Implementation of the API RP 584 Integrity

Operating Windows Methodology at the

Gibson Island Ammonia Manufacturing
Plant

A Team Industrial Services Company

Integrity Operating Window

Operating
Operating
Window
Window

• API RP 584 Integrity Operating Windows standards

(IOW) best practices.
Start, trips, shutdown, stand by

• All changes in operation produce more damage than

continual operation.
• Operating windows set taking into account:
– Damage to the plant
– Demands on production

• Typical key parameters:

– Heating and cooling rates
– Flow rates
– Water chemistry
Examples of IOW Parameters

• Power output • Physical measurements

or conditions e.g.:
• Operating temperatures
– Iron content in BFW
• Water flow rates – pH
• Heating and cooling – Thermocouples
rates – Pressure drop
• Standby temperature. – Thermography
– Vibration from a
• Steam flows in dearator
vibration sensor
• BFW chemical dosing – UT thickness
Case Study Incitec Brisbane 2010

• 1960’s terrace fired reformer with

preheater furnace added at a later
date.
• Fire incident after process gas
leak outside of the primary
reformer from pigtail failure
• Previous pigtail and convection
section coil failures
• RCA showed operation had been
above a safe “Operating Window”
• Implement the API RP 584
Integrity Operating Windows
standards (IOW) best practices.
The Equipment Involved in IOW
Assessment

Coffin box section:

2010 failure location
Pigtail Failure

• A single pigtail contained extensive creep voids at the failed

weldolet, while nearby pigtails were in good condition. The
root cause of the incident was extended operation at high
temperatures meaning operation had been above a safe
“Operating Window”.
• Seen 3 years of operation with 10 shutdowns or trips.
• Design-pressure 2.75MPa and temperature 815˚C Pigtails are
side exit from the reformer tubes (900mm from the bottom)
are straight and are relatively short ie prone to system
stresses.
• Prior issues with pigtail failures and bull tee cracking
• Implications defined were poor compensation for thermal
stresses in the manifolds/pigtails
Wall Fired Reformer with Top/Side
Convection Section
IOW Deliverables Required

A clear understanding of likely failure modes, remaining life and

integrity of components under controllable process variables
(e.g. temperature, pressure, flow, etc.) and operational guidelines
outlining the upper and lower bounds of these limitations.
IOW Process as Executed

1. Team – process, engineering, reliability, management

2. Identify production targets and preferred operational limits
3. Use RBI program for defining and ranking the risk of particular
failure modes and mechanisms.
4. Simple screening API 579 level 1
5. Detailed analysis on high risk areas using API 579 level 3 CFD and
FEA analysis to:
– better understand possible issues with operating the unit under
current conditions.
– estimate remaining life for different operating windows.

6. Defined IOW limits for operation and operational improvements.

IOW Process as Executed
Detailed Analysis

• High risk areas identified as convection section coils

and reformer outlet components; required an
understanding of temperature variation especially in
convection section:
– completed by computational fluid dynamics modelling
(CFD).
– additional plant measurement - installation of
thermocouples on all pigtails
CFD Model Geometry & Objective

Objectives:
Fan location
1. Determine the flue gas
distribution in the unit for
two operating conditions.
2. Identify the cause of
observed uneven reformer
tube temperatures along
the end walls of the
furnace

Burners terraces
Side View of Flow Plot above
Burner Terrace
Standing vortex affects convective heating on the
reformer tubes adjacent to the side walls
 CFD Results –
Flue Gas Temperature Distribution

Outcome
• End reformer tubes run hot and prone to
bowing.
• Temperature variation along convection
coil

Flow circulation along

end walls caused uneven
flue gas distribution.
Stress Analysis Mixed Feed
Superheater Coil Outlet

Outcome
Creep fatigue issue at the weldolet welds due to bending
Mixed Feed Coil Outlet Manifold Remaining

Life for Different Operating Conditions

  Remaining life (hr.)
Pressure: Pressure:
Temperature 2.69 MPa 2.96 MPa
˚C
560 52,540 50,747
574 26,223 25,023
579 19,764 18,794
584 14,759 14,027
589 11,147 10,582
594 6,208 5,777
598 6,096 5,777
603 4,416 4,183
Outcomes

• IOWs set for the operation to give predicted lives:

– Flue gas temperatures
– IR temperature measurement on reformer tubes
– Flow rates
– Pigtail temperatures
• Recommendations for redesign of some equipment or
material change.
• Recommendations for planned equipment replacement
Example Actions

• Further Inspection: Reformer Inlet header tee

– Investigation suggested 30% damage may have occurred.
Inspection found very little damage. Run and change out in 2015.

• Modification: Mixed Feed Superheater Outlet Header

– 80% damage at un-inspectable location. Temporary modification
and redesign/replace in 2015.

• Replacement: Reformer Outlet Manifold

– New in 2011 but retained hanger system shown to be inadequate
and scheduled for upgrade.

• Replacement: HP Steam Coil in Convection Section

– 304SS tubes predicted high damage levels.
Replace with Alloy 800H
Discussion