1. Primary Reformer (F-101) Tee Collector and Transfer Line Problems
Muhammad Waqas Younas
(Mgt. Associate) Projects-TSD

2. OBJECTIVE
The objective of my presentation is to discuss the replacement plan and problems associated with;
Primary Reformer (F-101) outlet Tee Collectors
b)Transfer Line (F-101 to C-102)

3. CONTENTS Problems observed Brief history Replacement Project
Introduction
Brief history
Problems observed
Way Forward
Replacement Project
Recommendations

4. F-101 Piping Inlet Pigtails Top Flanges C-102 Inlet Miter Elbow
Riser Tee
Tee Collector
Transfer Line
Bottom Flanges
Catalyst Tubes
Outlet manifold

5. F-101 Transfer Line Plan View
North West Header
North East Header
South West Header
South East Header
C-102 Inlet

6. TEE COLLECTOR PROBLEMS

7. Background
At LCA :
One Manifold each chamber, connected by a tube
Material A-297
Two manifolds each chamber
Material : Incoloy 800 Grade 2 (800H)
Design life 100,000 Operating Hrs
Cracks observed in both cells outlet manifold
Cracks repaired by Welding as per FW procedure
At PQA :
Hair line cracks observed in Bull head tee weld joints
At FFBL :
Procurement of Bull Head Tees and Manifold initiated
FW regret to provide Bull Head Tess of Incoloy 800 H
Bull Head Tees and manifolds replaced with upgraded material
New material 2032Nb
1966
1972
1991
1997
1998
2000

8. Tee Collector Component Material Replacement Year Outlet manifold
Wiscolloy 2032Nb
Replaced in 2000
Bull head Tee
Expander
Incoloy 800H
Replaced in 1972
Cone
C - 1/2 Mo
Cone
Bull Head Tee
Expander

9. Outlet Manifold Tee Collector Crack
Severe circumferential cracks in weld toe of all four bull head Tee to expander joints.
Bull Head Tee (20Cr-32Ni-1Nb)
Cracked weld Joint
Expander (Incoloy 800H)

10. Outlet Manifold Tee Collector Crack
Grinding of crack

11. Short Term Remedial Actions for Cracks Repair
Stabilization Heat Treatment was carried out prior to welding
125˚C/hr above 425˚C to 980 ˚C
Soaking temperature hrs
Followed by rapid air cooling
Root pass : Inconel 82
Weld completion : Inconel 182
Stage wise DPT and 100 % RT (Root + Final)

12. TRANSFER LINE PROBLEMS

13. Transfer Line Refractory
Hot Face
Cold Face
Greencast 94
High Alumina, Low Silica, Outstanding abrasion resistance
Thickness 3”
Max Temperature 1870 ˚ C
Thermal 870˚ C 2.03 W/mK
Kaolite 2300 LI
Backup Insulation, Light weight, Low thermal conductivity
Thickness 5”
Max Temperature 1260 ˚ C
Thermal 870˚ C W/mK

14. Riser Edge
Diffuser and Pipe Junction

15. Transfer Line Refractory Problems
Partly refractory damages observed in TA-2011,12 & 13
Location : Approximately 7.0ꞌ eastwards from manway center
Approximately ~ 2ꞌꞌ thick refractory missing from a band of 2.5” from 8 O’clock to 11 O’clock
7’0 Eastwards from manway center Refractory damage

16. Transfer Line Refractory Damages TA-15
East Leg Opposite the Riser
Crack 5mm wide and 10 cm Long
Refractory damage in Junction of Diffuser and Pipe (West Leg)
Refractory detached at East Side about 1.5’ above Riser edge

17. Transfer Line Access Problem
Visual inspection to access health of 1998 vintage refractory not possible due to access problem
Thermo-graphic inspection was carried out
Riser Tee
Access Manway

18. Transfer Line Skin Temperature Problem
Gradual rise in skin temperature is observed in the past few years (130˚C ~ 230˚C)

19. Scope of Project Material Up-gradation for complete scope
Refractory evaluation and upgrade
Flexibility analysis of process gas for complete circuit
Refractory and component joint design
Material Supply
VSM Services for Project execution monitoring

20. AMEC-FW Response
Proposed material: Transfer Line Fabrication: Transfer line to be supplied in 22 no. pre-lined and fully heat cured section due to dry out problem at site.
Part Description
Existing Material
New Material
Bull Head Tees
20-32 Nb
(Centrifugally Cast)
Expanders
Incolloy 800H
Transfer Line Tee Collectors
C Mo
1.25 Cr – 0.5 Mo
Transfer Line

21. Proposed Assemblies of Tee Collector
AMEC-FW proposed to provide 2 X complete assembly as shown below:
Transfer Line Fabricated Tee
Centrifugally Cast Bull Nose Tee
Spun Cast Cone

22. Transfer Line Inspection Points
AFW Proposal:
1 peephole in each horizontal straight section.
Total Peepholes: 9
FFBL proposed 4 manways instead of peep holes in TL
ID 508mm
ID 406mm

23. Cost Break Down of Project
Sr. No
Description
Cost
Currency 01
Design Services
76,800
GBP 02
Additional Engineering Cost if required
50,000 03
Material Cost CFR Karachi
1,423,145 04
Sub Total
1,549,945 05
AFW VSM Cost
337,078 06
FFBL Execution Cost
142,898
Total cost in GBP
2,029,921
Total cost in PKR with 5 % Contingency
346,355, 270

24. To be confirmed with AFW
Tentative Timeline
Task
Start Date
Duration
End Date
Budget Approval CAPEX
1- Oct
2 months
1- Dec
VSM Visit Plantsite
4 - Jan
6 days
09 - Jan
Contract and PO
10 - Jan
1 months
10 – Feb
Kick Off Meeting
25 – Feb
2 days
26 – Feb
Design Work
01 – Mar
To be confirmed with AFW
01 – May
Material Arrival
01 – May
7 months
01 – Nov
Pre-fabrication
01- Jan
Execution in TA-2017
08 – Jan
22 days
30 – Jan – 2017

25. Gantt Chart Complete execution of the project (Replacement
of 2 X Tee Collectors and Refractory Lined Transfer line)
will be carried out in TA-2017 planned in Jan-17.

28. References

29. Hot spot (~334C) & (~554C) were observed only at west side Tee collector (controlled with steam application during startup after TA-2012 & 15 respectively). No Hotspot at other locations.