High Temperature Hydrogen Attack A Catalytic Reformer Case
?? High Temperature Hydrogen Attack in a Catalytic Reformer ??
Have you ever wondered about the potential risks associated with high-temperature hydrogen attack (HTHA)? It's a phenomenon that occurs when steels are exposed to hydrogen gas at elevated temperatures and pressures, leading to severe consequences. In this article, we delve into a real case study of a semi-regenerative catalytic reforming unit to highlight the importance of understanding and mitigating HTHA risks.
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The incident involved a leak in the combined reactor feed-effluent exchanger at a weld joining carbon steel and 1% chromium steel shell courses. Upon investigation, it was discovered that the failure was caused by localized HTHA at the fusion line between the weld and the carbon steel base metal. This HTHA occurred below the carbon steel Nelson curve and was attributed to joint design and welding defects.
One of the key observations made during the examination was the extensive leak observed in the insulation of the platformer reactor feed-effluent exchanger. This prompted the shutdown of the unit, and upon removing the insulation, a through-wall crack was revealed on the weld joining the upper 1Cr ? Mo section of the vessel to the lower carbon steel section. Surprisingly, hardness readings and weld metal examinations appeared normal, but an ultrasonic inspection detected a crack extending around the full circumference of the shell.
This case study emphasizes the importance of meticulous joint design, comprehensive quality control procedures, and continuous monitoring to mitigate the risks associated with HTHA. It is crucial to evaluate potential failure points, ensure proper material selection, and implement robust inspection and maintenance protocols. By doing so, we can minimize the likelihood of equipment failure, enhance operational safety, and protect valuable assets.
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For a more detailed analysis of this case and further insights into high-temperature hydrogen attack in catalytic reformers, visit our website and read the full article. Stay informed, stay safe, and stay ahead of potential risks!
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I Mech E I Eng. BSc Hon’s NDT AM Inst.
1 年Plant operators should consider creating baseline scans of those components that will operate close to the design limits or risk going beyond design limits transiently during service. These baseline scans should ideally be performed at installation, which also gives the plants the opportunity to prepare effective inspection procedures (ideally with formal qualification) that can then be used on those components during service. This approach (starting from a baseline and using well-designed procedures containing techniques suited to those components) should aid in better monitoring of the microstructures as they age, thereby helping to detect early-stage damage. It there is visual evidence on the insulation and or the weld then it’s too late ! At least two NDT methods will be necessary to confirm stage 2 damage !
Managing director at TETA
1 年#acousticemission #Acoustic_Emission
Chemistry Manager at MAPNA Operation & Maintenance Co.
1 年Hydrogen damage is initiated when acid contaminants (mainly chloride) concentrate at the base of the deposit.
Matheus Sousa