oO GBH Enterprises Ltd. @ steam Reforming: Tube Design Wwe Gerard B. Hawkins Managing Director@ GBH Enterprises Ltd. Aim » The aim of this presentation is to - Give an understanding of - Tube design principles >» Tube manufacture ° Failure mechanisms > Inspection techniques , —oO GBH Enterprises Ltd. Reformer Tube Design - Based on predicted creep life of material - Laboratory short-term test are performed for each material time to rupture is evaluated for a range of temperatures at constant stress a range of different stresses done - All of the data for a given material can be represented in one diagram by defining the Larson-Miller parameter, P, as a function of time (t) and temperature (T) - Data is analysed statistically and extrapolated to longer time-scalesoO GBH Enterprises Ltd. Larsen Miller Plot @ 100,000 P=T (log (t) + K) 50,000 1000 where T = temperature time K = constant 10,000 5,000 Rupture Stress (psi) 1,000 6 #617 :« «6186 ~619) «620 21 22 23 24 #25 26 P (Larson-Miller Parameter)O GBH Enterprises Ltd. Larsen Miller & Tube Design Oo - Process pressure (stress) is defined - Get P from Larson-Miller curve for a given metallurgy » From P, assuming a desired life (t) of typically 100,000 hours, a maximum allowable temperature (T) is defined » Repeat calculation until satisfactory design achieved - Doinclude some margin » Use 80% of the average stress ° Allow for 25°C difference between design temperature and maximum allowable operating temperature . —Oo GBH Enterprises Ltd. — Design Margins - Stress Data Used Average Reported Stress Stress Design Curve 80% of Average Reported Stress Pr Temperature© GBH Enterprises Ltd. Max Allowable & Design Temperature Average Reported Stress Stress Maximum Allowable Operating Temperature sik Temperature Design Curve 80% of Average Reported Stress. Design Temperature© GBH Enterprises Ltd. Tube Life @ - Tube life is usually 100,000 hours - In reality statistics have been used » Should expect 2% failure before 100,000 hours - Provided tubes are operated at Maximum Allowable Operating Temperature ) —oO GBH Enterprises Ltd. Effect of Temperature on Life Mean Tube Life (Hours x 1000) 50, 900 950 1000 1050 1100 (1560) (1650) (1740) (41830) (1920) (2010) Temperature °C or °FoO GBH Enterprises Ltd. Material Types HK40, Alloy HK40, 20% Ni 25% Cr IN519 Alloy IN519 24% Ni 24% Cr 1% Nb 36x Manaurite 36X (Pompey) 33% Ni 25% Cr 1% Nb 800H Incoloy 800H 21% Cr 600 Incoloy 600 15% Cr 1% Min H39Ww Alloy H39W (APV) 25% Cr 1% Nb H39WM Paralloy H39WM 25% Cr 1% Nb + Ti XM Manaurite XM 25% Cr 1% Nb+Ti KHR35CT Kubota Heat Resistant 25% Cr 1% Nb + Ti0.45%C A304 Stainless Steel 18% Cr 800H and 600 are for GHR tubes A304 is only suitable for Bayonet tubes.oO GBH Enterprises Ltd. Material Types hk40_ insl9 10 wn Allowable stress (MN/m*) 2 700 740 780 820 860 900 940: 980 720 760 800 840 880, 920 960 1000 Temperature °C© GBH Enterprises Ltd. HK40 : 25 Cr/ 20 Ni » Development of wrought stainless steel » Historically “standard” material for the last 30 years » Generally available - Served industry well (reliable) =© GBH Enterprises Ltd. HP Modified : 25 Cr/ 35 Ni+Nb - Available for the last 30 years - More expensive than HK40 - Choice of thinner tubes at same price, or longer lives - Typical names include H39W, 36X i —GBH Enterprises Ltd. Microalloy : 25 Cr/35 Ni+Nb + Ti » Most recent development - Twice as strong as HK40 - Cost effective (not twice the price) - Offers options of higher heat flux, increased catalyst volume, fewer tubes, improved efficiency or longer tube life - Requires skill to produce - Typical brands include H39WM, XM, KHR35CT PRGBH Enterprises Ltd. © 1K Alloy Developments @ Ni, Cr, c Microalioy Additions Improved Improved Carbides ‘Carbides TUBES MADE BY CENTRIFUGAL CASTINGS =—— (High Carbon 0.4%) —- HP Mod Microalloys. Low Carbon 25/3511 25/35/41 plus Stainless CriNiINb Cr/NiIND Wrought additions Pipes Creep Strength 1960 41975 1985Comparison of Alloys —eearaT] 35 = e012 Si = 7 3 om = a E 0.008 s = o P20 = — 6 a 5 = 2 10 3S 0.006 Das a = g 5 % a 2 > 2 5 2 fio o £ 5 5 & Be 9 + z 0.002 = = Tube Material Tube Material Based on 425.2mm (4.93") OD tube, 35.7 kglcm? (508psi) pressureGBH Enterprises Ltd. Manufacturing Methodology© GBH Enterprises Ltd. Manufacturing Methodology© GBH Enterprises Ltd. Welds @ - Welds of different metallurgies are a source of weakness - Tube material developments with resultant higher stresses put more demands on welds - PAW and EBW now increasingly available —narrow welds —no shrinkage — flexibility in tube metallurgy (no consumable required) - With HK40 welds weakest point » Therefore placed welds away from peak heat flux i =oO GBH Enterprises Ltd. Failure Mechanisms - Creep O - Slow, sustained increase in length/diameter as a result of stress at elevated temperature - Culminates in rupture Creep Strain r | | Exposure TimeGBH Enterprises Ltd. Creep Propagation© GBH Enterprises Ltd. Common Failure Modes @ Normal “end-of-life” failures —creep rupture —weld cracking due to creep - Overheating accelerates normal “end-of-life” —over-firing —flame impingement - Thermal cycling also accelerates normal “end-of- life” PR© GBH Enterprises Ltd. Uncommon Failure Modes - Thermal gradients » Thermal shock - Stress corrosion cracking » Dissimilar weld cracking + Tube support system i =i) GBH Enterprises Ltd. Failure By CreepOo GBH Enterprises Ltd. Creep Rupture - Cross SectionoO GBH Enterprises Ltd. ok Failure at Weld@ GBH Enterprises Ltd. Actions to Take if Tube Fails @ - If leak is small with no impingement on neighbouring tube, continue running! But monitor regularly - Replace tube - Nip pigtails (but consider effect on remaining tubes) ioO GBH Enterprises Ltd. Pigtail Nipping O Nipped Tube Header niet Pigtail == === Bofore Leak nip Impingement on Alter refractory and other nip tubes Header ce Outlet Pigtail© GBH Enterprises Ltd. Inspection Techniques » NDT —visual examination ~—tube diameter (or circumference) measurement —ultrasonic attenuation ~—radiography —metallurgical examination rr —LOTIS™oO GBH Enterprises Ltd. Classification of Problems Damage — Corresponding Parameter Action in Plant A - observe B - observe, fix inspection intervals c -lim rvice until D replacement -plan immediate replacement Creep Strain Exposure TimeoO GBH Enterprises Ltd. Visual Examination - Prior to shut-down —hot tubes, hot spots, leaks » Bulges, distortion, scale, color, staining —can indicate overheating —adequate access (scaffolding) needed » Use TV camera to look at bore —cracking often starts in bore@ GBH Enterprises Ltd. Girth Measurement @ - Auseful, often undervalued method - Tube diameters as cast can vary by up to 3 mm - 1% growth (around 1 mm (40 thou)) significant ° HK40 - Bulge to 2-3% then fail ° HP Alloys - Bulge to 5-7% (less data) then fail » Must have base-line readings » Need to measure at same locations » hot spot and max temp areas » Tubes can go oval P - Need staging for accessoO GBH Enterprises Ltd. Ultrasonic Attenuation 9 o ol oO a 45° AN x4 Sketch of the inspection system 1 Inspected tube 6 Water chamber 2 Emitting probe 7 Ultrasonic pulser 3 Receiving probe 68 Amplifier 4 Probe assembly 9 Analog gate 5 Water feed 10 RecorderGBH Enterprises Ltd. Ultrasonic AttenuationoO GBH Enterprises Ltd. Ultrasonic Attenuation @ - Excellent in principle - Poor track record in practice — tends to fail sound tubes - Difficult to calibrate - Best to use repeat tests — look for deterioration - Manufacturers recommend radiography of suspect areas - Scaffolding not needed PeoO GBH Enterprises Ltd. Radiography @x¢ - Use in suspect areas — hot spots and bulges - Main benefit in butt weld inspectior - Time - consuming > area sterilisation - Limited to sampling » Sensitivity ° accurate alignment * catalyst removal Staging needed ,—=oO GBH Enterprises Ltd. Eddy Current Measurement » Eddy current measurement ¢ Similar crawler to ultrasound device ° No contact, uses AC coil/sensing coil » Baseline readings recommended - Issues ° Magnetic permeability variation in HP alloy ° Depth of penetration through wall less sensitive to inner wall cracks - Can also include OD measurement . —GBH Enterprises Ltd. LOTIS™ Tube Inspection Do eccirin of obtaining measurements within 0.002” (0.05mm), allowing tube diameters to be determined within 0.05% » Tubes can be scanned quickly - typically 3 minutes per tube - Well proven and reliable equipment Used by the US military for over 20 years > Proven in methanol plant reformers over 15 years iO GBH Enterprises Ltd. LOTIS™ Tube Inspection Oo » GBHE experience from design and operation of reformers can be used to interpret LOTIS creep measurement data » Assessment of remaining tube life - Recommendations for adjusting process conditions to optimise performance and life - Recommendations for adjusting firing pattern to compensate for differential creep iGBH Enterprises Ltd. © 1K LOTIS™ Tube Inspection O Axial Position (In) iki —Good Tube —Tube with Creep Damage Tube Diameter (in) > anGBH Enterprises Ltd. LOTIS™ Tube InspectionGBH Enterprises Ltd. >» LOTIS™ Tube Inspection Set up takes less than 30 minutes LOTIS can be used on horizontal tubes prior to installation No couplants (water or gel) required & no damage to the tube Typically used on new tubes as a quality control check and to establish a baseline Used at each catalyst change (4-5 years) to assess damage and collect data for allow tube life prediction and reformer tuning Can be used on aged tubes to compare creep with baseline of top section Used on failed tubes to assess actual creep strainoO GBH Enterprises Ltd. LOTIS Compared to External Inspection External inspection can be confused by rough tube exterior Tube bowing can restrict access to external tube crawlers Refractory can restrict access to external inspection External inspection tends to rely on careful interpretation, which may be subjective » LOTIS gives a precise measure of diameter PeGBH ENTERPRISES, LTD VULCAN Catalyst Process Technology Consultancy Sales and Service Gerard B. Hawkins Managing Director, C.E.0. Skype: GBHEnterprises Office: +1-312-235-2610 Cell: +52 55 2108 3070 GBH@GBHEnterprises.com HawkinsGerardB@qmail.com www.gbhenterprises.com www. linkedin. com/in/gerardbhawkins www. gplus.to/GBHEnterprises www. renaltenergy.com