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Technical Discussions
Farshid Alizadeh
NDT Inspector, Eng. sales
Hitan Co Ltd, Iran, Joined Oct 1999, 5

Farshid Alizadeh

NDT Inspector, Eng. sales
Hitan Co Ltd,
Iran,
Joined Oct 1999
5
05:28 Sep-05-1999
searching for reformer tubes testing system

Dear freinds,

I am searching for a system that can be detects cycle stress and creep problem that can cause reformer tube rupture.

It would be my pleasure that if there is any company that can sell such system e-mail me.

Regards

Farshid


    
 
 Reply 
 
Richard D. Roberts
Engineering, Executive Managment
Quest Integrity Group, USA, Joined Nov 1998, 78

Richard D. Roberts

Engineering, Executive Managment
Quest Integrity Group,
USA,
Joined Nov 1998
78
08:41 Sep-05-1999
Re: searching for reformer tubes testing system
Dear Farshid,

Conventional NonDestructive Examination(NDE) inspection techniques such as Ultrasonics (UT) and Eddy Current (ET) currently applied to tubing in process plants are geared to finding creep damage in the form of internal cracking within or accross grain boundries. However, with the trend towards larger tube diameters and longer intervals between turnarounds, the detection of such defects may not allow for sufficient time for forward planning of tube replacements. Also, such ‘end of life’ techniques do not allow any differentiation between the ‘good’ tubes. Early detection of underutilized tube life can prevent the lost opportunity on both unrealized production through running them too cool and tube life ‘giveaway’ if good tubes are discarded prematurely.

Tubes in furnaces, reformers, etc. undergo creep strain, in the form of diametrical growth, from the first day that they are fired. The ability to accurately measure and record this growth means that the tubes’ condition can be monitored from day one. Therefore, not only can individual tubes be retired from service at an appropriate time, but also the component as a whole can be assessed for performance. The use of QUEST Integrated, Inc. internal laser mapping technique is not only useful in preventing tube failures but has huge potential in optimizing production from the whole tube set without sacrificing reliability. Of course, EXTERNAL diameter measurements can be used but they are limited as the automated devices only measure across one diameter and are often access restricted. Manual measurements are too time consuming to provide more than a few readings per tube. Furthermore, neither way can provide diametral growth data at or through the furnaces or reformers refractory. External measurements are inherently less precise as they are based on a crude surface rather than the internal surface and do not take into account the effects of oxide shedding. The most accurate growth measurements are obtained when ‘as new’ baseline data has been taken prior to the tube being fired for the first time.

Recently, the use of the laser mapping method referred to as “laser profilometry” has gained worldwide acceptance as a viable inspection method for the early detection and characterization of creep. Process plants in New Zealand, South America, Canada, and the United States have successfully used the laser profilometry method. Whenever furnace, reformer, etc. tubes are operating under pressure in their creep temperature range, their ID will increase over time.. Use of laser profilometry allows mapping and quantification of a tube’s ID as several hundred thousand diameter readings can be acquired down its length. Since small diameter increases on the tube’s interior (i.e.1% are indications of early stages of creep, it is essential to gather data with such accuracy).

QUEST Integrated, Inc. has developed a laser-based system which provides precise inner diameter dimension down the length of catalyst tubes in reformers. This process has been quite successful in providing data to 3-Dimensional (3D) model steam reformer tubing in several Methanol and Ammonia plants. The advantage is that scale, corrosion, etc. on the tubes exterior has no effect on the data quality. When Eddy Current or Ultrasonics is utilized scale, corrosion, etc. tend to create noise levels which can produce erroneous results. QUEST’s laser method could also be used in your situation as well. If you have interest in knowing more please contact Richard D. Roberts/QUEST at 1-253-872-1275.

Regards,
Richard D. Roberts



    
 
 Reply 
 
Dinesh Bapu Khairnar
Dinesh Bapu Khairnar
09:31 May-19-2000
Re: searching for reformer tubes testing system
: Dear Farshid,

: Conventional NonDestructive Examination(NDE) inspection techniques such as Ultrasonics (UT) and Eddy Current (ET) currently applied to tubing in process plants are geared to finding creep damage in the form of internal cracking within or accross grain boundries. However, with the trend towards larger tube diameters and longer intervals between turnarounds, the detection of such defects may not allow for sufficient time for forward planning of tube replacements. Also, such ‘end of life’ techniques do not allow any differentiation between the ‘good’ tubes. Early detection of underutilized tube life can prevent the lost opportunity on both unrealized production through running them too cool and tube life ‘giveaway’ if good tubes are discarded prematurely.

: Tubes in furnaces, reformers, etc. undergo creep strain, in the form of diametrical growth, from the first day that they are fired. The ability to accurately measure and record this growth means that the tubes’ condition can be monitored from day one. Therefore, not only can individual tubes be retired from service at an appropriate time, but also the component as a whole can be assessed for performance. The use of QUEST Integrated, Inc. internal laser mapping technique is not only useful in preventing tube failures but has huge potential in optimizing production from the whole tube set without sacrificing reliability. Of course, EXTERNAL diameter measurements can be used but they are limited as the automated devices only measure across one diameter and are often access restricted. Manual measurements are too time consuming to provide more than a few readings per tube. Furthermore, neither way can provide diametral growth data at or through the furnaces or reformers refractory. External measurements are inherently less precise as they are based on a crude surface rather than the internal surface and do not take into account the effects of oxide shedding. The most accurate growth measurements are obtained when ‘as new’ baseline data has been taken prior to the tube being fired for the first time.

: Recently, the use of the laser mapping method referred to as “laser profilometry” has gained worldwide acceptance as a viable inspection method for the early detection and characterization of creep. Process plants in New Zealand, South America, Canada, and the United States have successfully used the laser profilometry method. Whenever furnace, reformer, etc. tubes are operating under pressure in their creep temperature range, their ID will increase over time.. Use of laser profilometry allows mapping and quantification of a tube’s ID as several hundred thousand diameter readings can be acquired down its length. Since small diameter increases on the tube’s interior (i.e.1% are indications of early stages of creep, it is essential to gather data with such accuracy).

: QUEST Integrated, Inc. has developed a laser-based system which provides precise inner diameter dimension down the length of catalyst tubes in reformers. This process has been quite successful in providing data to 3-Dimensional (3D) model steam reformer tubing in several Methanol and Ammonia plants. The advantage is that scale, corrosion, etc. on the tubes exterior has no effect on the data quality. When Eddy Current or Ultrasonics is utilized scale, corrosion, etc. tend to create noise levels which can produce erroneous results. QUEST’s laser method could also be used in your situation as well. If you have interest in knowing more please contact Richard D. Roberts/QUEST at 1-253-872-1275.

: Regards,
: Richard D. Roberts




    
 
 Reply 
 
Abdulrhman Al-Ghamdi
Abdulrhman Al-Ghamdi
02:18 Apr-15-2001
searching for reformer tubes testing system
Dear Sir

I have the following questions:

How long your testing procedure can take?
Is it applicable to crude distillation heater or vacuum heater where coke has tendency to accumulate?
Can laser method detect small cracks?

Best regards


    
 
 Reply 
 
Richard D. Roberts
Engineering, Executive Managment
Quest Integrity Group, USA, Joined Nov 1998, 78

Richard D. Roberts

Engineering, Executive Managment
Quest Integrity Group,
USA,
Joined Nov 1998
78
06:03 Apr-16-2001
Re: searching for reformer tubes testing system
Dear Abdulrhman Al-Ghamdi ,

The length of the inspection with our LOTIS technology depends upon the total amount of tube length to be inspected. For example in a Steam Reformer containing 100 tubes this can be easily inspected in a shift but a Steam Reformer containing 300 tubes may take 2-1/2 shifts.

It sounds like your application is more for a serpentine tube ‘furnace”, rather than a “reformer”. QUEST has also designed and built serpentine tube inspection system (FTIS) which employee’s both the Ultrasonics and Laser methods. This is a featherless system that can travel up to 3000 feet (915 Meters) through unlimited 1-Dimensional (1D) return bends. For more information on this system please visit our web-site at http://www.qi2.com/field/fsddef.htm
Regards,
Richard D. Roberts
International NDE Services Manager
QUEST Integrated, Inc.
1012 Central Avenue South
Kent, Washington 98032 USA

Direct Tel: 1-253 872-9500 ext. 1275
Toll Free Tel: 1-800 233-3345 ext. 1275
Fax: 1-253-872-8967
Email: richardr@qi2.com
Web Site: http://www.qi2.com/field/fsddef.htm

---------------- ORIGIONAL MESSAGE -----------------
: Dear Sir
.
: I have the following questions:
.
: How long your testing procedure can take?
: Is it applicable to crude distillation heater or vacuum heater where coke has tendency to accumulate?
: Can laser method detect small cracks?
.
: Best regards
.



    
 
 Reply 
 
Ketan Amin
Ketan Amin
07:07 Jul-05-2001
Re: searching for reformer tubes accelerated creep rupture testing system
: Dear freinds,

: I am searching for a system that can be detects cycle stress and creep problem that can cause reformer tube rupture.

: It would be my pleasure that if there is any company that can sell or give service for such system e-mail me.

: Regards

Ketan Amin




    
 
 Reply 
 
Cameron Waters
Director, Asia Pacific
Applus RTD, Australia, Joined Nov 1999, 5

Cameron Waters

Director, Asia Pacific
Applus RTD,
Australia,
Joined Nov 1999
5
07:51 Jul-05-2001
Re: searching for reformer tubes accelerated creep rupture testing system
pndt have a purpose built remote crawler assemly used for the detection of 1st 2nd and 3rd stages of creep damage to reformer tubes.

Refer to our wed page www.pndt.com.au or contact me direct for further information

Regards

Cameron Waters


    
 
 Reply 
 

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