API TR 942-A

Materials, Fabrication, and Repair Considerations for Hydrogen Reformer Furnace Outlet Pigtails and Manifolds

API1ECHNICAL REPORT 942-A FIRST EDITION , JUNE 2014

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energy ~~

A M ER I CAN PET RO LE UM I NST IT UT E

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~ , tee., and fmi'l ll', is important 10 the .""u..IuI~ _ lem1 peralion 01 hydrogen and .y~ • • reIormer /u",. eeo. The..., compooento 1ypid by reviewing _""'" II"l>Iohed literal"", and indY.tr)' expe_u and the dog_

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Thermal de9r. d~ . moot "",.bIy creep. io the prim ..... damage me cho .. "", lor hqI~empeeflIture . ~ . too h ... equation. kif the hiIIl>-tempero"". fa t""" nCfl\lth 01 AJe " ~< N ~ i _ prem n _ c .tainless, ..... e nitic .tainleu, and nd e , ""sed oI1oyo nereooeo re.istance 10 "'e pIle"""",noo . A. "'" amount of iron n ere . ..... !he ",Ie of metal dusting inerea ..,. in both lenib< and • . , . _ ..... Ie.. .. eel Nic kel n ere . .... resistance '" metaldmtng n ",ck_sed alloys, but decre .... . !he reoj","""" of • . , . _ c oteelo . The _ - . oI.iIi the !he, elemefl1S . . wel _ ChemisO",lor lOme typig_term . mbfi!tlement isooe> . Howe"",. most reIormef ope"""" choose IO use AJIoo; 6'7 !Of IIighef creep strength at ,emperature. a bove 843 "C ( ' 550 "Fl. Ineooel ' 17 and AJIoo; 617 or. typ; bted in Table 2 ha"" comprloitioo • .milar to those of the AJIoo; 800 varian" and the . Umiting eompoob>n value. a,., avaloble lor the ni< ~ _oed m.,erioIs, a. indir>el 82 weklmen .. ha"" highef otreu--rupl>K. oIreba ..... i .t aI ..., feCO"" ,.. nded the US< of • "9'>-"'.~~ alloy metal (IneI 82 ) !of w~ 2OCf_31N~Nb m"",I• . Kobm ~. 0 _ superiof ",..,Ito usin11.., metal. The -Ie cs: (1) om~ (NH,). (2 ) hydr"""", (H, ). and (3) methoool (CH,oH). The range 01 operating press"'" decreueo and the '""I/< o! operating lempera...., increa ..,. a . !he re10rmer type chanll".1rom ammooio to ~ydroe_r 10 T"" Weld: 0 "'" A,. 2OCr_J2N i~lb C. .li . preuore. Ru,ioko aod WorIen poinlo.

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Il) HoI CoIo !rom f. brieation ( ",Id _~lding l or "' "" ~ from , yet< &. been rel'ised m..,.,. tim .. sines, . ¥ding . /.." " chaf>geo in !e" __

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c_. ·~ presented an ...mple «>nea1 ... eoiIlaiIure>

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4.2 Designers of Reformers The ....... ey response. ioeluded do .. on 22 re - . from 12 "'1Iefent 0"" ~ . I"OQramo. The .de'" of .otieo -Nb -.,. l arson_Mile< pOOl. andIOf . ..... V.B LlO lime to rup1Ufe plots (.."hoot ""'t d . t. points ) ""re _ in technil:a l IilefOtur. from fo-ruplU'" faiklre. of many Alloy 800H OO!Iet pigtails on ... am""""a reformer. An imestig !h. l~ _ MiIer par. meteon AIoy 1I00HT, be""u..., AIoy SOON """ "'e""'" m."" used in tho ROKh . nd V... E eho ~" ·o work . AIoy SOO HT ... _g ..,ven ca.., _ .

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C o.., 1: Creep C r acking

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typjc.Iol problem. idenlifled n !he ...-vey of n ooou.,.

of Bull Tee 10 Heode.- Welds

17 oIlow.!he • dra~ of ~ . eentrof portion of . ~ r e _ oo!Ie1 monilokf wtt. • _ lee eoonected 10 two h. _ eytnden and one eone I»' bum ....,1IIs_ .... of !he.., «>n"4>OOel82.- p.... Ineonel 82 nef 182 for !he """oindef of!he ~ . Th"', !he mojofify 01 the ... ekf !iller metal n !he joinIs .... . Inoonel 182 . Weld rep.r. hod been m_, usineo'ice literature _ rid _ _ indu .. ", " 'peOenoo-rupture 6 "'a.ior 01 21 J3 M n and 21/3J So Weklo with Th o, '" 21Cr _ 32Ni -N ~ Alk>y B.se Metal

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. . -I' .•••.•• • • • • • • • • • ••• • - j••• f igure 11_ 0fOwing or Centrol p Oftjoo of Outlet Manifold Show ng Con tral Portion 01 He_f, Bull Tee, a nd Iocr ..... CO""

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Figure Il----l'hOlg'aph 01 Tee ShO'Wiflg Ar . . . Where C,acking o f Weld. W•• Ob.."nd lC. II"'.... r.I., to otIIe, flgur • • ifI repan from ,.hich photograph w •• tok... : fig", •• are not included in the pre..,nt r.port.)

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'" Finrt • ..,I0"",nl Str . . . "'n.r~ ... 01 O",lot Manifold lor InterMI Pmsure loadiflg ",f 11162 k P. (270 ".ig)

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f Og .... 2G-P hotomic'ograph of C'.'I> C •• d;ifIg a nd Vo ids Obo ..... ed .. e.. 11 T"" Wok!

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ea"" 2: Creep Fail...-" ofOutle! Header

The Irf< feIormer oriIIinal'\' had ...,.,. H K-oIO eataly., tube> and an AIIo)' IIOOH outIe1 m_.,,;u., Inconel 621162 weld • . The relorme< WlI . revamped in 2000 to _ fade the 1f)' the damage mech_m kif the er>ding 10 !het final ~ t ion . The ~h ood ! t1ing. "'" we lded ~ In ,, ," \el 62 ood lneoW.kI A RIef metal> During 1I>e .orvirroded

5.5 C...... 4: Stress Relaxa!ioo Cracking of Alloy 800HT Pigtail Secti"" ....". SOOtH _ Type 304H .toinIe.. . tee! (see Fie pigtai w• • mode 01 Type 3114 _ .. steef . The opee IiI 0

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f ig .... Z&-Photograph 01 C f 'C ~ "g 1 Alk>y 1I00 HT Inle' Pigt.il Shown .. Figu re 25

f igure 21_ Photom",rogrOj>/l 0 1 Cra c l. in Alloy 800HT Inlet Pigt.il Showing E.Klence 01 Str.... Relanbon Cracking Me!aIkr'llieal .... tyo.;o wa s perlomled on ho weld...,. test..."pIe to determine the eou"", 01 the « .ctin • ~ 10 the of Ammonia PIonto & Related F.