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31 (2012), 759767
Abstract.
1 Introduction
Reformer tubes in refineries, chemical and petrochemical
industries have finite life because of progressive damage
accumulation due to prolonged high temperature exposure
under stress and aggressive environment.
Primary reformer furnace unit of a petrochemical plant
produce hydrogen rich gases for the synthesis of ammonia, methanol and other organic chemicals. The primary reformer furnace consists of catalyst filled heater tubes made
of cast austenitic steel fired from outside. In plants as process fluids consisting of either naphtha or natural gas and
steam pass through these tubes they get reformed as a result
of endothermic reactions giving a mixture of gases rich in
hydrogen. Higher creep rupture strength of this alloy is the
main criteria for selection. The primary heater tubes were
designed for a life time of 100,000 h (11.4 years) at the
design temperature of 1191 K. Primary reformer tubes of
a fertilizer plant have served approximately for 118,260 h
(13.5 years) without any failure. Seven months prior to
this investigation, there was a failure due to increase in
methane slip and this phenomenon re-occurred thrice within
two months. Three to four months preceding the failure,
increase in tube wall temperature and hot spot were reported. At the bottom casing of radiant section, leakage
and hot spots were observed (1st tube in 8th row). Inspection during shutdown showed longitudinal cracks near the
weld joint (1st tube in 8th row) and circumferential cracks
in outlet manifold at the bottom, between the 1st and the
2nd tube in the 8th row. Maximum length of the crack was
62 mm and cracked area showed bulging. Chocking of catalyst due to carbon deposition was reported at the middle
portion of the tube. There was a carbon deposits on the
cracks located at the inner wall of the tube. Heavy carbon
deposition was observed on the catalyst in the area of high
heat flux zone of the burner flame. Flame disruptions for
some burners were also reported. In many cases, the premature failure seems to be the result of overheating leading
to creep damage, and service ageing leading to embrittlement [14]. Failure was investigated prior to this work [5]
and the remaining life was assessed using sample tubes
from the plant during the current shutdown in November
2010. This investigation incorporated measurement of tensile properties at 2981223 K and stress rupture properties
at 11731248 K. Additionally chemical composition, hard-
760
Plant
Unit
Year of retrofit
Process fluid
Inlet temperature of fluid
Pressure inside the reformer tubes
Tube outlet temperature of fluid
Riser outlet temperature
Reformer tube recommended design skin temperature
Outlet manifold pressure
No. of catalyst tubes
Reformer tube dimension
Ammonia-II
Primary reformer
1996
Natural gas C steam
783 K
37 kg=cm2
1093 K
1118 K
1191 K
34.1 kg=cm2
504
OD (outer diameter) : 109 mm;
ID (inner diameter) : 85 mm;
Thickness : 12.5 mm
H39WM (Paralloy make)
40
April 2007
Experimental
2.1
Element
C
Si
Mn
S
Ni
Cr
Mo
Nb
P
Cu
Ti
Zr
Fe
Specified
0.400.45
2.0 (max.)
1.5 (max.)
0.03 (max.)
3337
2428
0.5 (max.)
0.71.5
0.03 (max.)
0.25 (max.)
0.030.3
0.010.3
Bal.
Weight (%)
Analyzed
0.40
1.74
0.74
0.03
33.16
24.14
0.011
0.86
0.013
0.074
0.046
0.0065
Bal.
Centre portion tube cut at the centre of the vertical Table 2. Chemical analysis of the service exposed primary
length (T5),
reformer tube.
Chemical Composition
761
2.4
Hardness
Tensile Test
762
4.0
001
4.0
3.5
001
Cr
3.5
3.0
Si
Ni
2.5
2.0
1.5
1.0
Ni
Ni
Cr
Cr
Fe
C
Fe
Nb
Si
Ni
Cr
Fe
Nb
FeKesc
Fe
0.5
0.0
0.00
Ni
Nb
2.00
4.00
ms%
19.61
4.67
5.40
43.91
5.48
15.34
5.58
6.00
mol%
0.06
0.06
0.05
0.09
0.12
0.19
0.11
8.00
keV
2.0
1.5
1.0
10.00
12.00
14.00
Sigma Net
Kratio
40477 0.0000000
45906 0.0000000
267455 0.0000000
2560441 0.0000000
237858 0.0000000
518262 0.0000000
672750 0.0000000
100.00 100.00
Line
K
K
K
K
K
K
L
Ni
2.5
Ni
Fe
Fe
Cr
Cr
Nb
0.5
Chemicalformula
C
5.27
O
1.67
Si
3.39
Cr
51.07
Fe
6.85
Ni
20.14
Nb
11.60
Total
Counts[x1.E+3]
Counts[x1.E+3]
3.0
0.0
0.00
2.00
Chemicalformula
Si
9.70
Cr
2.11
Fe
5.63
Ni
50.63
Nb
31.93
Total
100.00
Fe
Cr
FeKesc Cr Fe
4.00
ms%
20.41
2.40
5.96
50.94
20.30
100.00
6.00
mol%
0.08
0.15
0.17
0.28
0.19
Ni
8.00
keV
10.00
12.00
14.00
Sigma Net
Kratio
769736 0.0000000
108397 0.0000000
230538 0.0000000
1416958 0.0000000
1788300 0.0000000
Line
K
K
K
K
L
portion) service exposed tube revealing nickel rich precipitates at the inter-dendritic boundaries.
tube region of the primary reformer tube in the earlier investigation [5], as SEM image of the same revealed coarse
dendritic region, which are mostly Cr rich carbide and some carbides at dendritic boundaries and disappearance of fine
of them may be Nb rich carbide. It is in the healthy region intra dendritic precipitation (Figs. 56) [6]. Micro cracks
of the tube which is the centre portion of the tube.
were absent but creep cavitations were observed. It is noteThe main damage mechanism for reformer tube is the
combination of thermal stresses and internal pressure [9
Material
Average hard- NRIM
17]. This combination of stresses causes creep damage that
ness(VHN)
(VHN) [18]
typically develops at the inner diameter or just below the
Bottom portion
203
internal diameter surface [6]. Previous investigation on 20
155160
Centre
portion
210
years serviced exposed MOBIL (Altona) refinery furnace
tubes [16] had revealed similar observation. It was pointed
Top portion
196
out that applied testing stress was different from service
stress because various pressure and wall thickness combi- Table 3. Hardness measurements of the service exposed
nation did exist [16]. There was overheating in the failed reformer tube.
763
8.0
001
8.0
7.0
6.0
Counts[x1.E+3]
Counts[x1.E+3]
5.0
4.0
2.0
1.0
Ni
Fe
Fe
Cr
Cr
Ti
Ni
Ti
0.0
0.00
Nb
Si
Cr
FeKesc
Ni
Ti
CrFe Fe
Ti
5.0
4.0
3.0
2.0
1.0
Ni
Ni
Cr
Cr
Fe
CFe
0.0
0.00
2.00
4.00
6.00
CrFe
FeKesc
Ni
Fe
Ni
Ni
8.00
keV
10.00
12.00
14.00
Chemicalformula ms%
mol%
Sigma
Net
Kratio
Si
1.72
4.39
0.05
119585 0.0000000
Ti
3.64
5.45
0.10
155553 0.0000000
Cr
17.27 23.82 0.13
607000 0.0000000
Fe
3.38
4.34
0.17
89894 0.0000000
Ni
10.93 13.35 0.25
218349 0.0000000
Nb
63.06 48.66 0.14
3063922 0.0000000
Total
100.00 100.00
Line
K
K
K
K
K
L
portion) service exposed tube revealing Nb rich precipitates at the inter-dendritic boundaries.
worthy that the healthy portion of the service-exposed alloy
was free from any signs of deterioration.
3.3
Cr
Nb
6.0
3.0
002
7.0
Mechanical Properties
2.00
4.00
Chemicalformula
C
4.69
Cr
75.75
Fe
14.58
Ni
4.97
Total
100.00
ms%
17.81
66.42
11.91
3.86
100.00
6.00
mol%
0.07
0.15
0.21
0.32
8.00
keV
10.00
12.00
14.00
Sigma
Net
Kratio
41353 0.0000000
3112484 0.0000000
389364 0.0000000
99928 0.0000000
Line
K
K
K
K
764
4.0
002
2.0
002
1.8
3.5
Cr
2.0
1.5
1.0
0.5
Ni
Ni
Fe
Fe
Cr
Cr
C
0.0
0.00
Chemicalformula
C*
Cr
Fe
Ni
W*
Total
Ni
W
W
W
Cr
Fe
FeKesc
W
Ni
1.2
1.0
0.8
0.6
W
W
ms%
0.32
21.86
41.86
35.21
0.74
100.00
4.00
mol%
1.49
23.35
41.63
33.31
0.22
100.00
6.00
Sigma
0.06
0.09
0.13
0.21
0.20
8.00
keV
Net
2359
1015847
1350259
775999
19776
Ni
Fe
Mn
Fe
Cr
Mn
Cr
Ni
Mn
Si
Cr
Mn
WW
0.4
2.00
Ni
1.4
Cr
2.5
Fe
1.6
Fe
Counts[x1.E+3]
Counts[x1.E+3]
3.0
10.00
12.00
Kratio
0.0000000
0.0000000
0.0000000
0.0000000
0.0000000
Ni
FeKesc
0.2
14.00
Fe
Line
K
K
K
K
M
0.0
0.00
2.00
Chemicalformula
C*
0.19
Si
1.16
Cr
21.39
Mn*
1.05
Fe
41.87
Ni
34.12
Nb
0.24
Total
100.00
4.00
ms%
0.85
2.26
22.59
1.05
41.18
31.92
0.14
100.00
6.00
mol%
0.06
0.06
0.09
0.11
0.12
0.19
0.12
8.00
keV
10.00
12.00
Sigma Net
Kratio
1365
0.0000000
70272 0.0000000
1020598 0.0000000
40092 0.0000000
1385356 0.0000000
770951 0.0000000
11306 0.0000000
14.00
Line
K
K
K
K
K
K
L
Centre Portion
Bottom portion
Temperature (K)
298
1123
1173
1198
1223
298
1123
1173
1198
1223
0.2%
Proof
Strength (MPa)
369
100
84
73
71
362
120
103
79
77
Tensile Strength
(MPa)
507
134
104
94
84
561
144
120
102
90
% Elongation
1.7
22.78
33.10
26.31
26.00
6.2
19.28
18.61
28.58
24.56
%
Reduction
Area
0.3
50.46
61.03
62.44
58.00
6.6
46.40
47.71
47.71
40.89
765
200
100
80
(a)
60
Stress, MPa
40
20
10
8
6
(b)
2
26
28
30
32
34
36
38
-3
(c)
perature of the service exposed reformer tube. (b) Variation of ultimate tensile strength with test temperature
of the service exposed reformer tube. (c) Variation of %
elongation with test temperature of the service exposed
reformer tube.
766
Sample location
Centre portion
Bottom portion
Temperature (K)
1248
1248
1223
1223
1223
1198
1198
1173
1173
1248
1248
1223
1223
1223
1198
1198
1173
1173
Stress (MPa)
35
25
48
48
40
45
37
50
42
35
25
48
48
40
45
37
42
50
% Elongation
25.17
7.99
24.95
26.87
23.17
35.37
19.28
33.34
20.06
13.84
11.50
16.53
17.93
17.95
17.90
18.23
17.22
27.96
% Reduction Area
66.81
34.04
57.68
62.43
63.29
60.66
62.59
64.32
68.18
61.72
73.74
61.39
53.89
58.19
54.54
46.84
43.01
63.29
Table 5. Results of accelerated stress rupture tests of the service exposed primary reformer tubes.
Conclusions
Based on analysis of 1173 K to 1248 K stress rupture testing of samples machined from 13.5 years at 1191 K and
15.4 MPa exposed H39WM reformer steel tubing, and additional life of 10.6 years at 1191 K and 15.4 MPa predicted.
This is valid only if there is no evidence of any localized
damage in the form of surface cracks, cavitations or dents
and overheating of the tubes resulting in early onset of creep
damage. Another check for safety of the service exposed
tubes, similar to the current work, in terms of residual life
is recommended to be carried out after expiry of about 5
years of service life from the view of economical and safety
reasons
Acknowledgement
[9] J. M. Brear, J. M. Church, D. R. Humphrey and M. S. Zanjani, Int. J. Pres. Ves. Pip., 78. (2001), 985994.
The authors are grateful to Mr. P. K. Roy for his assistance in conducting high temperature tensile test and to [10] P. P. Psyllaki, G. Pantazopoulos and H. Lefakis, Eng. Fail.
Anal., 16 (2009), 14201431.
Dr. S. Srikanth-Director, NML Jamshedpur for his moral
support and permission to publish this manuscript.
[11] E. A. Kenik, P. J. Maziasz, R. W. Swindeman, J. Cervenka
and D. May, Scripta Mater., 49 (2003), 117122.
References
[1] A. K. Ray, S. K. Sinha, Y. N. Tiwari, J. Swaminathan, G.
Das, S. Chaudhuri and Raghubir Singh, Eng. Fail. Anal., 10
(2003), 351362.
767
[18] NRIM creep data sheet No. 38A, Data sheets on the elevated
temperature properties of centrifugally cast tubes and cast
block of 25Cr-35Ni-0.4C steel for reformer furnaces (SCH
24), National Research Institute for Metals, Tokyo, Japan,
1991.