Optimizing reformer tube life through advanced inspection and remaining life assessment

Abstract

AbstractSteam reformer tubes must withstand high temperature and pressures during operation and are made from centrifugally cast materials, typically HK‐40, HP modified, and microalloy materials. As operating conditions can result in various forms of damage, the identification and quantification of damage is of vital importance if tube life is to be predicted accurately. This article describes the recent developments in an inspection system, which uses multiple nondestructive testing techniques to provide the most comprehensive assessment of current tube condition. This is coupled with a sophisticated remaining life assessment software model, which not only predicts the remaining life of each tube in a furnace but can also calculate the effect of changes in future operating conditions on tube ageing. Field experiences and findings are also discussed in the article. © 2010 American Institute of Chemical Engineers Process Saf Prog, 2010