKE THAT OF

COMPLETE REPLACEMENT COULD BE DONE TUBE LIFE.

DURING NORMAL SHUT DOWN AND TAKES

ABOUT 3 WEEKS.

44
 Mahmoud M. Hamza

(TABLE D CIRCUMFERENCE MEASURMENTS POR ROW<A)

PRIMARY REFORMER CATALYST TUBE?

1981 . 1982. . 1983 . 1985- . 1986.

1 458.5 458.5 458.5 459.2 459.0 t 58.9 459.0

2 458.5 459.5 458.5 459.0 459.0 57.9 458.0
3 457.5 457.5 4 58.0 457.8 57.2 1 57.8 457.9
4 458.0 45E.O 4S9.0 460.1 61.2 57.2 459.2
5 458,5 458.5 459.0 460. O 59.7 t 57.6 458.4
6 455.5 455.5 456.5 456-3 5.9. 0 57.2 457.5
7 457,0 457.0 4S7.S 458.9 57 -2 < 57 -O 459.0
8 457.0 457.0 457. 0 458.2 56,2 t S.7/-2 457.5
9 456.O 457.0 456-0 457.0 58 .0 t 57.2 457.1
10 455.0 455.0 456.0 454.8 54.2 4 55,3 456.0
11 456.0 456. 0 456.0 455.0 54.O 4 57-9 457. T
12 456.5 456.5 456,0 4SS.8 57.5 A 57.6 457.T
13 456.0 454-5 455.0 456.0 54.6 i 57'_2 457.77
14 457-5 457.5 458.5 459.0 59.9 t 59.2 459.3
15 456.5 454.5 457.0 4S7.2 57.9 57 „9 458.8
16 456.0 456.0 455.0 456.6 455.3 55.1 456.2
17 458.0 456.0 458.0 460.5 460. Tl 59.6 458.8
18 455.0 454.5 455 -O 455.0 4S4.4 55. 1 456.6
19 455.5 455.5 456. O 457.5 457.3 56.2 457.1
2O 458.5 459.0 459.0 460.0 457.1 59.8 456.1
Z\ 4,56.5 456.5 456.0 457.3 4S7.3 59.0 45 T. 3
23 456-5 456.5 456.0 4 56. C 455.4 56.5 458.5
of Tube & Weid Metal 24 456-0 456.0 456.0 457.0 456.3 5T. 1 459.3
25 457-0 456.5 456.5 458.0 457.0 59.4 460.4
25 458-0 458.0 459.0 469.5 459.9 61.2 458.8
27 457.5 457.5 459.0 46O.3 459.3 5913 46,1.1
28 457.0 457.0 458.0 458.2 456.6 5£.7 458.9
T. P. Marking C Si Hn P S Nt Cr Nb Ochers 29 458,5 458.5 457.0 457.8 457.8 58.3 457.9
30 456,5 456.5 458. O 458.2 456.6 57.2 458.6.

IN-519
Range

Noniinal
••d"-'
0.30 1 0.73
il.O '0.04 iO.04

0.75
23/ 23/

0.015 0.015 24.0

25 25
24.0
1.4/
1.8
1.5
31
32
33
34
458-Q
457.0
455.0
455-5
458.0
458.0
45-7-.0
455.5
457. O
457.0
457. O
457.0
457.0
458.0
458.2
458.2
457.2
457.2
456.2
457.4
456.3
457.6
sr.s
58.8
57.3
58.0
57.8
460.4
461. O
457.4
457. T
459.1
35 457*0 458.0 46 1. 5
B-O. 19 37? 456.0 45S.O 46O.5 460-6^ 460.3 60.4 457.5
Upper Tube 0.36 0.77 0.72 0,011 0.018 23.53 21.68 1.51
Mo-0.14 38 45 7 „5 457.5 459. O 458.9 459.8 59.4 459.8
W-O. 06 39 458.0 458.5 457. O 457.6 457.3 58.1 458.9
Weid Metal 0.36 0.86 1.17 0.008 0.014 23.8! 24.16 1.32 4O 459*0 459.0 4 58. 0 46O.O 46O.9 61.3 459.8
Ko-0.06
41 456.0 456.0 457.5 457.0 457.9 59.1 46O.8
Lower Tube 0.36 0.91 0.67 0.010 0.016 24.01 23.44 1.41 42 456.5 454.5 457. O 458.6 459.2 59.1 460.2
Ho-O. 14 41 459*0 459.0 461. O 460.5 461.2 62.0 460.9
44 4 56.0. 458.0 457.5 457.2 457.8 56. 2 458.0
W-O. 25 45 456.5 456.5 457.0 457.9 458.2 57.2 459.5
TP-C Tube 0.36 0.91 0.67 0.009 0.016 23.81 23.42 1.35 46 458. 458.0 459.5 46O.O 46O.3 60.8 459.7
Ho-O. 14
47 458.5 458.0 459. O 459.5 46O.1 61.2 46O.7.
48 458.0 458.0 46O.O 459.9 460.3 62. O 460.8

45
TASLC(2) AVERAGE. CIfl£UHFCHCMCE HLADlhGS FOR IN519 KEFOHHER CATAtYST TUBES

ÏEAB T. P.
ROM
Marking CC) (kgf/tti2 (h r) (2) <S) Pos it ion
1980 1981 1982 1983 1985 1986 198B 1990

6.0 27.5 41.6 45.8 A

A 456.6 456.9 457.6 458.0 458.1 458.2 458.6. 461.9

a 4S7.0 457.2 458 .0 45B.4 45B.5 45H.6 459.2 464.8

TP-A 900
c 456,4 456.5 457.7' 4SB.4 458.5 . 458.8 459.2 462.3 (Tube) 3.0 1242. B 32.3 40.1 A

o 456.5 456.7 457.8 458. 5 459.1 459. O 459.6 462.4 2.5 Scheduled

«eld
F 456. B 456.9 457.8 458.2 458.7' «58. 6 459.8 461. S 6.0 19.5 ~ 48.2
He cal
4.0 226.9 40.5
TP-B 900
(Held) 3.0 770.2 31.0

2.5 Scheduled

Ïable4. Short-Tlme Tensile Properties

6.0 25.2 60.3 61.8 A
at Room & Elevated Temperatures
4.0 244.0 66.7 52.0 A
(a) At Room Temperatute •: TP-C 900
(Tube) 3.0 975.6 52.8 60.4 A

2.5 Scheduled
Tensile 0.2ZProof Elongation Reduction Fraccure
Strength Stress of Area Position
(kgf/m?) (kg£/mm2) m m
New Tube 61.6 27.0 21.0 18.8 B r«8LE (5) MMBEB OF SHUT DOKHS D Ü R I X G
CKOBE STEEL)
TP-A 41.1 21.8 1.5 3.0 A THE TUBES SEB»ICE LIFE
(Lowar)
TP-C 43.2 22.4 2.0 3. '5 B
ÏEAR NUKBER OF
(b) At Elevated Temperatures : SHUT-ÜQWN

Tensile 0.2ZProof Elongation Reduction Fracture 1979 - 80 22

Strength Stress of Area Fosition
<kgf/«m2) (kgf/™2) m m 1980 - 81 7
1981 - 82 6
New Tube 1982 - 83 9
800'C 32.7 15.9 16.8 25.5 A 1983 - 84 S
900'C 17.6 11.8 25.1 42.4 A
1000'C 11.6 7.8 28.3 60.2 B 1984 - 85 5

TP-A
1985 - se 7
800 'C 24.3 10.8 23.0 24.8 A 1986 - 87 11
900°C 15.4 6.8 33.5 40.4 B 1987 - 88 a
1000'C 9.3 4.4 42.0 46.8 B
1988 - 89 a
TP-C
800'C 25.2 11.0 25.0 26.7 A 1989 - 90 7
900°C 16.4 6.9 36.8 39.0 A
1000'C 9.4 4.2 48.3 54.4 B
n ÏEAR 91

Table 6. Schedule of primary reformer catalyst tubes replacement.

I?-1 w„i J?3 Wnk 3'J w*«k 4 tó W., k S Ui we*k
N3 ITEM / DESCRIPIBN
i J 3 f. 5 6 7 1 1 3 4 5 6 7 1 2 3 t 5 6 7 t l 3 b 5 t 7 l J 3 « 5 6 7

np I*H
4— rpnLINrc DO^w ... - -
REFORMER

? OPENING. THE UPPER ^

F1.ANGES OP THE OL
-
TUBES.

3 CUTTING THE OLD

TUBES.
•
4 HEMOVJKL THE OLD
TUBES .
—
S INSTALLATIOH OP
THE NEtt-TUBES.

r. reiLDING THE TUBES

TO TH& HEAOBRS.
_

^ enBRfTTHn THE. bm »4

COMPENSATOR

a EHRECTING REPORME
ROOF.

9
FLANGES

10 START UP THE PLAN *• r

11 ERRECTING THE
IHSULATION OF THE *

ÏOP FLANGES.

INSPECTION ACTIVITIES C A R R I E D OUT THROUGH THE SCHEDULE IN TIME NOT HINDERING WORK PROGRESS.

46
 30
TP-A (Tube)

/\ TP-B (Welded Joint)

f"] TP-C (Tube)

Band of IN-519
(Data Source
INCO.)

10* Time to Rupture ( hrs )

Figure 1. Creep-rupture strength at 900°C.

Mox. allowaWe circumierence -A79.85

MEASUREDAT SITE AVGMANUFACTURED

Figure 3a. Reformer tube measurements. Row A.

RAW B

461 - 1

460 - /
E
£
u /
/
Retormer tube on bricklined hesder 5
I

1 Reformer tube -----B-'"''

2 Header
„'* Mox. allowvable circumfwence -479.85 mm.
3 Imermediale connection wilh
assembly weiding seam
4 Relomer ceiling
5 Retormer bottom
B Inlet pigtail 81 82 83 8S 66 88 90
7 Cata/yst VEAR
D MEASUREDAT SITE + AVGMANUFACTURED

Figure 2. Reformer tube on bricklined header. Figure 3b. Reformer tube measurements. Row B.

47
 REFORMER TUBE MEASUREMENTS REFORMER TUBE MEASUREMENTS
RAW F
RAW C
463

46! -
<< 461 - /

461 - f' £ "0- /

E
E /
u
o
2
460 -
' 1 «,-
!
* 459 -
*,'-'"* i ,--"V'

u ^ „-s-

458 - ^_ ^ ' Max . aüowabt? circumlerenee - 479 85 mm

z" MOX allowablectrcumfefence -479 85 mm
j i i i i i

457 -

456 - e! 82 83 85 86 BB 90
8' B? 83 85 86 BB 90

n MFA5URED AT SITE
YEAR
+ AVGMANUFACTURED
K MEASUREDAT SITE
YËAR
* AVGMANUFACTURED

Fi
Figure 3c. Reformer tube measurements. Row C. §ure 3f' Reformer tube measurements. Row F.

REFORMER TUBE MEASUREMENTS

RAW D

y
462 -

/
461 -
DATE HAX. ROW MIN. ROW DATE MAX. ROU MIN. ROW
E j
60
az ' ' 10/83 883 F 793 A. 06/89 898 C 847 A
10/83 905 F 782 F 08/89 895 £ 844 F
10/83 906 E. 829 F 09/89 904 F 842 A
1
01/84 885 E 812 C 10/89 889 F 849 A
ar
, Max allowable circumlsrenc'e - 4 7 9 85 mm
03/84 906 D 840 A. 11/89 882 C 847 A
-/ 03/84 877 B 830 A'F 12/89 885 D 830 B
06/84 881 F 854 A 12/89 883 D 841 ft
8\ 82 83 85 86 88 'J > 07/84 896 D 845 F 01/90 888 F 835 At

D MEASUREO AT SITE -. AVGMANUFACTURED 09/84 908 a 820 A 01/90 888 F 84O A

02/85 893 D 832 C 03/90 902 A 843 f
Figure 3d. Reformer tube measurements. Row D. 05/85 887 F 834 F 04/90 895 F 84O f
05/85 385 F 838 a 05/90 891 S 842 A
07/85 89O C 843 ai 06/90 883 C 849 P
07/85 889 C 847 ai 06/90 883 D 853 B
08/85 890 F 841 B O6/90 898 0 84T A
REFORMER TUBE MEASUREMENTS
RAW E 08/85 900 C 829 B> 07/9O 892 S. 847 A
461 .5-r
10/85 879 T 838 A* 07/90 886 E 840 A
«1.0- 900 F 859 Bi 07/9O 886 E 846 B
02/86
460.5-
/ 04/86 900 t 830 Bi 07/9O 885 BI 847 A
06/86 890 B-r B45 S 07/90 901 C 847 9
E 460.0-
e 11/86 893 F 828 B 07/90 886 D 850 B
459.5- ^--'e"
S 12/86 884 A 840 a 08/9O 687 D 851 &
4590-
—w"
s B 09/88 882 F 841 A. 08/90 886 E 848 B

D 458.5- / 09/88 881 C 844 A 08/90 894 C 850 A

/ Max. allowablp circumfefwce -479.85 mm. 12/88 893 F 835 A 08/90 894 C 850 h
45BO-
01/89 883 C 835 At 08/90 894 D 849 a
457.5 _
r"" 01/89 884 E 839 A 08/90 892 D 847 B
4570- 02/89 883 C 833 A
81 62 83 85 86 BB Sti
04/89 884 D 845 A,
YEAR
0 MEASUREDAT SITE + AVG MANUFACTUPED
05/89 885 0 845 A

Figure 3e. Reformer tube measurements. Row E. Figure 4. Skin temperature record.

48
 1. Operation History of Test Tube :
BATCH HO. FHOM TO SERVICE LIFE

FIRST BATCH APRIL 1979 JUHE 1981 2 YEAFS

1-1 Temperature;
3ECOND BATCH JU1IE 1981 MARCH 1985 3.5 „.
(i) Out-let Gas 780°C
THIRD BATCH MARCH 1985 MAY 1988 3 "
(il) Tube Skin 850-900°C
Ciü) Reformer Box 800°C (Floor) FCL'BTH BATCH MAÏ 1988 SEP 1990 2.3 "

1-2 Pressure 34 barr

1-3 Service Period 4 yrs & 2 mnths
1-4 Steam/Carbon Ratio 4,2 Figure 7. Catalyst replacement during the
ICI 857
1-5 Catalyst
life of IN519 tubes.

2. Position & Marking of Test Pieces :

CH Ü TEMP CATALÏST
PLANT REFORMER
LOAD EXIT TEMP'C EXIT APPROACH TE«P°C REPLACEMENT DATE

97.21 761 1.5 8.0 - 880 JOKE 1981

90.6 780 2.7 8.2 12 870 MARCH 1985
1CQ.2 795 2.1 9.0 12.17 875 MAY 1988
- TP-A ' Tube) 96.7 770 1.8 9.0 6 - SEP. 1990
ÏP-R ( U P Idprl .lotnl-

* TKE APPROACH & T

WHERE & T = TA - T_

IS ALWAYS FCSITIVE IN CASE OF METHANE OR NAPHTHA REFORMING,LOW

VALUES CF&T (BELCW 20°C ) CORRESPOND HIGH CATALYST ACTIVITY THE

TP-T - Ttihp) AFPBOSCH IS AFFECTEO BY SPACE ÏELOCITY. STEAM RATIO,TEMPERATtlRE

ANC FHESSURE.FOR REFORMING TEMPERATURE UP TO 800°C AND PRESSURES
•Jp 7C 53 5AP.THE CATALYST IN PRIMARY REFORHER CIVES AN APFRCACH CF
>~~-'5 °~ i SLIGHTLY AEtVE 2C! :C JL'ST 5EFCRE PEFLACEMENT.

Figure 8. Operation parameters before catalyst

replacement.

Figure 5. Greep rupture test result of an

TP-B and TP-C show n e a r l y the same and the lowest strenqth
IN-519 reformer tube.
w i t h the residual life of about 20,000 hrs.

This value can be calculated from the followinq formula and

Fiq. 1.

(1). (ƒ = -^ii—.p ;(Hean Diameter Formula)

e l
2(K-1) ^

,where 6T = Equivalent Hoop Tensile Stress

K = 00 / 10

(2) Thus,

137.« - 2x0.8
K= = 1.236
110
' 2.236
C. 1 «n Si 1 P ' s Ni Cr - Ho Nb i O" = f 34 ( barr )
0.472
P.ANGE KIN 0.35 32.0 23.0

MAX 0.«5 1.501.50 : 0.03 0.03 35.0 27.0 . 0.50 1.50 2.236
x 34.5 ( k g f / IMI )
0.472

ACTUAL O . « 1 | 1.3 1.27 j 0.01 ' 0.013 33.17 14.6 ! 0.06 0.71 = 1.63 k g f / IM

Figure 6. Chemical composition of 36X - alloy. Figure 9. Estimation of residuaï life.

49
Figiire 10. Lifüng crane.
Figure 11. Lifting crane.

50
 \ H
TP-A l', (a)

(b)

^...^•••:::-'.' /^%$-
>-c-fI::V-
• tr --ij^v s.'^- !•*.
f
-' ^ t-
IWv^»'""?.'« •• . J',

yf.

Photo 2. Microstructures of weid (x200).

Photo 1. Microstructures of tube section
(x400).

51