0308-0161(95)00098-4

ht. J. Pres. Ves. & Piping 66 (1996) 233-241

Copyright 0 1995 Elsevier Science Limited
printed in Great Britain. All rights reserved
0308~161/96/$15.00

ELSEVIER

CRITERIA

FOR THE EVALUATION

REFORMER

OF DAMAGE AND REMAINING

FURNACE TUBES

LIFE IN

I. Le May, T. L. da Silveiraband C.H. Viannac

Metallurgical Consulting ServicesLtd., P.O. Box 5006, Saskatoon,S7K 4E3, Canada,
bTito Silveira Engenhariae ConsultoriaLtda., Rua Couto Magalhaes744,
20930-090Rio de Janeiro,Brazil
ISQ - Instituto de Soldadurae Qualidade,EstradaNational 249, km 3, Cabanas,
Leiao, Apartado 11,278l OeirasCodex, Portugal
ABSTRACT
The mechanismsof damageoccurring in reformer furnacetubesare discussed,togetherwith the
methodsof assessingthe extent of damageand remaininglife. The useof characteristiccurves
is described,theseillustrating the extent of aging and the amountof the accumulateddamageby
creep. The applicationof a simplified evaluationmethod to a removed sampletube to provide
rapid indication of the extent of damageis described,togetherwith a radiographicprocedureto
evaluatethe extent of creep crackingin the welds.
KEYWORDS
Reformers; furnace tubes; creep;remaining life; characteristiccurves; metallography.
INTRODUCTION
Reformer furnacesare usedwidely in the petrochemicalindustry, and are subjectedto extremely
demandingconditionsowing to the constraintof the processesinvolved. The tubesare arranged
vertically in the reduction chamber and receive a mixture of hydrocarbonsand steam at a
temperatureof the order of 500C or aboveand at a pressureof from 980 kPato 3500kPa. The
gas mixture is heated in the presenceof a catalyst, producing a hydrogen-rich gas at a
temperaturetypically between 850 and 900C. The temperaturein the tube walls may exceed
1000C at the end of a campaignwhen the catalyst is closeto exhaustion.
Reformer tubes are designedfor a nominal life of 100,000h (11.4 years) on the basisof the
American Petroleum Institute (API) RecommendedPractice 5301. The length of a normal
campaignfor a reformer furnacemay vary from 12to 36 months (8,760to 26,300h). However,
the useful servicelife is found to rangefrom around30,000to 150,000h, dependingon the actual
operatingconditionsand the characteristicsof the particular material.
To achievethe most economicuse of the tubesand to plan in advancefor their replacement,the
extent of damageand the remaining life shouldbe assessedin advanceof a full campaignto
233

234

I. L.e May et al.

ensure that there is likely to be adequatelife to avoid failures and an unplannedshutdown.

Analytical methodsare availablefor predictingfurnacetube life, for example,usingthe procdures
describedin API 5301,using the computer methodsof Jaskeand his associatesz3,
or using the
GeneralizedLocal StressStrain (GLOSS) robust method4,but it is very useful to evaluatein a
more direct way the probableextent of damageand the remaininglife in a particular furnace.
The basic problem with the analytical methods is the large degree of uncertainty involved,
becauseactual conditionsmay be different from those considered,and an assumedworst case
condition would give a generally pessimisticestimateof remaining life. It should be noted,
however, that the initial use of an analytical method is likely to indicate if there may be a
potential problem, and whether more direct evaluationshouldthen be made.
Owing to the severe operating conditions, reformer tubes are generally fabricated from
centrifugally cast creep-resistanthigh carbonausteniticsteel of ASTM A297 Grade HK (25 Cr,
20 Ni, 0.4 C) or Grade HP (26 Cr, 35 Ni, 0.4 C). In somecasesother high temperature,heatresistantalloys may be used, in generalwith a compositionderived from the HP grade.
NATURE OF THE DAMAGE
The damagethat can lead to tube failure is primarily creep,initiating within the tube wall some
two thirds of the way through from the outer surface,making it impossibleto detect by in situ
metallography,ascan be usedin boiler superheaters
andheaders,in which creepdamageinitiates
at the outside surface. other relevant damageforms are carburization, thermal shock and
accidentaloverheatingleadingto recrystallizationand, in the extreme,to liquation of the eutectic
carbides in the heat-resistantcast austenitic alloys. All of these damage forms can be
characterizedusing destructivemetallographicmethods,althoughjudgementcriteria will not be
presentedhere for other than creepdamage. Gn other occasionstubesmay suffer grossdistortion
that, in extreme cases,can interfere with the fitness-for-purposeof the furnace.
Figure 1 shows the nature of the creep damagewithin a reformer tube and how it can be
classified. The five levels of damagethat are assignedare basedon the approachof Neubauer
and Wedel for steamgenerators,in which damagewasclassifiedasbeingof four different levels,
ranging from the formation of isolatedcavitiesto the presenceof macrocracks. The modified
approachillustrated considersLevel A as having no detectablevoids, Level B as displaying
isolated cavities, Level C having oriented cavities, Level D having microcracks and Level E
having macrocracks. The damageis revealedfrom the sectioningof a tube and careful (and
repeated)polishingand etchingto emphasizethe damagein the form of cavitiesor microcracks6.
This point is important as it appearsthat the voids that may be disclosed are not of any
significant size up to the time that separationoccurs along boundariesand microcracks are
present. The initial mechanismis thoughtto be decohesionat the interfaceof a precipitate,this
openingup through the repeatedapplicationof polish-etchcycle&.
The voids that are disclosedon tube sectionsin the form of rings are arrangedinitially at the
dendritic boundariesapproximatelyone third in from the inner surface. Their alignmentfollows
a direction normal to the principal tensile stress. The microcracksthat developpropagateto the
internal surfaceand later to the externalsurfaceto produceleakage. Experiencehas shown that
the processis sufficiently slow that an effective forecastof the remaininglife expectancycan be
made by simple qualitative metallographyapplied to the cross-sectionsof an extractedsample
tube.

Damage and remaining life in furnace tubes

235

life

cross section
cross

of the lube

clamage

I/3

I/2

2J3

ICVtA

Fig. 1. Classificationof the damagein the wall of a reformer furnace

tube, as indicatedafter metallographicpreparation.
Reformer tubes are fabricated from several spindle-cast segments butt-welded together.
Experiencehas shownthat there are two possiblesites for the alignmentof the voids. When the
weaker link correspondsto the spindle-castmetal, the alignmentand the cracks that follow are
arrangedin longitudinal planeswithin the tube. When the weaker link is the weldment, the
alignment may be localizedin a plane transverseto the tube axis and lying either in the centre
of the weld or within the heat affectedzone. Thus, different levelsof creeplife consumptioncan
be attributed to different sectionsof the reformer tube, basedon the distribution of voids and
cracks, leadingto the simple assessmentcriteria basedon the qualitative observations.
An important point is that the extent of creep damageis seldomdistributed evenly aroundthe
complete cross-sectionof a reformer tube, and this needs to be consideredin the sampling
procedurefor metallography. Regions,ratherthanjust segmentsof the tube wall are requiredfor
the evaluation.
The microstructuresof the cast austeniticstainlesssteelsof the I-K, HP or similar types change
substantiallywith aging temperatureand so do their mechanicalproperties. For example,the
ambient temperatureductility falls to the extent that the tensileelongationmay be lessthan 5%
for material agedbetween600 and 700C. Suchbehaviouris normal and the furnace geometry
is suchthat this limited ductility doesnot interfere with the fitness-for-purposeof the tube. Thus,
the agingprocessin itself shouldnot be consideredas a processof damage. The microstructural
changesare, however, useful indicationsof the actual wall temperature. They may be evaluated
by meansof field metallographyusingreplicasor by moreconventionaldestructivemetallography
appliedto cross-sectionsof a sacrificedreformer furnace tube.
The microstructural changesthat take place in cast steel as a result of prolongedexposureto
temperatureare primarily alterationsin the carbidemorphology. While time has an influence,
the most important factor is the temperature,and the structuresthat result can be correlated
closelyto the servicetemperature.Below about600C microstructuralchangesarenot detectable
with light microscopy,andthis is designatedStateI of aging. From 600 C to 700 C the primary
carbidestend to coalesceandbecomeblocky: aswell, secondarycarbidesnucleatein the interior

236

I. L.e May et al.

of the austenite matrix. precipitating first along the edges of the dendrite arms. This is termed
State II. Between 700 C and 800 C, the primary carbides transform completely from a eutectic
morphology for form compact blocks, and very fine secondary carbides are dispersed through the
matrix, producing State III of aging. Between 800 C and 900 C the morphology of the primary
carbides stabilizes and the secondary carbides coalesce. Because of carbon diffusion to the
primary carbides, there is a loss of secondary carbides along the dendrite boundaries. This is
termed State IV. For material exposed to temperatures between 900 C and lOOOC, larger
coalesced secondary carbides are observed, their numbers being much less than at lower
temperatures. A zone denuded in secondary precipitates surrounds the primary carbides. This
is State V. Above lOOOC, secondary carbides disappear and the austenite matrix has an
appearance similar to the as-cast condition. This is termed State VI.
The microstructural features described are illustrated in Fig. 2.
Observations made by the authors of the transformation of steels of the type considered here
indicate that the initial changes in microstructure take place relatively rapidly at a given
temperature level (certainly within a few thousand hours) and that thereafter the extent of change
with time becomes small. Thus, as indicated above, microstructural changes provide a reasonable
estimate of the temperature profile to which a furnace tube is subjected.

CHARACTERISTIC

CURVES

By removing a single tube from a reformer furnace and cutting a series of ring samples along its
length, the extent of the microstructural changes and of the creep damage can be determined.
The curves that are plotted are termed characteristic curves, and Figs. 3 and 4 illustrate typical
ones.
Several uses have been made of these curves in assessing actual furnaces. First, the levels of
damage and of remaining safe life have been evaluated, and these have been demonstrated to be
very different from estimates computed on the basis of assumed operating conditions in some
cases. Second, on the basis of the microstructural state, it has been possible to identify
unexpectedly high local temperatures that have occurred owing to poor control of the furnace at
some stage during its operation. Third, large variations in operating temperature across a furnace
have been confiied when there has been concern that such might be the case and more than one
tube has been removed from the furnace and sectioned as described above. Experience has
shown that the characteristic curves based on metallography frequently provide a better
description of the working conditions than can be obtained from direct temperature readings based
on the emissivity of the heated surface.

WELDED JOINTS
When the life of a reformer tube is limited by creep crack propagation at the welds, those that
are most prone to damage are the two nearest to the top of the radiation chamber. In such a
situation the positions of the cracks that develop are well defined and it has been found possible
to use radiography to evaluate creep damage that is at an advanced, but not yet terminal stage.

Damage and remaining life infurnace tubes

Fig. 2. The state or condition of aging during extendedservice for

HK40 steel. Specimensare takentransverseto the tube axis,
mechanicallypolished and etched in Aqua Regia saturated
with CuCl,. They were all taken close to the inner tube
surface. They are from a singletube exposedto 69,000h of
service. (a) Top left - StateI; (b) top middle - StateII; (c)
top right - State III; (d) bottom left - State IV; (e) bottom
middle - StateV; (f) bottom right - StateVI. Note that the
dark cavities in (d) and (f) are indicationsof creep damage
occurring at the higher temperatures.

237

238

1. Le May et al.
STATE

OR CONDITION
OF AGING

LEVEL

,L

DISSIMILAR
METAL
JOINT

OF
CREEP

ACCUMULATED
DAMAGE

ABCDE

44
WELDED
JOINT

E
9
ol

WELDED
JOINT

600

000

OPERATING

1000
TEMPERATURE

lC)

l/3

l/2

LIFE
@

2/3

CONSUMED

WELD

METAL

Fig. 3. Characteristiccurvesfor a reformer tube of HK40 removed

after 45,800h of service. The observedstateof aging is on
the left with the temperature corresponding to the
microstructure observed. On the right the extent of creep
damageis shown for different positionsalong the tube.
STATE
OF

LEVEL

OR CONDITION
AGING

OF
CREEP

ACCUMULATED
DAMAGE

ABC

DE

DISSIMILAR
)?METAL
JOINT

WELDED
JOINT

WELDED
JOINT

DISSIMILAR
METAL
JOINT
n

OPERATING

TEMPERATURE

tiii
l/3

LIFE

l/2

2/3

CONSUMED

(%I
@

WELD

METAL

Fig. 4. Characteristiccurves for a reformer tube of HK40 removed

after 65,000 h of service.

Damage and remaining life infurnace tubes

239

Figure 5 showsthe criteria usedfor the evaluationof the level of accumulateddamagein welded
joints betweenthe centrifugally cast sectionsof a reformer tube. The damagelevels (A to E)
correspondto those alreadydiscussed. In the majority of casesthe useful life of weldedjoints
is limited by the propagationof cracks in the planeof the weld and lying within the deposited
metal. Cracking may also be observedin the heat affectedzoneand this may also be the limiting
factor. Only rarely is the life limited by crackstransverseto the weld deposit, lying along the
tube axis, and extendinginto the basemetal of the centrifugally cast tube.

Level A: life consumed0%.

Absenceof lenticular creepvoids.

Level B: life consumed30%.

Voids widely distributed but not aligned.

Level C: life consumed50%.

Voids alignedbut not linked.

Level D: life consumed75%.

Microcracks resulting from the interlinking

of aligned voids. The microcracks do not
reachthe mid-wall thickness. They occupy
limited sectorsof the weldment.

Level E: life extinct.

Cracksthat approximateor exceedthe depth
of ?43of the wall thickness. The cracks
occupythe major part of the perimeterof the
weldedjoint.

Fig. 5. Criteria usedfor the level of accumulateddamagein welded

joints betweencentrifugally cast sectionsof a reformer tube,
as shown by sectioningand metallographicpreparation.

240

I. Le May et al.

Radiographicprocedureshave beendevelopedand qualified for the detectionof damageat the

various levels indicated. Theseutilize y-radiographyoriented (a) in line with the weld deposit
(angle of incidenceof 0) and (b) at an angle of incidenceof approximately 15 to the weld.
The former provides for detection of cracks lying within the plane of the weld metal at right
anglesto the tube axis, while the latter gives better detection of cracks lying within the heat
affected zone. Radiographyis conductedin place without removal of the reformer tube, but
following removal of the catalyst from it.
The test program run has demonstratedthat damage in welds can be detected with good
sensitivity. In the event that seriouslevels of damageare apparent,it would be good practiceto
removea tube for confiitory metallographicevaluation,which is the more sensitivetechnique.
RAPID EVALUATION PROCEDURE
Whena reformer tube hasbeenremovedfor metallographicexaminationit may be useful to have
a relatively rapid indication of the state of damage,as the metallographicassessmentis time
consuming. This may be donesimply by a qualifiedtechnicianusing liquid penetrantprocedures.
Five segmentscut appropriatelyfrom the column length can be preparedfor examinationby
chamferingby turning as shown in Fig. 6. The surfaceof the chamfer shouldbe kept as smooth
as possible.
Liquid penetranttesting is conductedover the chamferedsurface. If cracking is presentit will
be in the form of longitudinalradial cracksin the wall, andthis will appearas linear indications
on the chamfer. If suchcracksare detectedbut are lessthan 25% of the wall thicknessin radial
dimension,it can be assumedthat the risk of failure is sufficiently low that a further campaign
can be undertaken. However, if they extendthrough more than 25% of the wall thickness,then
a more detailedmetallographicexaminationshouldbe made.

-100

mm

bl

70C

8-=
80"

Fig. 6. Procedure for preparation of the inner tube surface of

specimens.

Damage and remaining life infurnace tubes

241

CONCLUSIONS
Basedon the damagemechanismsthat have beenobservedto occur in reformer furnacetubes,
methodsof estimatingthe extent of this damageand of the remaininglife have beendescribed.
Characteristic curves provide a simple and useful display of the temperaturedistribution as
inferred from microstructuralchanges,andof the damageasdeterminedmetallographically,based
on a sacrificed sampletube.
Nondestructiveradiographicprocedureshavebeendevelopedfor the evaluationof creepdamage
in the welds betweentube sections. In the event that seriousdamageis estimatedto be present,
these can be supplementedby removal of a sampletube for which the characteristiccurve can
be prepared.
A simple testing procedure using liquid penetrant has also been describedto allow rapid
evaluationof a sacrificed sampletube, following which more detailedexaminationcan be made
if required.
REFERENCES
1. Calculation of Heater-Tube Thickness in Petroleum Refineries, API RecommendedPractice
530, 3rd edn. American PetroleumInstitute, Washington,DC, 1988.
2. Simonen,F.A. & Jaske,C.E., A computationalmodel for prediction the life of tubesusedin
petrochemicalheater service,J. Press. Ves. Technol., 107 (1985) 239-46.
3. Jaske, C.E. & Visvanathan, R., Remaining-life prediction for equipment in hightemperature/pressure
service. MatLs. Pefirmance, 30, No. 4 (1991) 61-7.
4. Gomes, L.C.F.C., Bhole, S.D., Le May, I. & Seshadri,R., Remaining life evaluation of
catalytic furnace tubes. In Materials Pefirmance, Maintenance and Plant Life Assessment,
eds I. Le May, P. Mayer, P.R. Roberge & V.S. Sastri. The Metallurgical Society of the
CanadianInstitute of Mining, Metallurgy and Petroleum,Montreal, Canada,1994,pp. 173-9.
5. Neubauer,B. & Wedel, V., Restlife estimationof creepingcomponentsby meansof replicas.
In ASME International Conference on Advances in Life Prediction Method, eds D.A.
Woodford & J.R. Whitehead. ASME, New York, 1983,pp. 353-6.
6. da Silveira, T.L. & Le May, I., Effects of metallographicpreparationprocedureson creep
damageassessment.Materials Characterization, 28 (1992) 75-85.
7. Samuels,L.E., Coade,R.W. & Mann, S.D., Precrackingstructuresin a creep-rupturedlowcarbon Cr-Mo steel: their nature and detection by light microscopy. Materials
Characterization, 29 (1992) 343-63.