Assessing Creep Damage Using N DE

Techniques

A number of nondestructive examination (NDE) tools can be used to help determine the presence of
creep damage in centrifugally cast reformer tubes. This article examines field-ready NDE
technologies in terms of their limitations, advantages, and overall reliability in determining remain-
ing life of reformer furnace tubes.

Brian E. Shannon and Norman Smith

IESCO, Worldport Business Center, San Pedro, C A 90731

Introduction every plant turnaround it would be advantageous if

NDE techniques could be used to screen tube condi-

R
eformer tubes normally used in the refining,
petrochemical, and fertilizer industries are cen-
trifugally cast and consist of high tempera-
ture-resistance stainless steel grades such as HK-40,
HP-40, and HP-Niobium modified materials. A design
life of 100,000 operating hours has been the normal
time-based criteria for considering retirement of tubes.
Many operators of furnaces using such tubes want to
change their maintenance philosophy for tube retire-
ment from time-based assessment to condition-based
assessment. Many reformer furnace tubes remain in
service beyond the 100,000 h criteria. Metallurgie
examination of tubes removed from such service has
typically indicated carbide agglomeration but no dis-
cernable creep voids or fissues (Independent
Metallurgie Engineering Report, 1996). This provides
the opportunity to improve reformer furnace life-cycle
value by extending the life of the tubes using condi-
tion-based criteria. Rather than remove tubes from ser-
vice for sectioning and métallurgie examination at
tion for environmental damage such as creep.
The disadvantages of removing tubes from service
on a sampling basis to determine tube integrity include
catalyst removal; early retirement of serviceable tubes;
late removal of unserviceable tubes, which impacts
turnaround critical path duration if all the tubes need
to be renewed; and maintenance costs. The main
advantage of removing tube(s) from service to deter-
mine condition is that the true métallurgie condition of
a particular tube is known.
An operating facility must have confidence in the
methods it uses to determine tube condition if a
change from a time-based to a condition-based philos-
ophy is to be made. Extracting tubes at a turnaround
close to the end of their design life and subjecting
them to métallurgie investigation is a fairly well-
accepted practice. Some facilities have also embraced
the use of certain NDE techniques to mark trends in
tube changes. The actual technique used is heavily
dependent on individual plant preferences, availability

AMMONIA TECHNICAL MANUAL 104 1998

of specialist services, historical experience, cost, turn-
around duration, availability of data from testing, and
knowledge of NDE technologies.
To reduce the frequency of furnace tube removal for
condition-based assessment, the use of NDE tech-
niques on a regular basis during reformer furnace turn-
arounds is beneficial. The condition of a reformer tube
is inferred from the response of an NDE sensor to a
change in material properties. There are certain limits
on detectability, sizing, and characterization of flaws
heavily dependent on the overall characteristics of the
test system, which takes into account the environment,
the instrumentation, the sensor, the tested material,
and, of course, the operator.
Discussion
Reformer tube condition can currently be inferred
in-situ by qualitative NDE assessment using the fol-
lowing techniques and parameters:
• Diameter growth (diameter change with creep)
• Measurement of wall thickness (apparent decrease
in wall thickness with creep)
• Replication
• Radiography (final stages of creep)
l l l i i i M i I l l $ i l l. l l §
Figure 1. The IESCO mechanical Figure 2. Chart of diameter measurement at tube intervals.
micrometer.
AMMONIA TECHNICAL MANUAL
• Eddy current (responds to chrome migration due to
overheating and conductivity changes)
• Ultrasonic techniques(responds to attenuation and
scattering)
Growth in diameter
The principal rationale behind this technique is that
the tube bulges when creep damage occurs. Each
material type has its own value of diameter change
where creep is considered to have occurred. The range
of diameter change when creep is considered with
steel grade HK-40 is 2-3% and with HP-45 is 5-7%.
To assess diameter growth, manual strapping of the
tube is normally performed and the results tabulated
per tube at specific locations on the tube, normally at
burner locations. This technique tends to be tedious,
time-consuming, and requires scaffolding; automated
techniques have been developed as a result. Current
automated techniques include eddy current proximity
sensors (Fowler, 1991) and mechanical micrometers.
A typical example of the IESCO mechanical
micrometer is shown in Figure 1. The tool is attached
to a crawler device that traverses an in-situ tube and
records the diameter measurement at predetermined
intervals. Because the crawler is fitted with an
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105 1998
encoder, the precise location of suspect diameter
changes can be recorded. The output of the tool is
input directly into a spreadsheet for data recording and
analysis purposes. A typical finished chart is shown iii
Figure 2. Due to variations in manufacturing it is
preferable if baseline data can be obtained on the tubes
when they are initially installed so that accurate trends
may be developed.
Wall thickness measurement
As creep damage occurs, an apparent decrease in
wall thickness is evident. As an example, average wall
thickness measurements were obtained from a tube
that had been sectioned at 0.4 m, 1.0 m, 7.0 m, and
11.0 m positions; the metallographic condition at each
section is depicted in Figures 3,4, 5, and 6, respective-
ly. Note the apparent decrease in wall thickness for
these four sections of tubes as shown in Figure 7. In-
situ continuous wall thickness measurements along the
length of a tube can be obtained when using the time-
of-flight diffraction (TOFD) ultrasonic technique.
Replication
Replication is useful for in-situ assessment of the
outside surface of reformer tubes for overheating that
causes microstructural changes. Replication is a spot
assessment and normally used as a supplemental tech-
nique. Note that only the advanced stages of creep
damage can be assessed utilizing in-situ replication.
Radiography
Random radiographie examination is normally used
as a supplementary technique to confirm the presence
of severe cases of creep damage. Locating such dam-
age can be expected when damage has extended
30-50% in the through-wall direction, when the tubes
are full of catalyst, and when isotopes are used instead
of an X-ray tube. Use of an X-ray tube normally pro-
vides an image of higher quality, but is not normally
used on-site due to practical considerations.
AMMONIA TECHNICAL MANUAL
Eddy current
Eddy current techniques have been used for a num-
ber of years on HK-40 and HP-45 tubes. The basic
principles of the technique can be found hi Volume 4
of the ASNT handbook series. The technique relies on
changes in electric circuit conditions, the circuit being
the instrumentation, cables, sensing coil, and the item
being tested. As the mechanical properties of the test
material change, a change in overall circuit impedance
occurs. This change is displayed on an oscilloscope.
By monitoring these changes it can be inferred that
creep damage is present based on observation of the
signal parameters in comparison to similar changes
that have occurred in materials known to be damaged
by creep. The depth of penetration of eddy currents is
primarily influenced by frequency, conductivity, and
relative permeability. For practical purposes, eddy cur-
rent has proven useful in detecting creep damage
located from the midwall to the outside of the tube. It
is less sensitive to creep damage located towards the
inside of the tube.
Eddy-current coil design is important to obtain ade-
quate sensitivity and signal-to-noise ratio. Some tubes,
such as those made of HP-40 and similar materials
that have a high percentage of nickel, require the use
of magnetically shielded or biased coils to reduce the
effects of variation in material permeability. This
improves the signal-to-noise ratio so that a reliable test
result with adequate discrimination of creep damage
from general material property characteristics is
obtained.
Referring again to Figures 3, 4, 5 and 6, which
depict varying degrees of damage within a reformer
tube, the eddy current responses to these samples are
as shown in Figure 8. Note the differences hi response
to the various stages of damage. These changes in sig-
nal response are what the eddy current operator evalu-
ates. Other factors that the operator considers include
varying lift-off, which influences the signal response
(scale and welds being typical examples), and over-
heating, which causes chrome migration, scale forma-
tion, and a significant eddy current response hi terms
of phase and amplitude changes (Warren, 1995).
106 1998
 Figure 3. Micrograph of 0.4 m test sections Figure 4. Micrograph of l m test sections
(left, x 50; right, x200). (left, xSO; right, x200)

Figure 5. Micrograph of 7 m test sections Figure 6. Micrograph of 11 m test sections

(left, xSO; right, x200). (left, x50; right, x200).

Auftrag» Wall Thieknen

! MM J ! i J i H i H I

Figure 7. Chart of average wall thickness for four sections of tubes.

AMMONIA TECHNICAL MANUAL 107 1998

 .t
'' l

0.4 m lm 7m llm
Figure 8. Eddy current response to the four samples.

FIRED SIDE

EDDY CURRENT PROBES

TOFD TRANSMITTER , ... TOFD RECEIVER
TRANSMITTING TRANSDUCER i.x-M-/"1 •-,.'; . RECEIVING TRANSDUCER

Figure 9. Diagram of forward scattering/transmission technique.

Ultrasonic techniques
Ultrasonic techniques utilized for the detection and
estimation of creep damage include through-transmis-
sion ultrasonic attenuation and ultrasonic scattering
techniques (Smith, 1996; Birring). The forward scat-
tering/transmission technique is shown in Figure 9.
The basis is a pitch-catch technique and relies on
ultrasound attenuating and scattering due to the pres-
ence of creep voids and fissures. The amount of scat-
tering is assumed to be a function of the amount of
damage present. Referring again to Figures 3, 4, 5 and
6, which depict varying degrees of damage, the images
outlined in Figure 10 depict the four samples and their
responses to the ultrasonic examination.
The primary disadvantage of this technique is the
influence of tube surface condition, which can vary
from smooth, dimpled, tightly-adhering scale to loose
scale, or a combination of all the different scales. This
combination affects the ultrasonic signal, giving the
impression of creep damage.
The TOFD-based ultrasonic scattering techniques are
similar in principle to the ultrasonic backscatter tech-
nique used in high temperature hydrogen attack evalu-
ations in that it is shape, amplitude, and location of the
signal response that the operator evaluates and com-
pares to the signal response from a "sound" section of
the tube. The ultrasonic backscatter technique used for
high temperature hydrogen attack relies primarily on
signal features such as amplitude, shape and location;
the TOFD scattering technique utilizes similar signal
features. Figure 11 illustrates a sound section of tube
and Figure 12 a damaged section of tube. Note the high
amplitude signals with length. This technique indicates
when surface conditions influence the ultrasonic signal.
Combining NDE Techniques: 'H' Scan
Review of the NDE techniques outlined above illus-
trates the advantages and disadvantages associated
with each individual technique. Therefore, combining
NDE techniques to improve overall reliability of

AMMONIA TECHNICAL MANUAL 108 1998

 Figure 10. Response of four samples to ultrasonic examination.

Figure 11. Undamaged section of tube.

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Figure 12. Damaged section of tube.

AMMONIA TECHNICAL MANUAL 109 1998


Figure 13. IESCO assembly of carrier and sensors.
reformer tube condition evaluation is prudent. The
optimum combination of NDE techniques depends on
the type of material, the surface condition of material,
time frame allowed for data analysis, and the cost.
The one common element in obtaining NDE data is
use of a powered carrier mechanism that traverses the
length of a tube. Ultrasonic, eddy current, and pro-
filometry NDE sensors can be loaded onto a carrier
mechanism for simultaneous data collection.
Figure 13 shows the IESCO assembly of carrier and
sensors. It takes about 4 h to set up such a system on-
site and 10-15 min per tube to collect data and assign
a provisional condition status. Data analysis and
reporting is dependent on the number of indications
and the reporting needs of the client.
The NDE specialists evaluate each tube and assign a
damage grade per tube based on the worst section of
tube. These grades are assigned based on comparison
to the NDE responses obtained from samples at
IESCO that have been subject to metallography (Wang
and Parra, 1995). Based on the comparison of the
IESCO samples' metallographic result to the métallo-
AMMONIA TECHNICAL MANUAL
graphie results in Jaske (1990) and Mohri et al. (1996)
it is possible to assign a remaining lifespan to the tube.
Conclusion
The reliability of NDE evaluation of reformer fur-
nace tube condition can be improved by combining a
variety of techniques that individually monitor differ-
ent physical parameters. The advantages and disadvan-
tages of each technique when compared against each
other reduce the occurrence of false calls.
Acknowledgments
We thank Bill Carlin for producing and editing the
ultrasonic data, Mark Cassidy for the eddy current
data, and Noeleen Kawakami for production of the
manuscript.
Literature Cited
Birring, A. S., Ultrasonic Methods for Detection of
Service-Induced Damage in Fossil Plant Components
EPRI Funded RP-1865-7.
Electromagnetic Techniques, ASNT Handbook Series,
Vol. 4.
Fowler, J, Reformer Tube Technical Bulletin, Thermal
Technology (1991).
Independent Metallurgical Engineering Report
N52357 for ffiSCO client, (July 1996).
Jaske, C.E. and Viswanathan, NACE Paper No. 90213,
"Predict Remaining Life of Equipment in High
Temperature/Pressure Service," NACE Paper
No. 90213, NACE, Corrosion (1990).
Mohri, T., T. Shibasaki, and K. Takemura, "Feature of
Creep Rupture Damage of Nb Containing Catalyst
Tribes for Steam Reformer Furnace," AIChE
Technical Manual (1996).
Smith, N., "Non-Destructive Examination of In-Situ
Reformer Tribes for Creep Damage," Structural
Integrity, NDE, Risk and Material Performance for
Petroleum, Process and Power, PVP Vol. 336,
ASME(1996).
110 1998
 DISCUSSION
G. M. Joorse, Nagarjuna Fertilizers, India: In the
paper you did not mention the time interval at which
mandatory inspections are done. When we are starting
a plant and at every turnaround we normally do an
eddy current inspection of the reformer tubes, but is
there any mandatory interval at which these inspec-
tions are to be carried out?
Shannon: I'm not aware of any mandated intervals for
inspection. It's very dependent on the risk philoso-
phies that are followed by each individual plant.
However, I will say that if one has an opportunity to
conduct a baseline inspection on new tubes before
they go into service, it is extremely helpful for com-
parison analysis after subsequent inspection, but I'm
AMMONIA TECHNICAL MANUAL
not aware of any mandated inspection interval. A lot of
people don't inspect until they get close to 100,000 h
operating time. My recommendation would be to look at
each heater at least on a baseline examination, and then
subsequently inspect at three-year or potentially six-year
intervals.
G. Schlichthärle, BASF: How long does it take to
examine a tube in situ, and what is the mixture of mea-
surements you would advise?
Shannon: The inspection duration for a 10- to 15-m
tube is approximately four to six tubes per hour. The
data analysis is somewhat dependent on how many
techniques we're using and what sort of information
the client is looking for.
111 1998