Metallurgical Investigation Of Hydrogen Reformer Tube Rupture – A Case Study

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Hydrogen Reformer or so-called Steam Methane Reformer (SMR) is an important equipment to produce hydrogen or synthesis gas for refineries, petrochemical and fertilizer plants. It is basically a fired heater component that consists of four main sections which are radiant section, convection section, transition duct and stack.1 The configuration and general arrangement of SMR varies from different designers.

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A catalyst tube for Hydrogen reformer at one of the refiners leaked and led to an unplanned shutdown of the entire hydrogen production unit. The material of construction for catalyst tube is HP Modified (25%Cr-35%Ni) and the tube was in the service for almost 18 years. The failed tube was subjected to metallurgical examinations that include chemical analysis, dimensional/strain measurement and metallographic examination. Visual examination of the failed tube showed that the tube suffered from severe bulging on a localized portion, particularly on the lower section of the tube. The investigation revealed that accelerated creep damage was the main damage mechanism that was encountered. This paper discusses the root cause(s) and preventive measures to prevent such failure from reoccurrence.