Regular Article

Damage analysis and integrity assessment of a few steam-reformer components at a syn-gas plant

Corrosion Consultant, 701, Landmark Building, Plot No. D2, Sector 12, Kharghar, Navi Mumbai 410 210, India

^* e-mail: bhupendragaur@hotmail.com

Received: 16 March 2016
Accepted: 8 February 2017

Abstract

Study deals with damage-analysis and integrity-assessment for a few components of a steam-reformer at a syn-gas generation plant, including catalyst tubes and hot-collectors. Selected components include the ones which either suffered from a fluid-leakage in the service or noticed with a constant high-temperature exposure during normal plant operation. The field investigation activities included visual inspection, dimensional check, die-penetrant test and pressure-drop measurements. Laboratory investigation, made on selective samples, included precise and detailed dimensional-measurement, visual examination, die penetrant test, microstructural characterization, creep-rupture test, etc. As a result of diagnostic analysis, creep was identified as the principal mechanism of degradation of the studied components. Catalyst tubes were found to be in sound condition and, hence, recommended to continue in use for the remaining period of the service-life, even after high-temperature exposure in the past. Other items; however, were noticed with a limited residual creep strength, hence, rejected for future use. Further, recommendations were made for improvement in practices of process- and operation-management, to avoid pre-mature deterioration of the reformer components. In addition, suggestions were given for enhancing the versatility and reliability of plant inspection and monitoring methods, using latest tools and technology of the field. Moreover, suitability and limitation of different analytical approaches regarding interpretation of test and inspection results are highlighted.