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51313-02369-Creep Rupture of a Hydrogen Production Reformer Outlet Header of Nickel Base Alloy

Picture for Creep Rupture of a Hydrogen Production Reformer Outlet Header of Nickel Base Alloy
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Product Number: 51313-02369-SG
ISBN: 02369 2013 CP
Author: Laxma Reddy Kethi Reddy
Publication Date: 2013
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$20.00
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Hydrogen gas is in demand in the petroleum refinery for desulfurization and hydro-cracking of heavier hydrocarbons to lighter premium products. The steam methane reformer is widely used in the oil industry to make hydrogen.  The development of super-alloys for high temperature service applications e.g. nickel-iron-chromium alloys in wrought form (UNS N08810/N08811) for reformer outlet pigtails and header became industry standard materials in the 1970s.

Usually even after the intended design life (100000 hours) creep failure is less common in reformer outlet header compared to catalyst tubes. On-stream isolation by nipping is a commonly used maintenance practice in the event of reformer catalyst tube rupture to sustain H2 production. The failure of an outlet header can result not only in a plant shutdown but will also take a longer time to be put back into service.

In this paper an incidence of UNS N08811 header that failed by creep at multiple locations after approx. 210000 hours in service will be described. This paper investigates the mode of failure the current practice of NDT methods to monitor the onset & progressive growth of creep degradation risk-based inspection approach and proactive measures to minimize downtime of production.


Key words: Hydrogen gas steam methane reformer catalyst tube outlet pigtail header Nickel-iron-chromium alloys (UNS N08810 / N08811) creep rupture nipping failure investigation risk based inspection approach minimize downtime of production.
 

Hydrogen gas is in demand in the petroleum refinery for desulfurization and hydro-cracking of heavier hydrocarbons to lighter premium products. The steam methane reformer is widely used in the oil industry to make hydrogen.  The development of super-alloys for high temperature service applications e.g. nickel-iron-chromium alloys in wrought form (UNS N08810/N08811) for reformer outlet pigtails and header became industry standard materials in the 1970s.

Usually even after the intended design life (100000 hours) creep failure is less common in reformer outlet header compared to catalyst tubes. On-stream isolation by nipping is a commonly used maintenance practice in the event of reformer catalyst tube rupture to sustain H2 production. The failure of an outlet header can result not only in a plant shutdown but will also take a longer time to be put back into service.

In this paper an incidence of UNS N08811 header that failed by creep at multiple locations after approx. 210000 hours in service will be described. This paper investigates the mode of failure the current practice of NDT methods to monitor the onset & progressive growth of creep degradation risk-based inspection approach and proactive measures to minimize downtime of production.


Key words: Hydrogen gas steam methane reformer catalyst tube outlet pigtail header Nickel-iron-chromium alloys (UNS N08810 / N08811) creep rupture nipping failure investigation risk based inspection approach minimize downtime of production.
 

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