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Technical Discussions
Al-Mabrook Omar Al-Irwi
Al-Mabrook Omar Al-Irwi
09:56 Nov-09-2007
Base line Inspection H2 reformer Tubes

When it is recommended to carry-out eddy current testing or any other NDT Technique on a newly installed Methanol reformer tubes? Is it after two years working or four years or more? Taking into consideration that all operations parameters are kept under controll.


 
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Rich Roberts
Engineering, Executive Managment
Quest Integrity Group, USA, Joined Nov 1998, 78

Rich Roberts

Engineering, Executive Managment
Quest Integrity Group,
USA,
Joined Nov 1998
78
08:31 Nov-12-2007
Re: Base line Inspection H2 reformer Tubes
Good Day Al-Mabrook Omar Al-Irwi,

We’ve been assisting clients manage reformer tubes globally for over a decade in Methanol, Hydrogen, Ammonia and DRI plants.
Our recommendations are as follows:
(1) “Always” perform baseline exam / inspection on all new reformer tubes prior to them being installed in the reformer. Carrying out a baseline inspection allows the tube manufacturer to fix any problems in the tubes “prior” them being installed into the reformer. Flaws such as; (a) Gouges on the interior surface of the tube, (b) Over boring of the ID bore beyond acceptable specifications, (c) Excessive weld root penetration, (d) Suck back or lack of fusion (lof) in the circumferential joint welds, (e) etc. etc. etc. can be identified and corrected. If a client installs a tube with any of the mentioned flaws, chances of premature tube failure is very likely. We suggest the use of LOTIS for this process as it provides very high resolution scans, which is basically a laser generated 3D image of the tubes internal bore with detailed dimensions.
(2) The tubes should also be tested every time the reformer is brought off line after the initial start up. This exam can be carried out either externally (when the catalyst is still in the tube) or internally (when the catalyst is being changed out). Obtaining continuous inspection data enables plant inspectors / engineers to quickly identify small patterns of damage and rectify the problem “prior” to the damage becoming so severe the tube cannot be saved.
(3) We also recommend Remaining Life Assessment (RLA) calculations be carried out after each inspection is performed to maximize the full life of the tube. It’s very important that when RLA calculations are carried out the Strain Curves for the proper material is being applied. For example if HK-40 strain curves are being applied on HP-Modified material, the effort is wasted. HP-Modified curves should be applied on HP-Modified materials.
If you would like additional details pertaining to Reformer Tube management, please feel free to contact me directly.

Regards, Rich Roberts
http://www.questtrutec.com
Tel: +1.253.893.7070
Email: RichardR@QuestTruTec.com

----------- Start Original Message -----------
: When it is recommended to carry-out eddy current testing or any other NDT Technique on a newly installed Methanol reformer tubes? Is it after two years working or four years or more? Taking into consideration that all operations parameters are kept under controll.
------------ End Original Message ------------




 
 Reply 
 
Brian Shannon
Brian Shannon
07:46 Nov-16-2007
Re: Base line Inspection H2 reformer Tubes
----------- Start Original Message -----------
: When it is recommended to carry-out eddy current testing or any other NDT Technique on a newly installed Methanol reformer tubes? Is it after two years working or four years or more? Taking into consideration that all operations parameters are kept under controll.
------------ End Original Message ------------
When considering the inspection and assessment of Reformer tubes ,at the baseline stage or in aged units,it is necessary to have an understanding of all of issues which affect their continued and effective operation. True "condition assessment" will require the deployment of an inspection technology containing several techniques,which will target the various damage mechanisms appropiately.
To that end the H SCAN approach which utilizes Eddy Current, Ultrasonics, tube profiling and dimensioning in a single inspection system has been developed and deployed by plant operators worldwide.
The approach allows direct remaining life determination from the inspection results, where plant operating data is available. This is acomplished through a unique software developed through the results of a major industry research project and through values for all reformer tube materials,HK,HP Modified and HP Micralloy.
Please contact me directly for further information.




 
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