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In this paper some failures are described that occurred in the aging ammonia plants of OCI Nitrogen
in Geleen. Three failures cases affected the reforming/waste heat recovery section of the plant.
These failures could be related to the aging of the plants in combination with an underestimation of
the impact of certain failure mechanism.
Jack Stoffels
Sitech, Geleen, The Netherlands
1971. The other plant (AFA3) was designed and 3. Crack indications at the transition be-
constructed by M.W. Kellogg based on Kel- tween the reformer/riser tubes and the
logg's reduced energy ammonia technology; the weldolet of the outlet header of the
plant was commissioned in July 1984. AFA3 plant.
In both ammonia plants a number of aging fail- Case 1. Failure of reformer inlet
ures appeared in a relatively short period (the pigtails in the AFA2 plant
last 3 years).Aging is not only determined by
the age of the plant, but is also about what is Introduction
known about its condition. In this paper three
failures are described, the actions taken to repair After the Turnaround (April 2014), two leak-
and the lessons to be learned to prevent these ages occurred just after the start–up of the am-
failures in the future. monia plant (AFA2) at the inlet pigtails of the
primary reformer.
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Details
Process parameters
P T
[barg/psi] [°C/°F]
Design 41/595 613/1135
Process ~ 33/479 ~ 591/1096
Table 1. Process parameters at the inlet pigtails
of the reformer
The age of the pigtails is 43 years. The pigtails Figure 2. Indication of a Leakage
were still from the original installation in 1971.
During these 43 years it is estimated that these Failure investigation
pigtails have had 43 x 5 = 215 start/stops.
A failure investigation has been carried out
The process gas flowing through the inlet pig- together with a third party Element Materials
tails is coming from the pre-reformer and con- Technology on the removed tube part of one
tains about 19 (vol.)% CH4, 75 % H2O, 1,6 % pigtail (see figure 3).
CO2, 4 % H2 and small amounts of CO, N2, Ar
and He. The partial hydrogen pressure (pH2) is
about 1.43 bar-abs (20 psi), which is too low to
cause degradation due to Nelson hydrogen at-
tack. (See table 1)
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firmed by the failure investigation done by
Element Materials Technology.
High-temperature oxidation
Temperature increase
Lessons to be learned
Figure 9 1997
• High temperature oxidation is a slow pro-
Life time calculation on the end of the weldolet cess but due to the aging of the plants this
(d = 4,00/0.15 inch) failure mechanism must be included in the
inspection program.
• When carrying out NDT inspections, atten-
tion must be given to the surface prepara-
tion. It should be carried out in such a way
that wall thickness does not decrease.
• Temperature increase and oxidation reduce
the life of the pigtails and has to be imple-
mented in the life time calculations.
Figure 10 1997
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Case 2.Failure of a riser between
the waste heat boiler and the
steam drum, AFA3 plant
Introduction
Details
Pipe material:15NiCuMoNb5-6-4,
material identification no. 1.6368 (WB36)
Medium: water/steam
Process pressure: 125 barg/1813 psi
Process temperature.: 327°C/620°F
Figure 12. Ruptured riser
Failure investigation
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boiler water feed inlet. Due to process upset
conditions. This corresponds with the observed
crack orientation.
This failure was not predicted because it was as- • The final cause of the cracking of the
sumed that the steam system was protected by riser is a sudden overload due to process
an excellent water treatment (good quality mag- up-set conditions.
netite layer). • Cracking has initiated by corrosion fa-
tigue of the protective magnetite layer.
The aging of the plant for about 30 years plays a • Advice: Make sure a thin denser mag-
big role. The amount of start/stops has a nega- netite layer will be formed.
tive effect on this failure mechanism. • Advice: Avoid mechanical and tempera-
ture shocks in the steam drum and the
A combination of corrosion fatigue (low cycle waste heat boiler.
fatigue) and finally an overload due to process
up-set conditions caused the failure of this riser. Lessons to be learned
The cracked riser has a smaller diameter and
wall thickness (10 mm, 0.4 inch) compared to • Apply an optimum water treatment in
the other three risers (36 mm, 1.4 inch). This re- these high pressure steam systems, e.g.
sults in more tensile stresses from the start/stop by using film forming amine treatment.
cycles. The waste heat boiler has a fixed posi-
• Take the correct process precautions to
tion compared to the steam drum. The steam
avoid sudden overload.
drum has moved sideways in the direction of the
Reformer/riser tube
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The crack initiated from the outside. Along the Discussion
crack almost no creep cavities were present. In
the cracks, oxides and nitrides are presence, All risers (7 pieces) and adjacent reformer tubes
which indicates that the crack already has been (14 pieces) have been checked by dye penetrant
present for a long period. (See figure 20). testing. (for an overview see figure 21).
Material identification
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• Crack propagation is (very) slow and
grows preferentially due to thermal cy-
cles (starting / stopping) of the reformer.
Lessons to be learned
Conclusions