Sie sind auf Seite 1von 13

1

FATIMAFERTILIZERCOMPANYLIMITED
TSD/INSPECTIONDEPARTMENT
F101PrimaryReformerCatalystTubesNorthSide

Equipment:F101(CatalystTubesReplacement) Plant:Ammonia

InspectionTechnique:VI,DPT,RTandUTm Date:04/04/13

Introduction&BriefHistory:
TheprimaryreformeratFatimaFertilizerCompanywassuppliedbyFosterWheelerintheUSA,
and is a Terrace Wall type with two levels of burners in each wall. It has two radiant cells
containing the catalyst tubes. The flue gases flow from the radiant section to the single
centrally mounted convection section through horizontal ducts which contain the Hip coils.
The flue gases are extracted from the convection section by two Induced Draught Fans
mounted on the top of the convection section. The furnace has two terrace wall radiant
sections. The cells have two rows of 20 burners on each wall (total 160 for the complete
furnace).Thecatalysttubesareinasinglerowinthemiddleofeachradiantsection,heatedby
theburnersfiredfrombothsides.Eachradiantsectionhas130catalysttubesmadeupof25Cr
35NiNbMicro,Schmidt&Clemenstubes.

DuringtherelocationofAmmoniaPlantfromKEMIRAROZENBURGallthereformertubeswere
thoroughly inspected by IESCO in the year 2007. The inspections performed were collectively
calledHscanningofthetubes.AftertheHscanareportwasissuedinwhichallthetubeswere
dividedintofourmaincategoriesA,B,C&Dthesecategorieswereonthebasisofhealthof
the tubes and their remaining life. A being the healthiest tubes with maximum life and D
beingpoorhealthtubeswithminimumornolifeavailable.Soonthebasisofthisreport,best
tubes from Category A & B were selected for installation in Fatima Fertilizer primary
reformer.Atotalof130tubeswereselectedwhichweretheninstalledinthenorthcellofthe
primary reformer furnace. The South side tubes at the time of construction were completely
changedandreplacedwithnewTubesfromSchmidt&Clemens.

Duringtheannualturnaroundof2011theNorthcelltubeswereinspectedbyDONEGANIItaly,
after their assessment a report was issued which estimated the remaining life of the tubes to
be around four years. Hence considering the aforementioned it was decided to replace the
existingNorthCelltubeswithnewtubes.

SpecificationofNewCatalystTubes:

Vendor: Schmidt&Clemens

MaterialofTube: 25Cr35NiNbModified

LengthofTube: 14.160m

OuterDiameter: 139.7mm

MeanSoundWallThickness: 9.5mm

SpecificationofOutletHeader:
Vendor:
MaterialofTube: 2032Nb
Length: 24.980m
OuterDiameter: 350.824mm
InnerDiameter: 276.225mm

SpecificationofInletHeader:
Vendor:
MaterialofTube: ASTMA312TP321H
Length: 24.875m
OuterDiameter: 304.8mm
InnerDiameter: 284.18mm

SpecificationofStresscollar:
Vendor: Schmidt&Clemens
MaterialofTube: GX45NiCrSiNbTi3525
Length: 89mm
OuterDiameter: 57.32mm
InnerDiameter: 44.5mm
SpecificationofInletPigtail:
MaterialofTube: ASTMA335GrP11
OuterDiameter: 42.2mm
InnerDiameter: 35mm
3

SpecificationofHairPin:
MaterialofTube: Incloy800HT
Length: 1010mm
OuterDiameter: 42.2mm
InnerDiameter: 32.5mm

ElectrodeSpecification:

ERNiCr3(NoHeatTreatment,NoPreHeating)

REPLACEMENTJOB

Abriefchronologicaldescriptionofeventsthattookplaceduringthecatalysttubereplacement
jobisasfollows:

The catalyst tubes were purchased from S+C and arrived at site in 2012, and were
dimensionallyandphysicallyinspected.AplanforthereplacementofNorthSideCatalysttubes
was made. The job was contracted out, and the contract awarded to M/S Descon Engineering
Company. Before job execution the job execution plan was discussed between contractor and
FFCL maintenance department. The procedure consisted of cutting out the inlet pig tails from
catalyst tube socket joint, and removal of the hair pin from the outlet header joint and old
catalysttube,afterthistheoldcatalysttubewaspulledoutandnewwasinstalledinitsplace.
Hence there were three points where the welding of the catalyst tube was required, one was
the socket welded joint between the inlet pig tail and the catalyst tube, second a socket joint
betweentheoutletheaderandthehairpin,andthethirdwasabuttjointbetweenthesocket
of the catalyst tube and the stress collar which is mounted on the hair pin for expansion
provision.

WeldingProcedures:

Theweldingproceduresforthejointbetweenthecatalysttubeandtheinletpigtail&thehair
pin with the outlet header were provided by Descon Engineering. The welding procedure for
thebuttjointbetweenthestresscollarandthecatalysttubewasprovidedbyFosterWheeler.

InspectionScope:

Theinspectionjobscopeduringthisactivityconsistedof:

Y LPE(LiquidPenetrantExamination)ofalltheweldingjointsasperweldingprocedures;
Y SFT (Soap Film Test) of the all the installed catalyst tubes after completion of welding
activityat2Kg/cm
2
gpressureofNitrogen.

Problem

Duringth
of weldin
following
manner:

Crackin

Whenth
the oute
pictureb

This prob
were bei
header, t
assuranc

msFacedD
heexecution
ng, material
g is the list
Crackingoft
Failingofthe
gofOutle
ehairpinw
er surface of
below:
blem did no
ingwelded,
the procedu
e.
DuringJob
nofthejob
l of the com
and brief e
heJointand
estresscolla
tHeader&
wasweldedw
f the socket
t occur in o
a strategy w
ure accordin
Execution
somecritica
mponents b
explanation
dMaterialof
arjointsduri
&HairPin
withthesock
t and near t
ne or two t
wasdevelop
ng to which
n:
alissuesaro
eing welded
of the prob
fOutletHea
ngtheSFT;
Welding:
ketoftheou
to the weld
ubes but wa
ped which in
welding wa
osewhichw
d and the q
blems that
derafterha
utletheader
in the heat
as prevalent
ncluded the
as applied a
werepertaini
quality of w
occurred in
airpinweldin
rcracksstart
t affected z
t in most of
review of m
and proper j
ingtothequ
orkmanship
n a chronolo
ng&
tedappearin
one as show
the tubes w
material of O
joint prepar
4
uality
. The
ogical
ngon
wn in
which
Outlet
ration

Materia

Metallog
headerw
of result
thermalf

JointPr

During th
fabricato
therevie
cutsinth
grinding

Welding

Whenth
Clemens
procedur
anewpr
procedur
procedur
buttering
welding
Radiogra

Failingo

After the
performe
05tubes
qualityo
considera
collarjoi
to be pe
SFT.Soa
alAnalysis
graphyofOu
wasdoneby
s it was fou
fatigueand
reparation
he cutting a
ors did not g
ewofthepro
hesocketw
ofthesurfac
gProcedu
isissueoccu
were also
resfromEng
rocedurewa
re consisted
re, after the
glayerswith
procedure
phyof28jo
ofthestre
e welding jo
edbypressu
werefound
ofweldingat
ationdueto
ntsshouldb
rformed of
aftertherep
s:
utletheader
FatimaQA/
und out that
materialano
:
nd grinding
grind the sur
oblemitwas
hichwerea
ceofsocket
reReview
urredsugges
taken, they
gro,S+C&D
asdeveloped
d of weldin
e crack occu
hInconelWi
consisted o
ointsatrando
esscollarjo
b was comp
urizingthere
dleakingfro
tthestressc
othecrackin
beperforme
all the tube
pairworkco
rwasperfor
/QC.Alsoha
t intergranu
omalies.
out of the
rface of the
sobservedt
lsothereas
wasensure
:
stionsfromo
y provided t
Desconandt
dwhichwas
ng of the s
rred the cra
ireusingGTA
of LPE of
omwasperf
ointsdurin
plete a soap
eformingloo
omthestres
collarsides
gproblem.
edtoinspect
s including t
mpletedon
medbyPSQ
rdnessofth
ular oxidatio
old hair pin
socket prop
hatoldweld
onofthiscr
edbeforethe
otherindust
their weldin
takingintoa
pertinentto
ocket joint
ack was to b
AWwelding
the joint, a
formedforf
ngtheSFT:
p film test of
opto0.5kg
scollarside
inceatfirst
Itwasdecid
tthestreng
the five tub
thefivetub
QCA,andDim
hematerialw
on creep cra
n from the o
perly, when
dingwasstil
racking.Soi
estartofwe
trieslikeEng
ng procedur
accountthe
otheexistin
of the ou
be ground up
gwereapplie
also proper
furtherrelia
:
f the newly
g/cm
2
gdurin
e.Thisdrove
theoutleth
edthatthe
thofthere
es which we
besradiogra
mensionalv
wasmeasure
acking was
outlet heade
inspection
lintactand
twasinstru
elding.
groChemica
res, after re
findingsof
ngpredicam
tlet header
p to 4 mm a
ed.TheNDE
r heat inpu
bilityassura
installed ca
ngtheSFTa
eimmediate
headerside
Radiograph
mainingtub
ere found le
phyofthe1
erificationo
ed.Afteran
occurring du
er socket De
was done d
therewere
uctedthatpr
alsandSchm
eview of we
materialan
ent.Thiswe
r as per De
and two to t
Esappliedin
ut was ens
nceofjoints
atalyst tubes
atotalnumb
eattentiont
wasmoreu
yofallthes
bes.TheRT
eaking durin
130jointsbe
5
ofthe
alysis
ue to
escon
uring
small
roper
midt&
elding
alysis
elding
escon
three
nthis
ured.
s.
s was
berof
othe
under
stress
was
g the
egun.
6

Afterextensivehoursofradiographictestingtheresultswerereviewedandweldingjointof18
tubes were found defective. The joints of these tubes mostly had cut outs which would have
eventuallyresultedinleakage.Sothejointsofthesetubeswereallgrindedofffromthestress
collarsideandreweldedunderstrictInspectionvigilance,aftertheweldingwascompleteagain
SFT was performed at 2 kg/cm
2
g, this time 03 joints between stress collar to catalyst tubes
werefoundleakingagain.SothesetubeswererepairedandagainSFTwasperformedthistime
noleakagedetectedandpressureofthesystemwasbuiltto5kg/cm
2
g.
Atotalof156jointswereradiographedduringtheprocess.Furtherthetwotubeswhichwere
replaced in the South cell were also radiographed and one was found unsatisfactory hence it
wasalsorectified.

Conclusion&Recommendation:

Taking into account above events and workings following are conclusions and
recommendations:

Replacement of outlet headers for the primary reformer furnace is suggested as the
existing headers have lost their material properties due to thermal fatigue and aging.
Further due to improper preservation in Kemira the material of the out let headers
mighthavelostitsintegralstrength.
Proper workmanship of welders, fabricators and team involved is to be ensured and
practiceonMockupsaftertheproperselectionofweldersisnecessaryforsuchcritical
jobs.
Anewprocedureforrepairofthecrackedoutletheaderjointswaspreparedtakinginto
accountdifferentweldingproceduresofdifferentindustriesandhencetheproblemwas
eradicated.
NextinspectionofweldingjointsofthecatalysttubesistobeplannedafterOneYear.

Im
Burrs&
Pict
mproperGrin
CutsonGrin
torialView

ndingofHead
ndedSocket

w
derSocket
tJointofHeaader
7

S
S
tressCollar
tressCollar
JointDuring

JointDuring
gWelding
gWelding
8

Repa airDetected
Repai
InSocketJo
redSocketJ
ointofHead
JointofHead

er&HairPin
der&HairP
nduringDPT
Pin
T
9

Sock ketofCataly
Repairof
ysttubesbef
StressCollar
forewelding
rJoint
g
10

DPTResulto
DPTResulto
ofStressCol

ofStressCol
llarJoint
llarJoint
11

Inte
FlangeFac
ernalPitting
cingWasReq
andRustob
quiredOnNe
bservedinFl
ewCatalyst
langeofCata
Tubes.
alystTubes.
12

Deteriorat tedFlangeFaceoftheNNewCatalysttTube.
13

Das könnte Ihnen auch gefallen