Session: OAC-07-01: Plant Life Extension: Aging and Life Management

Paper Number: 85600

85600 - In Service Repair Challenges With Pyrolysis and Steam Methane Reformers High Temperature Metallurgy 

The high temperature section of pyrolysis and steam methane reformers are exposed to conditions ranging from ambient temperature during shutdowns up to temperatures near 1093°C (2000°F) when in service in the case of pyrolysis tubes. These conditions lead to variety of metallurgical transformation affecting materials properties at different temperatures. Additionally, the involved materials are exposed to internal and external environments leading to chemical and metallurgical reactions causing additional material property changes. Due to the specific environment, pressure boundary components need to withstand in addition to the high temperature metallurgical reactions other damage mechanisms including creep, stress-relaxation cracking, thermal fatigue, and thermal shock.
The paper covers several case histories in both pyrolysis and steam methane reformer services as well as a summary of research activity on thermal shock and thermal fatigue.
Described case histories in pyrolysis include furnace coil failures due to thermal fatigue/thermal shock and carburization, quench nozzle failures and transfer line exchanger tube failures. For steam methane reformer several failures in furnace coil tubes, reducer, pigtails, and outlet headers are covered.
The R&D activity description included Gleeble™ based and quench water immersion testing protocols and metallurgical characterization.
General guidance on material selection, failure prevention and welding repairs is included.

Presenting Author: Sophia Zhu Shell Global Solutions (US) inc.

Presenting Author Biography: • Corrosion and Materials Engineer- 14 years with Shell

Authors:

Jorge Penso Shell Projects and Technology
Mitul Dalal Shell Global Solutions US Inc
Sophia Zhu Shell Global Solutions (US) inc.