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- since 1996 -

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Technical Discussions
Ram Iyengar
Director
India, Joined Feb 2000, 13

Ram Iyengar

Director
India,
Joined Feb 2000
13
04:43 May-11-2000
Ultrasonic Inspection of Reformer Tubes.

Gentlemen,
I need information about Ultrasonic Inspection of Reformer Tubes used in fertilizer plants.
Information with respect to the above subject will be appreciated.
regards
ram iyengar


    
 
 
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
05:06 May-11-2000
Re: Ultrasonic Inspection of Reformer Tubes.
Dear Ram Iyengar,

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 monitoredfrom 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 beentaken 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
-------------------------- origional message -------------
: Gentlemen,
: I need information about Ultrasonic Inspection of Reformer Tubes used in fertilizer plants.
: Information with respect to the above subject will be appreciated.
: regards
: ram iyengar




    
 
 
John O'Brien
Consultant, -
Chevron ETC , USA, Joined Jan 2000, 278

John O'Brien

Consultant, -
Chevron ETC ,
USA,
Joined Jan 2000
278
06:43 May-12-2000
Re: Ultrasonic Inspection of Reformer Tubes.
Ram

an alternative for screening Reformer Tubes is to use Acoustic Emission - this has been done successfully very recently for a Refinery in Europe. If you are interested go to www.pacuk.co.uk and ask for details.
Regards



    
 
 
Prof.Dr. Aly El-Domiaty
Prof.Dr. Aly El-Domiaty
09:34 May-14-2000
Equipments for Ultrasonic Inspection
: Gentlemen,
: I need information about Equipments for Ultrasonic Inspection (Portable, Price and Types).

Best Regards




    
 
 
Brian Shannon
Brian Shannon
04:05 May-20-2000
Re: Ultrasonic Inspection of Reformer Tubes.
: Gentlemen,
: I need information about Ultrasonic Inspection of Reformer Tubes used in fertilizer plants.
: Information with respect to the above subject will be appreciated.
: regards
: ram iyengar
Cast materials utilized in steam reformer furnaces undergo time temperature related damage. The degree of absolute damage and the resultant remaining life is dependent on various factors. Determination of the level of actual damage by NDE techniques has been successfully carried out in these types of furnaces by using a multi-parameter approach of a series of ultrasonic , eddy current and dimensional techniques , performed in one scan. It has been shown that to improve the reliability of these inspections no one technique (ultrasonics , ID measurements ect)can act as a stand alone assessment tool as the degree of damage in a particular material may or may not lend itself to that particular technique. However by combining several techniques , the overall reliability of the examination can be improved , and tube condition assessment can be optimized.
For further information on this issue and "H" Scan Technology contact Brian Shannon at IESCO. e mail brianshannon1 @msn.com





    
 
 
vozi andrian
vozi andrian
08:51 Jul-29-2000
Re: Ultrasonic Inspection of Reformer Tubes.
: : Gentlemen,
: : I need information about Ultrasonic Inspection of Reformer Tubes used in fertilizer plants.
: : Information with respect to the above subject will be appreciated.
: : regards
: : ram iyengar
: Cast materials utilized in steam reformer furnaces undergo time temperature related damage. The degree of absolute damage and the resultant remaining life is dependent on various factors. Determination of the level of actual damage by NDE techniques has been successfully carried out in these types of furnaces by using a multi-parameter approach of a series of ultrasonic , eddy current and dimensional techniques , performed in one scan. It has been shown that to improve the reliability of these inspections no one technique (ultrasonics , ID measurements ect)can act as a stand alone assessment tool as the degree of damage in a particular material may or may not lend itself to that particular technique. However by combining several techniques , the overall reliability of the examination can be improved , and tube condition assessment can be optimized.
: For further information on this issue and "H" Scan Technology contact Brian Shannon at IESCO. e mail brianshannon1 @msn.com





    
 
 
P.K.Deshpande
P.K.Deshpande
01:55 Dec-06-2001
Re: Equipments for Ultrasonic Inspection
: : Gentlemen,
: : I need information about Equipments for Ultrasonic Inspection (Portable, Price and Types).

: Best Regards

Deshpande



    
 
 

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