Strange Operation Experience in Synloop Boiler Ends in Extensive Repair of Ammonia Converter Cartridge
Strange Operation Experience in Synloop Boiler Ends in Extensive Repair of Ammonia Converter Cartridge
Strange Operation Experience in Synloop Boiler Ends in Extensive Repair of Ammonia Converter Cartridge
Reinhard Michel
ThyssenKrupp Uhde GmbH
Fahad Al Sawat
Saudi Arabian Fertilizer Company (SAFCO)
S
AFCO operates a 3300 MTPD (~3638
stpd) ammonia plant (SAFCO 4) having
two synthesis loop waste heat boilers,
each downstream of an ammonia con-
verter. The first ammonia converter, 41-R-611,
is a two bed converter followed by the first
waste heat boiler, 41-E-601. This first waste
heat boiler is a mere evaporator, receiving its
boiler feed water from the second waste heat
boiler, 41-E-612, which is downstream of the
During the time for equipment cool down, a To make matters worse, between the "false
visual inspection of the connecting piping be- tubesheet" and the internal gas box flange metal
tween converter and waste heat boiler was per- parts were stuck between the flange facings
formed. The finding was that the connecting holding the gap open (Figure 4). The gap was
piping looked like it was freshly cleaned with- directed towards the gas inlet nozzle explaining
out any indication of a catalyst leak or other de- the indication of increased wall temperature in
bris. the thermography.
Inside the gas box a lot of bent metal particles As the inlet temperature of the downstream sec-
were found in different sizes (Figure 5). These ond ammonia converter is controlled by an ex-
particles were found sticking inside the insulat- ternal bypass around the boiler, the increased
ing ferrules protruding from the "false outlet temperature of the first boiler was com-
tubesheet" into the hot tube shanks of the tube pensated by the bypass control and the overall
bundle (Figure 6). This blockage explained the steam production was maintained.
increased pressure drop in the boiler and the
failure mechanism of the false tubesheet flange. The change in pressure drop and outlet tempera-
The particles had blocked the tubes and in- ture after the last power outage was due to tem-
creased the pressure drop between inlet and out- porary reverse flow. The reverse flow caused
let of the boiler until the flange connection some of the metal particles in the ferrules (red
failed. arrow in Figure 7) to be blown out. As a result
the pressure drop decreased, which also allowed
elastic reduction of the gap. The reduction in
the gap explains the reduction in boiler outlet
temperature.
Inner
Gas Outlet Pipe
2nd bed
Manhole
Figure 8. Four distance plates with punched
part No.
It had been drilled only about 10 mm (3/8") Figure 13. Outlet pipe deflected by outer pres-
deep in the pipe wall of 12 mm (~1/2"). With- sure (after removal of insulation cover)
out this vent the external pressure in the con-
Figure 14. Bottom plate of cartridge eroded to Figure 15. Surface of fragment
<5 mm (~1/4")
Due to very different remaining wall thickness
nd
As the pipe below the bottom of the 2 bed was of the fragments within a short distance, genera-
deflected by external pressure, the old outlet tion of the defect by friction between outlet pipe
pipe had to be cut below the original site weld and inner gas collector of the 2nd catalyst bed
for fitting of the new outlet pipe. The remaining was very unlikely. Furthermore, it does not ex-
outlet pipe, after cutting off the defective part, plain the initial damage, as friction was only
was 100% UT tested for laminations and was possible after the damage had occurred in the
found to be intact. The remaining outlet pipe bottom of the pipe allowing movement of the
was reused and the connecting piping did not pipe inside the gas collector. In addition, the
need to be dismantled for installation of a com- surface structure was not typical for friction but
plete new pipe, saving about 3-4 days of work. looked like separation in thickness direction.
As the found damage was severe and difficult to The target of a permanent repair required a very
repair, different repair options were discussed in close cooperation between repair workers and
a meeting with the top management of SAFCO. inspection department in a fully integrated team.
The following priorities were unanimously Whatever task was ahead, it was discussed in
agreed upon: detail before execution, taking care of any in-
1. Safety termediate inspection step. Also, inspection op-
2. Quality tions like UT and DP were discussed and com-
3. Time monly agreed upon.
It was further agreed that the repair should be a The repair team itself was very international -
permanent repair, suitable for the next 20 years mainly Indian, Nepalese, Pakistani from Ana-
beeb, an Austrian welder deputed by Schoeller
Challenges and other aspects of the repair were Figure 18. UT test of welds at new outlet pipe
as follows:
The new central pipe had been delivered in three
Parts which had to be brought to the repair
pieces by air freight from Austria. The pieces
location were preferably transported through
had to be welded together in a nearby workshop.
the central opening of the outlet pipe, as
During assembly it was noted that the pipe sec-
long as the new pipe was not installed, to
tions were somewhat out of round due to
avoid damage of the catalyst bed wire mesh
shrinkage of the longitudinal welds of the pipe
during transportation of parts.
sections during this welding. To compensate for
Cooling down the weldments to the accepta-
the deformation, the selection of the cut loca-
ble temperature for testing UT and/or PT
tions for the required length was done with the
cost a lot of time because of the narrow
aim of reducing this problem. As the pipe had
space available and necessary ventilation.
to be provided with new distance plates, the ex-
During the total time of the repair, safety isting cover flange for the cover of the 2nd bed
and quality were never questioned or com- outlet spacing had to be provided with slots to
promised in favor of time. This commit- allow trial assembly.
ment was valid from the top management
down to the working team in the converter. The new outlet pipe was inserted several times
The existing surface of the bottom of the to check the fit to the remaining outlet pipe por-
cartridge was ground to remove the thin ni- tion in the converter outlet nozzle and to adjust
trided layer of material before welding of the new support ring connected to the bottom of
the new parts. the 2nd bed. The fit was checked after tack
Step by step the new parts were installed, welding as well as after completion of the root
including 100% testing of all welds by UT layer.
wherever possible and DP of the root layer
and the final weld (Figure 18). Step by step the new outlet pipe and the neces-
In addition, all newly installed plates, rings, sary thermal insulation were installed. After
and the new outlet pipe were 100% UT test- finishing the repair the temporary supports of
ed to exclude any lamination and reoccur- the bottom part of the outlet pipe were removed
rence of the same damage. and the missing insulation of the bottom head
was reinstalled. After the final inspection in the
As everybody was aware of the importance of bottom hemisphere of the converter, the man-
each work step, only few repairs were found hole in the bottom of the 2nd bed was closed and
necessary. catalyst loading started.
During the time of repair, all accessible parts of Most of the smaller particles which had flaked
the cartridge had been thoroughly UT tested for off were swirling around and had been further
100% of the surface. There were no findings of deformed and broken to a smaller size. Thus,
concern. As a result there was a doubt about the most of the potential evidence was blown away
correct root cause of the damage. Vibration of with the gas flow towards the inlet of the second
the outlet pipe in the outlet spacing was exclud- ammonia converter.
ed by simulation performed by SAFCO. The
only potential root cause left was the presence
of defects (cavities) in the plate material that Conclusion
had allowed ionic hydrogen to collect and re-
combine to diatomic hydrogen. The resulting The unexpected damage was due to the defects
interstitial pressure had probably led to flaking in the original casting of the plate material. It
off of material. This mechanism fits the found must be noted that plates of 12 mm (~1/2")
surface appearance of the particles found in the thickness do not require a UT test by code and it
waste heat boiler. Still, there were doubts as no therefore was not performed during equipment
remaining cavity was found during the inspec- manufacturing. Undetected material defects,
tions. which for non-hydrogen applications are uncrit-
ical, caused this damage. This failure was un-
The final piece of evidence was found in a part expected and was the first experienced damage
that had been taken to Germany for laboratory of this kind. All TK Uhde converters have such
analysis. This part revealed an indication of de-
Lessons Learned
Trusting in good workmanship and quality con-
sciousness of the workshop personnel, and even
visual inspection, does not protect us from sur-
prises. Something like an inadequately drilled
vent hole, while seemingly simple, is not detect-
able with the bare eye without special effort.