High Temperature Service Equipment

and Piping Maintenance in Plant

Equipment and piping operating under high pressures and temperatures are affected by creep
damage and severe oxidation, as well as stress corrosion cracking under ambient temperatures. This
article explores maintenance strategy to control the remaining life of the equipment and piping for high-tem-
perature service.

Toshikazu Shibasaki and Takaaki Mohri

Chiyoda Corporation, Yokohama, Japan

Outline Pre-heater Coil

F
igure 1 shows the typical materials used in the The main purpose of the pre-heater coil is to heat the
high temperature system of the steam reformer process gas before being fed into the catalyst tube.
furnace in an ammonia plant. The usual con- Usually, the process gas is heated to about 500°C. The
struction materials for preheater coils, distributor, inlet heating source of the process is the flue gas from the
hairpin tube, catalyst tube, outlet hairpin tube, and out- radiation section of the steam reformer furnace. The
let header are Type 321H stainless steel, 2.25Cr-lMo pre-heater coil is located next to the radiation section.
steel, Type 321H stainless steel, Nb containing heat- It is heated by the radiation of the flue gas and the tem-
resisting cast alloys (IN519, HP-Nb/Ti), Alloy 800H, perature of the coil increases to more than 700°C. This
and 20Cr-32Ni-Nb heat-resisting cast alloy, respective- causes rapid deterioration of the coil due to creep dam-
ly. In this article, we describe the maintenance strategy age. Measuring the outlet temperature of process gas
to control the remaining life for the high temperature monitors the increase in coil metal temperature. The
service. outlet temperature of the process gas should be kept at
There are two main factors which determine the less than the design temperature to avoid a reduction in
remaining life for equipment and piping under high life expectancy due to creep damage. At design condi-
operating pressures and temperatures. One is creep tions, the coil skin temperature will be more than
damage and severe oxidation since those materials are 700°C. In this temperature range, increasing the tem-
applied for equipment and pippins under high pressure perature by only 50°C will reduce the coil life by 20%.
at high temperature operating conditions. Another is This is specifically the case for the lowest tube of the
stress corrosion cracking under ambient temperature coil, which will exhibit creep damage after an expect-
during the turnaround period, or lower temperature gra- ed operating period of more than 100,000 h. It is nec-
dients, for example, on top of the catalyst tube, which essary to examine the tube condition to predict the
is out of the furnace and insulated internally. remaining life expectancy. If sampling cannot be car-
ried out, nondestructive testing, dimensional check and
microprinting for the highest temperature portion and

AMMONIA TECHNICAL MANUAL 156 2002

 Process Preheater Coil (2.25Cr-1Mo Steel)

Distributor (2.25Cr-1Mo Steel)

Inlet Hairpin Tube (Type 321H S.S.)

^\
Ca
Catalyst Tube
(IN519,
( HP-
Nb

ifrrÎTÎiîiiiin

Outlet Hairpin Tube

(Alloy 800H)

Outlet Header (20Cr32Ni-Nb)

Transfer Line (Cold Shell Type)

Figure 1. High-temperature service system of primary reformer in ammonia plant.

AMMONIA TECHNICAL MANUAL 157 2002

 Figure 2. Shape of distributor nozzle and inspection area for creep damage (arrows indicate the inspected
portion).

for the lowest temperature portion, which is located about 500°C, the life of the tube is not reduced by creep
outside the furnace, should be performed and evaluat- damage. However, the temperature condition will
ed by a materials engineer. affect the Type 321H stainless steel tube after a long
service time. If the material has been affected, stress
Distributor corrosion cracking (SCC) at the weldment and inter-
granular cracking of the base metal might occur. The
An inlet header divides the process gas, which has possibility of SCC and intergranular cracking depends
been heated by the pre-heater coil, to the catalyst tubes. on the ambient conditions and the suspension of plant
The distributor is usually made from 2.25Cr-lMo steel. turnaround. Photo 1 shows the result of dye penetration
This material has been used for 20 to 30 years, even inspection (DPI) for the inlet hairpin tube weldment
though the catalyst tubes were sometimes replaced after a long suspension of plant operation. The indica-
from HK40 to IN519, HP-modified materials. If the tions are that the intergranular cracking is due to weld-
temperature of the distributor exceeded 500°C, the ing stress under a wet sulfur containing environment.
material was damaged by creep phenomenon after a Photo 2 is the section of the crack. It is noted that the
long service period. After 20 or 30 years, cracks could crack propagates along the crystal boundaries.
be observed in the outer surface of the distributor. Due As the above infers, the inlet hairpin tubes should be
to the combination of bending stress and the deforma- kept under dry conditions to avoid corrosion cracks
tion of the inlet hairpin tube, these areas should be during downtimes, and DPI should be performed
examined by magnetic particle inspection (MPI) after before starting operations to confirm that no cracking
expected service life. Figure 2 shows some construc- has occurred at the weld.
tion designs of the distributor nozzle and the location
where MPI should be carried out during the plant turn- Catalyst Tube
around. If defects are found, the cause may be estimat-
ed by observing the microstructure of the defect by Creep damage
microprinting.
The catalyst tube is the main piece of equipment in
the highest temperatures under high internal pressures.
Inlet Hairpin Tube It is important to control the life of the catalyst tube to
keep the plant operating safely. Figure 3 shows the
The inlet hairpin tube connects the distributor to the trends for the different materials used for catalyst tubes
catalyst tube to introduce the process gas. The inlet (HK40, IN519 and HP-Nb/Ti). The creep rupture
hairpin tube is usually Type 321H stainless steel. The strength and creep ductility of Nb containing materials
inlet hairpin tubes have been used for a long period as are superior to the properties of HK40, and, recently,
the distributor; because the temperature of the tube is

AMMONIA TECHNICAL MANUAL 158 2002

 Photo 1. Result of dye penetration inspection for cracks (stress corrosion crackings) found in the inlet
hairpin tube to flange weld joint.

Photo 2. Microstructare of stress corrosion cracking found in the inlet hairpin tube
weldment (electrolytic: oxalic acid solution, xlOO).

AMMONIA TECHNICAL MANUAL 159 2002

those materials have been used frequently for the cata- microprinting (replica method) to confirm the metal
lyst tubes, with HP-modified (microalloying) materials temperature and the creep damage.
becoming a standard material for the catalyst tube in
this time. For these materials, it is observed that the Hardness distribution and temperature profile
change of dimension of the tube relates to the con-
sumption of the tube life. The change of the dimension Catalyst tubes are made of heat-resisting cast alloy.
is measurable, therefore, monitoring the change of the The hardness of heat-resisting cast alloy changes with
dimension is very useful to control the remaining tube respect to temperature. In the case of used catalyst
life. The procedure for IN519 catalyst tubes is tubes in the same furnace, the service time is the same.
described as below. The hardness change of catalyst tubes along the tube
(1) The first step is measurement of hardness distri- length shows the temperature profile during the opera-
bution along tube length to find the temperature profile tion.
of the catalyst tube. Figure 4 shows the Vickers hardness distribution
(2) The second step is measurement of outer diame- along the tube length after 15 years of operation. The
ter and tube wall thickness at the same position to eval- temperature at the top portion of the catalyst tube is
uate the amount of creep deformation, which relates to lower than 550°C and the hardness of its portion shows
the creep damage. as cast condition. On the other hand, in the cell, the
(3) The third step is observation of microstructures temperature of the catalyst tube gradually increases in
from the outer surface side of the catalyst tube by the downward direction. Hardness changes along with

4000

_ HK40
• IN519
• HP-Nb,Ti

3000

2000

1000

Tfl
1967 1972 1977 1982 1987 1992 1997

2000
Year

Figure 3. Change in materials for catalyst tubes (from 1965 to 2000).

AMMONIA TECHNICAL MANUAL 160 2002

 260

240

220

200

180

160

140
20 40 60 100

Location (Top Bottom :

Figure 4. Change in Vickers hardness distribution of IN519 catalyst tube after 15

years use.

the morphology of the precipitated carbides due to the change of dimension corresponds to degree of creep
aging. At around the 1 to 2 m portion from the ceiling, damage, and the remaining life of the tube can be esti-
much fine carbide precipitate in the matrix of the cata- mated by measuring the change of dimensions.
lyst tube, and the hardness indicates the maximum The external surfaces of catalyst tubes are exposed to
level. As it descends, the precipitated carbides coalesce the flue gas and attacked by oxidation and a reduction
and coarsen. The distribution density, being the number in the external diameter. Therefore, the external diame-
of carbides in a unit area, decreases and the shape of ters do not reflect the bulging by the creep. The inter-
carbides become massive and then the hardness nal surfaces are exposed to the reformed gas and hard-
reduces. Therefore, the distribution of hardness corre- ly oxidize or corrode with respect to the external sur-
sponds to the temperature profile of the catalyst tube. faces. In fact, the original machining scratches remain
The softest portions are those that have been exposed after a long service time in many catalyst tubes. As
to the highest tube skin temperatures. It is important to indicated above, the increase in internal diameter cor-
find the highest temperature portion, since the creep relates to the creep bulging.
damage in this portion is the most severe, and the In the actual catalyst tubes, there are some manufac-
remaining life is the shortest. turing deviations in sizes for each unit spun-cast tube.
Measurement of Dimensions (Outer Diameter and The manufacturing deviation of the external diameter
Tube Wall Thickness). Catalyst tubes bulge due to creep is bigger than that of the internal diameter, since the
phenomena after long operation periods, and the outer external surface of a unit spun-cast tube is as the cast
diameter increases, as well as the inner diameter. The condition and the internal surface is machined. The

AMMONIA TECHNICAL MANUAL 161 2002

 2

O 1994 to 199S I
o
O 1999102001 J

1 5
g '
of Inner Diameter

-'S f^.
«*

o
O
o>
E
0 <>
° 0.5
o
«> 0 0
0

0
12'O 140 160 180 200 220

Vickers Hardness (Hv)

Figure 5. Relationship between Vickers hardness and change of inner diameter.

manufacturing deviation should be compensated. Relationship between the dimensional change

Measuring the dimensions on both sides of the weld and the hardness
joint and comparing the differences of the internal
diameters can perform the compensation of the devia- Figure 5 shows the relationship between the meas-
tion. This is another reason to measure the internal ured Vickers hardness and the change of inner diame-
diameter rather than to measure the external diameter. ter at the portion of the highest service temperature for
The change of dimensions is calculated based on the the sampled IN519 catalyst tubes from 1994 to 2000. It
initial dimensions of the tube, not based on the dimen- is clear that the softening positively correlates to the
sion of the drawing of the tube. Usually, the portion change of inner diameter.
exterior to the firebox retains its original dimension. Figure 6 shows the relationship between the change
Observation of Microstructure. The microstructure of inner diameter and the estimated creep rupture time
of the catalyst tube changes by the aging, namely tem- at 900°C under 13 MPa, which corresponds to the typ-
perature and time. If the database of microstructures, ical temperature and stress conditions in the actual
which shows the relation of the microstructures and plant at the highest service temperature portion. It is
aging conditions arranged by an appropriate aging observed that larger differences of inner diameter result
parameter such as the Larson-Miller parameter, is in a reduction of tube life. Those creep data were ana-
available, it is possible to estimate the approximate lyzed according to Theta projection and Omega meth-
service temperature of the catalyst tube from the ods, the criteria (numerical value) to assess the remain-
microstructure observation. ing life of the tube.
The creep damage of used catalyst tube material can
also be confirmed through observation of the micro- Case of local overheated catalyst tube
scopic distribution of creep voids and fissures formed
at the interface between the matrix and primary car- When the operator observed the IN519 catalyst tube
bides and/or sigma phases of gram boundaries. through the inspection window after having detected

AMMONIA TECHNICAL MANUAL 162 2002

 0 0 1994 to 19981
Estimated Rupture Urne (hour) at 900 C, 1.4kg/mfn

O 1999 to 2001J
€
°«

0°
—».

vy
AA

^>.

o o
0
°»
_k

S\

) 2 4 6 8
Change of Inner Diameter (%)

Figure 6. Relationship between change of inner diameter and remaining life (esti-
mated rupture time under typical temperature and stress).

something unusual, he found the blue colored flame Photo 5 shows the microstructures of Tube A and
from the external surface of the tube. The tube had been Tube B at the area of maximum bulging. In Tube A,
in operation for about 8 years. The furnace was stopped voids observed at the grain boundaries connected and
and that particular tube (referred to as Tube A) and the formed cracks. However, in Tube B, only small aligned
neighboring tube (referred to as Tube B) were removed voids along the grain boundary were observed.
from the furnace to investigate the cause of the leakage. Figure 9 is the Vickers hardness distribution along
Figure 7 shows the result of inner diameter measure- the tube length of Tube A. Severe softening was found
ment along Tubes A and B facing the burner. In Tube A, only at the portion where the maximum bulging
a large bulging of the inner diameter was detected, and occurred. This means there was a local overheating for
the maximum value was 3.5% at a height of 1.5 m from the tube, in a very limited area.
the floor. However, in Tube B, the maximum bulging of This case is typical of a local overheating accident. It
inner diameter was less than 0.4 %. is important to control the firing of the burner in accor-
Figure 8 shows the detailed measurement of the outer dance with the tube skin temperature and not outlet
diameter for the area (about 2 m range) to find the max- process gas temperature at the outlet header, which is
imum bulging of Tube A. The bulged area was limited the only reference
to about l m length along the tube. Stress Corrosion Cracking (SCC). Another material
Photo 3 is the result of DPI for the tube section at the deterioration, excluding creep damage, is described
location exhibiting maximum bulging. Many cracks below. It is SCC, which occurs at the low temperature
were found in the area of even 0°, means the direction portion where water can exist under pressure. For
faced on the burner. Photo 4 is the macrophotograph of example, (1) the top of the catalyst tubes where the out
the section at the area where many cracks were found. of steam reformer furnace and dead end structure is
Cracks propagated from the inner surface to the outer located, which depends on the design of catalyst tube;
surface. (2) all of the portions are ambient temperature during

AMMONIA TECHNICAL MANUAL 163 2002

 3.5
• Creep Damaged Tube (Tube A)
• Sound Tube (Tube B)

g 2.5
fe

1.5

0.5

20 40 60 80 100
Location (Top — Bottom : %)

Figure 7. Change of inner diameter distribution for creep damaged and sound
tubes.

159

154

Location (Top — Bottom : %)

Figure 8. Change of outer diameter in the area of bulged catalyst tube.

AMMONIA TECHNICAL MANUAL 164 2002

 Photo 3. Result of liquid penetrant examination at the section
of bulged catalyst.

Photo 4. Creep fissures and aligned voids found in the section

of bulged tube.

AMMONIA TECHNICAL MANUAL 165 2002

 Photo 5. Microstructures of creep damages found in lube A (left) and lube B (right).

turnaround. Case 1 is important since these cracks can absorption system, causes the stress of the supporting
be initiated and propagate during operation. The case lug corrosion cracking under welding residual stress of
below is the same as case 1. the supporting lug. We have experienced another stress
Figure 10 is the catalyst tube top, where the inlet corrosion cracking for HK40 catalyst tube. Photo 7
hairpin tubes boss is welded on the side of the catalyst shows the result of DPI for the inside surface of the cat-
tube top area to assist maintenance work. The material alyst tube top. Cracks occurred at the Type 310 stain-
of the catalyst tube is HP-rnicroalloying material, less steel (s.s.) stub-end to HK40 spun-cast tube weld
25Cr-35Ni-Nb-Ti Iron base spun-cast material. Figure jouit. Photo 8 is the microstructure of the cracks. The
11 shows the appearance of SCCs occurring at the cracks propagate intergranular hi Type 310 s.s. and
inside of the catalyst tube top section. Photo 6 is the interdendritic hi HK40. The mixture of sodium-phos-
section of the crack. The crack propagates in the den- phate and sodium-hydrophosphate, which was used for
dritic region. It is called transgranular cracking for boiler chemical, causes the SCC resulting from the
wrought stainless steel materials. The alkaline chemi- residual welding stress of the butt weld joint.
cal corrodant, which is introduced from the acid gas

AMMONIA TECHNICAL MANUAL 166 2002

 120

Figure 9. Vickers hardness distribution of bulged catalyst tube.

Insulation Plug

Stress Corrosion Crackings were

Found In the Inner Surface of
the Catalyst Tube

Supporting Lug Supporting Lug

Weld Boss for Inlet Hairpin Tube

rP-NbJi Catalyst Tube

Figure 10. Catalyst tube top (SCCs were found).

AMMONIA TECHNICAL MANUAL 167 2002

 Supporting Lug

Many Stress Corrosion Crackings

were Found in the Inner Surface
of the Catalyst Tuba •sx><^ (.( I

Supporting Lug

Catalyst Tube

Figure 11. Location of SCCs found in the inner surface of

HP-Nb, Ti catalyst tube.

Photo 6. Microstructure of stress corrosion cracking found in the section of HP-Nb, Ti

catalyst tube (electrolytic: oxalic acid solution, x400).

AMMONIA TECHNICAL MANUAL 168 2002

 Photo 7. Result of liquid penetrant examination for SCCs found in the inner
surface of HK40 catalyst tube.

Photo 8. Microstructures of SCCs found in the section of Type 310 (top: 18c) and HK40
(bottom: 18d) of catalyst tube.

AMMONIA TECHNICAL MANUAL 169 2002

Outlet Hairpin Tube

The outlet hairpin tube guides the reformed gas,

which is the outlet of the catalyst tube, to the outlet
header or transfer line directly. The main purpose of the
hairpin tube is to reduce the stress caused by the ther-
mal deformation of the catalyst tube during operation.
The shape of the tube is like an L, like a U, or others;
it depends on its design. The material of the tube is
Alloy 800H. The metal temperature of the tube is near-
ly 800°C. Creep damage is a phenomenon of the outlet
hairpin tube. Photo 9 shows the result of DPI for the
outer surface of an outlet hairpin tube used for 15
years. Many small longitudinal cracks were found.
Generally, the service condition of the outlet hairpin
tube is mild rather than that of catalyst tubes.
Therefore, the possibility of replacement of the tube is
less than that of the catalyst tube and the duration tends
to be longer than that of the catalyst tube. However, it
is harder to obtain an outlet hairpin tube (wrought
material) than a catalyst tube (spun-cast material). It is
important to assess the remaining life of the outlet hair- Photo 9. Result of dye penetration inspection for
pin tube and necessary to monitor the life expectancy outer surface of the Alloy 800H outlet hairpin
of the tube. It is possible to measure the change of the tube.
outer diameter of the tube.
The measurement of the outer diameter of the outlet would occur at the toe of the outlet header boss weld-
hairpin tubes at each turnaround is the effective method joint. Photo 10 shows the result of DPI at the toe of the
for determining the remaining life, although it is less weld joint where creep damage occurred due to bend-
accurate than creep rupture testing of sampled outlet ing stresses. A circumferential crack along the fillet
hairpin tubes for determining the extent of deforma- weld metal was found on the outer surface of the outlet
tion. The value of the deformation due to bulging of the hairpin tube. Figure 13 indicates the procedure for
tube is more than several percentages, it is measurable maintaining the supporting system of the outlet hairpin
by caliper. Figure 12 shows the relationship between tube.
the depth of creep damage and the bulging of the outer Outlet hairpin tubes are insulated to avoid cooling by
diameter for Alloy 800H outlet hairpin tubes used for the external atmosphere and are protected from expo-
different periods in the same plant. The crack depth of sure to rainwater, and so on. However, after long peri-
25% tube wall thickness corresponds to 8% of bulging ods of use without maintenance, the insulation of the
of the tube. The same tube material has approximately outlet hairpin tube and the protection will deteriorate.
30,000 h of remaining service life. Photo 11 shows the outer surface condition of an Alloy
Each end of an outlet hairpin tube is welded respec- 800H outlet hairpin tube after 15 years of use. The
tively to the bottom of the catalyst tube and to the boss outer surface of the outlet hairpin tube is covered with
of the outlet header. A spring or counterweight at the thick, rough scale. Photo 12 is a microstructure of the
middle of the outlet hairpin tube partly supports weight section of the tube shown hi Photo 10. Half of the tube
of the tube. The life of the outlet hairpin tube is nor- wall has been damaged by oxidation and some longitu-
mally reduced by creep damage due to internal pres- dinal cracks caused by internal pressure were found.
sure as explained above. However, if the supporting All of those tubes had to be replaced by new ones. It is
weight of the tube were not correct, bending stresses

AMMONIA TECHNICAL MANUAL 170 2002

 - •

PÄJ l
I.B C'*
1.4
'
.1.Z
/
Depth of (12}
Crack /
(mm) 1 ° >

4.8 I/
o
•K6
X« •W •

0.4 _x X
<1S) x^ ï " '

0,2
.... f^jH»
"tr <
D 1 a 3 4 5 S ? 8

Change of Outer Diameter (%)

Figure 12. Relationship between change of outer diameter and depth of

Photo 10. Result of dye penetration inspection (DPI) for the fillet weld joint of
Alloy 800H outlet hairpin tube.

AMMONIA TECHNICAL MANUAL 171 2002

 Figure 13. Maintenance of outlet hairpin tube supporting system.

AMMONIA TECHNICAL MANUAL 172 2002

necessary to check the weather protection to avoid Conclusion
rainwater directly touching the insulated tube, as
shown in Figure 14. We propose a procedure for maintenance of high
temperature systems of steam reformer furnaces to
Outlet Header (SubcoIIector) control the remaining life expectancies, as stated
below.
An outlet header is located between the catalyst tubes (1) It is necessary for the tube to be sampled and to
and the transfer line, which is cold shell design, to be examined to find the remaining life after more than
improve the maintainability of the high-temperature 10 years service. If it is impossible to be sampled,
service system. It is connected to the catalyst tube with nondestructive testing, dimensional checking, and
the outlet hairpin tubes and joined to the transfer line microprinting for the highest temperature portion and
directly. If a leakage of process gas occurs, the conse- the lowest temperature portion, which is located at the
quences are greater than that of the catalyst tube. outside of the furnace, should be performed and evalu-
Therefore, optimum material selection and design have ated by a materials engineer.
been performed as shown in Figure 15. (2) If the temperature of the distributor is more than
Photo 13 shows the result of DPI for the weld joint in 500°C, creep causes damages to the material, especial-
the Tee portion of the HK40 cast material's outlet head- ly the fillet weld joint of the nozzle. It is the stress con-
er. These cracks were caused by creep damage due to centration portion, due to the bending stresses with the
high residual welding stresses and less stress relieving deformation of the inlet hairpin tube, that should be
properties of aged HK40 material. This occurred after tested with magnetic particle inspection after extended
only 2 to 4 years service. service.
Photo 14 shows the macrophotograph of the crack (3) The inlet hairpin tubes should be kept under dry
found in the section, where the outlet hairpin tube boss conditions to avoid corrosion cracking during down-
was welded to the outlet header. That portion is diffi- time, and DPI should be performed before restarting
cult to insulate perfectly rather than the straight tube, operations to confirm no crack at the weldment after
and some crevices exist between the boss and the tube. prolonged turnaround.
This condition with insulation caused a temperature (4) Monitoring the changes of dimensions is very
gradient and then thermal stresses arose at the tube useful to assess the remaining tube life for Nb contain-
side's toe of the fillet welding of the boss to the tube. ing catalyst tube materials. The procedure is described
The temperature of the outer surface side was lower below.
than the inner surface side, and tensile thermal stresses The first step is measurement of hardness distribu-
occurred at the outer surface side. The crack was tion along tube length to find the temperature profile of
caused by creep damage due to thermal stresses as the catalyst tube. The next step is measurement of outer
explained above. It took an extended period of more diameter and tube wall thickness at the same position
than 5 years to propagate from outside to inside. to evaluate the amount of creep deformation, which
HK40 cast materials have been replaced by 20Cr- relates to the creep damage. The final step is observa-
32Ni-Nb-0.1C Iron base cast material (20Cr-32Ni-Nb), tion of microstructures from the outer surface side of
as shown in Figure 15, since the main reason for these the catalyst tube by microprinting (replica method) to
damages is the lower stress relieving properties of confirm the metal temperature and the creep damage.
HK40 cast materials following use at high temperature (5) The measurement of the outer diameter of the
service conditions. The mechanical properties of used outlet hairpin tubes at each turnaround is the effective
20Cr-32Ni-Nb materials at high temperature have been method for determining the remaining life, and it is
described in another article. In the outlet header sys- necessary to maintain the supporting system of the out-
tem, it is important to inspect the condition of insula- let hairpin tube.
tion during operation and turnaround. If the design (6) In the outlet header system, it is important to
temperature of the outlet header is above 700°C, 20Cr- inspect the condition of the insulation during the oper-
32Ni-Nb is a better material selection. ation and turnaround. If the design temperature of the

AMMONIA TECHNICAL MANUAL 173 2002

 Photo 11. External appearance of severe oxidized Alloy 800H outlet hairpin tube.

Photo 12. Macrostructure of the section of severe oxidized Alloy 800H

hairpin tube.

AMMONIA TECHNICAL MANUAL 174 2002

 Fuma« Main Column
«ping for Fuel

1F Platform

Fillet Wald

Protection of ,Ra|hy Water Leakage

Figure 14. Samples of rain water proof method.

100 D-o-QOQ-g
20/32Nb Outlet Header
25/35Nb,Tl Catalyst Tube

1970 1975 1980 1985 1990 1995 2000

Year

Figure 15. Change in advanced materials for outlet header and catalyst tubes.

AMMONIA TECHNICAL MANUAL 175 2002

 Photo 13. Result of liquid penetrant examination for the HK40 outlet
header (many cracks were found in the outer surface of Tee-portion).

Photo 14. Crack found in the Alloy 800H boss and HK40 outlet
header fillet weld joint.

AMMONIA TECHNICAL MANUAL 176 2002

outlet header is above 700°C, 20Cr-32Ni-Nb is the bet- Ammonia Plant Safety & Related Facilities, Vol. 35,
ter material selection. AIChE, New York (1995).
Shibasaki, T., K. Takemura, and T. Mohri, "Life
Literature Cited Assessment of Alloy 800H Tubes hi Primary
Reformer Furnace," Ammonia Plant Safety &
Shibasaki, T., K. Takemura, and T. Kawai, "Stress Related Facilities, Vol. 37, AIChE, New York
Corrosion Cracking of Heat Resisting Alloys for (1997).
Steam Reformer Plant," Ammonia Plant Safety & Shibasaki, T., K. Takemura, and T. Mohri, "Stress
Related Facilities, Vol. 23, AIChE, New York Corrosion Cracking of Nb-Containing Cast Alloys
(1981). for Steam Reformer Furnace," Ammonia Plant
Shibasaki, T., K. Takemura, T. Kawai, and T. Mohri, Safety & Related Facilities, Vol. 38, AIChE, New
"Experiences of Niobium-Containing Alloys for York (1998).
Steam Reformers," Ammonia Plant Safety & Shibasaki, T., T. Mohri, and K. Takemura,
Related Facilities, Vol. 27, AIChE, New York "Dimensional Check of Catalyst Tubes to Assess
(1987). Remaining Life," Ammonia Plant Safety & Related
Shibasaki, T., T. Mohri, and K. Takemura, "Experience Facilities, Vol. 39, AIChE, New York (1999).
with Cast Material for Steam Reformer Furnaces," Shibasaki, T., T. Mohri, and K. Takemura,
Ammonia Plant Safety & Related Facilities, Vol. 24, "Experiences with Nb Containing Cast Materials for
AIChE, New York (1994). Reformer Furnace," Ammonia Plant Safety &
Shibasaki, T., T. Mohri, and K. Takemura, "Remaining Related Facilities, Vol. 40, AIChE, New York
Life Assessment of Nb-Containing Catalyst Tubes," (2000).

QUESTIONS AND ANSWERS

Rob Gommans, Gommons Metallurgical Services: In creep voids and fissures formed in the outside surface.
reference to the hardness measurements described for Gommans: Figure 6 shows the relation between inner
catalyst tubes, is that done during turnaround or is a diameter change and remaining life. Has the effect of
tube taken out for measure? start/stop cycles been taken into account?
Toshikazu Shibasaki, Chiyoda Corporation: The Shibasaki: The effect of start/stop cycles does not
hardness of used catalyst tubes is measured along the include the assessment of remaining life of IN519 cat-
tube length during turnaround. The main purpose of alyst tubes. This is because stress relaxation property
the measurement is to estimate the distribution of the of IN519 materials is superior than HK40 materials
tube skin temperature and to confirm the location on and the total number of start/stop cycles for the plants
the maximum tube skin temperature. shown in Figure 6 is nearly same, 15 to 18 cycles.
Gommans: Why is replica (microprinting) taken at Gommans: What medium (source) caused sever oxi-
OD; while creep damage starts at OD? dation of Alloy 800 outlet pigtail?
Shibasaki: The main purpose of microstructure obser- Shibasaki: The insulation materials of the sever oxi-
vation at outer surface is to estimate the approximate dized Alloy 800H outlet tube were analyzed by
service temperature of the catalyst tube based on the EDX.Sulfur and Chlorine were detected. It is assumed
distribution of tube skin temperature examined by that some compounds including those elements would
hardness measurement. Especially at the last stage of accelerate the oxidation of the tube. However, if there
creep damage, the damage level can also be confirmed were no rainwater, the sever oxidation would not
through microscopic observation of the distribution of occur.

AMMONIA TECHNICAL MANUAL 177 2002