Skip to main content

Advertisement

SpringerLink
Log in

Failure Analysis of Incoloy 800HT and HP-Modified Alloy Materials in a Reformer

  • Case History---Peer-Reviewed
  • Published:
Journal of Failure Analysis and Prevention Aims and scope Submit manuscript

Abstract

The main causes of creep failure in the pigtails and tubes made of high-temperature Incoloy 800HT and HP-modified alloy materials of two natural gas primary reformers operating at a petrochemical plant complex were studied. Optical emission spectroscopy, high-resolution optical microscopy, scanning electron microscopy, and energy-dispersive x-ray spectroscopy were performed to verify that creep was the prevailing failure mechanism in both cases. Creep was confirmed in both cases by the (massive) presence of intergranular voids (aligned in some cases) at the grain boundaries and cracks originating from the edge and longitudinal to the edge in some areas. Localized overheating due to burner flame impingement most likely accelerated the creep rate deformation for the HP-modified reformer tube material though the material surpassed its design life of 100,000 h. The findings substantiate that high priority should be placed on reformer burner management and ensuring the catalyst in the reformer tubes is packed optimally to avoid downstream flows issues in the outlet pigtails. These measures can serve to mitigate the effects of localized heating that can contribute to the failure of these components.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

References

  1. Special Metals Corporation. The Story of the “Incoloy Alloys Series,” from 800, through 800H, 800HT (2004), http://www.specialmetals.com/documents/Incoloy%20alloys%20800H%20800HT.pdf. Accessed 16 May 2017

  2. C. Maharaj, C.A.C. Imbert, J. Dear, Failure analysis and creep remaining life of hydrogen reformer outlet pigtail tubes. Eng. Fail. Anal. 15, 1076–1087 (2008)

    Article  Google Scholar 

  3. ASTM International, in ASTM A297/A297 M-17 Standard Specification for Steel Castings, Iron-Chromium and Iron-Chromium-Nickel, Heat Resistant, for General Application. Book of Standards Volume: 01.02 (ASTM International, West Conshohocken, 2017)

  4. C.M. Schillmoller, in HP Modified Furnace Tubes for Steam Reformers and Steam Crackers. NiDITechnical Series, 1992, p. 1–11

  5. American Society of Mechanical Engineers, in ASME SB-407 Specification for nickel-iron-chromium alloy seamless pipe and tube, ASME Boiler and Pressure Vessel Code II Part B Nonferrous Material Specifications.( American Society of Mechanical Engineers, New York, 2010)

  6. S. Holdsworth, Creep-fatigue failure diagnosis. Materials 8, 7757–7769 (2015)

    Article  Google Scholar 

  7. D. French. Creep and Creep Failures. National Board Classic Series (1991), http://www.nationalboard.org/Index.aspx?pageID=181. Accessed 23 May 2017

  8. T.L.D. Silveira, I.L. May, Reformer furnaces: materials, damage mechanisms, and assessment. Arab. J. Sci. Eng. 21(2C), 99–119 (2006)

    Google Scholar 

  9. J. Huber, D. Jacobi, Centricast Materials for High- Temperature Service, in International Conference & Exhibition Nitrogen + Syngas (Dusseldorf, Germany, 2011)

    Google Scholar 

  10. M. Fulger et al., Analyses of oxide films grown on AISI 304L Stainless Steel and Incoloy 800HT exposed to supercritical water. J. Nucl. Mater. 415, 147–157 (2011)

    Article  Google Scholar 

  11. Bohler Welding Group, Ni and HT steel alloys for Petrochemical Applications. (UTP Schweissmaterial Application Technology, 2012), p. 1–40

  12. H.M. Tawancy et al., Failure analysis of catalytic steam reformer tubes. Anti Corros. Methods Mater 52(6), 337–344 (2005)

    Article  Google Scholar 

  13. C. Maharaj, J.P. Dear, A. Morris, A review of methods to estimate creep damage in low-alloy steel power station steam pipes. Strain 45(4), 316–331 (2009)

    Article  Google Scholar 

  14. M.A. Maleque, M.S. Salit, Materials Selection and Design (Springer, Singapore, 2013)

    Book  Google Scholar 

  15. A. Anwer, Reformer Tubes Material Selection (Articles and Publications, 2017), http://www.thepetrostreet.com/article_0011.html. Accessed 15 May 2017

  16. F. Gulshan et al., Failure analysis of superheater tubes supports of the primary reformer in a fertilizer factory. J. Fail. Anal. Prev. 5(3), 67–72 (2005)

    Article  Google Scholar 

  17. S.A.J. Jahromi, M. Naghikhani, Failure analysis of HP40-Nb modified primary reformer tube of ammonia plant. Iran. J. Sci. Technol. Trans. B 28(2), 269–271 (2004)

    Google Scholar 

  18. K. Hasegawa., in Repair Welding and Metallurgy of HP-Modified Alloy after Long Term Operation. Metal 2001. (Czech Republic, 2001)

  19. R. Voicu, et al., in Damage measurements after creep tests on samples of HP-40 alloys modified with a low level addition of Nb, ICF 12. (Canada, 2008), p. 1–10

  20. M.H. Shariat, In advanced Creep Failure of H.P. Modified Reformer Tubes in an Ammonia Plant. The Journal of Corrosion Science and Engineering 6(H012), 1–20 (2003)

    Google Scholar 

  21. ASTM International, in ASTM E3-11 Standard Guide for Preparation of Metallographic Specimens. Book of Standards. (ASTM International, West Conshohocken, 2011)

Download references

Acknowledgments

The authors would like to thank Ms. Janell C. Ramlal for her support in carrying out this study.

Author information

Authors and Affiliations

  1. Department of Mechanical and Manufacturing Engineering, University of the West Indies, St. Augustine, Trinidad and Tobago

    Chris Maharaj

  2. San Antonio, TX, USA

    Andres Marquez

  3. In-Corr-Tech Ltd.,, San Fernando, Trinidad and Tobago

    Riza Khan

Authors
  1. Chris Maharaj
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Andres Marquez
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Riza Khan
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Chris Maharaj.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Maharaj, C., Marquez, A. & Khan, R. Failure Analysis of Incoloy 800HT and HP-Modified Alloy Materials in a Reformer. J Fail. Anal. and Preven. 19, 291–300 (2019). https://doi.org/10.1007/s11668-019-00621-1

Download citation

  • Received:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11668-019-00621-1

Keywords

Search

Navigation