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ALERTE TECHNIQUE TECHNICAL ALERT 05-2004 rv.

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Fissure sur une tuyauterie du rformeur de RdR
Assistance Technique RdR Reformer Pipe crack

Voir ci-jointe, la description d'un incident survenu la raffinerie de Rome dans l'unit de rformage catalytique.

La cause la plus probable est la rutilisation de "bobines" de tuyauteries existantes qui ont t ressoudes dans des logements
socket welding neufs.

L'extrmit de la bobine introduite dans le socket comportait des restes de l'ancienne soudure d'angle (visibles sur la dernire photo du
rapport) et le nouveau joint soud a t de mauvaise qualit initiant une fissure qui s'est dveloppe avec le temps (4 5 ans).

Recommandations:

En cas de rutilisation de tubes emmancher dans un socket veiller la prparation de l'extrmit. Eliminer par meulage les restes de la
soudure d'angle et blanchir l'extrmit. Contrle par ressuage. Si l'extrmit est notoirement corrode, ne pas rutiliser le tube o couper
une section si la gomtrie de l'ensemble le permet.
Il est prfrable d'envisager le remplacement complet (socket + tube + vanne) et de raliser la transition ancien/nouveau en aval de la
premire vanne.

Dans le cas d'utilisation de o'let prfrer les "nippolets" plutt que des sockolets

Mme en cas d'intervention sur unit existante respecter dans la mesure du possible les dernires spcifications de tuyauteries.

Voir les exigences des dernires spcifications tuyauteries concernant le renforcement des les petits piquages (DN infrieur ou gal
DN40)

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Ce document est la proprit de TOTAL et rserv un usage interne
This document is TOTAL property and is reserved for an internal use
ALERTE TECHNIQUE TECHNICAL ALERT 05-2004 rv. : 0
Fissure sur une tuyauterie du rformeur de RdR
Assistance Technique RdR Reformer Pipe crack

See attached the report of an incident that recently occurred at the Roma refinery on the catalytic reforming unit.

The most probable cause is the re-use of old small bore piping that was re-welded in a new socket.

The end of the piping that was introduced in the socket had leftover from the old fillet weld (see the last picture in the report) and the new fillet
weld was of poor quality initiating a crack that propagated with time (4 to 5 years period)
Recommendations

In case old small bore piping is to be re-used in a new socket, control the quality of the end preparation. The old weld must be ground off.
NDE by dye-penetrant. If the end is corroded do not use the piping or cut out a section if that's possible without changing the piping
geometry.

It is better to replace completely the socket, the piping and the valve making the transition between old and new downstream of the first
valve.

In case of branching using an o'let, nippolet is a better option than sockolet.

Even in case of revamp piping works try to follow the last piping specifications

In case of small bore piping (NPS smaller or equal to 1"1/2) see the piping specifications for reinforcement requirements (against
vibrations, excessive external forces...)

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Ce document est la proprit de TOTAL et rserv un usage interne
This document is TOTAL property and is reserved for an internal use
ALERTE TECHNIQUE TECHNICAL ALERT 05-2004 rv. : 0
Fissure sur une tuyauterie du rformeur de RdR
Assistance Technique RdR Reformer Pipe crack

RdR Report

1. SUMMARY
On 13th April, at approx 08.00 p.m. in the evening, a small fire was detected from the 2nd Reforming reactor outlet line, in elevated location, close to a pressure gauge
nozzle underneath the pipe insulation. The fire was extinguished soon by use of one of the mobile firefighting monitor available at the units, with no injuries neither
damages to nearby installations. The unit was shutdown and depressurised in order then to be able to remove safely the insulation and carry out the inspection

2. CAUSES OF THE ACCIDENT

Immediate causes
The immediate cause of the fire was the leak of hydrogen and hydrocarbons from the outlet line of 2nd platformer reactor (at about 35Bar and 550C), close to a pressure
gauge nozzle under pipe insulation (Picture n1).

Fundamental causes
The radiographic inspection showed a crack, close the Heat Affected Zone between sockolets and tubing of the pressure gauge welding joint (Picture n2).
The crack was located in a zone with a reduced wall thickness.

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Ce document est la proprit de TOTAL et rserv un usage interne
This document is TOTAL property and is reserved for an internal use
ALERTE TECHNIQUE TECHNICAL ALERT 05-2004 rv. : 0
Fissure sur une tuyauterie du rformeur de RdR
Assistance Technique RdR Reformer Pipe crack

CRACK

The investigations revealed that 8 out of a total of 14 instrumental gauge connections relevant to the new lines of the reaction section circuit, installed during 1999 revamp,
were built using new sockolets but recovering old tubing.

All those instrumental gauge were inspected by radiography and magnetic inspection.

The radiographies carried out on all these connections showed a second 3/4" gauge with a similar defect.

The most probable cause of failure is a mechanical damage caused when removing the old welding joint.
This effect is visible looking the irregular section of cut tubing gauges (Picture N3).
The following welding phase, the instrument weight and temperature gradients had cooperated to generate the stress-crack.

Residual
thickness

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Ce document est la proprit de TOTAL et rserv un usage interne
This document is TOTAL property and is reserved for an internal use
ALERTE TECHNIQUE TECHNICAL ALERT 05-2004 rv. : 0
Fissure sur une tuyauterie du rformeur de RdR
Assistance Technique RdR Reformer Pipe crack

Old weld

3. RECOMMENDATIONS

Short term actions


Both the two 3/4" tubing gauges were cut off and plug welded.
On all the remaining 6 gauge connections, of higher diameter tubing, the radiography and magnetic inspections did not reveal any defect.

Middle term actions


We are planning metallurgical ad destructive tests to better define the origin of the crack.
We are planning anyhow to replace all these reused gauge tubing during the next regeneration shut-down (May-June 2004), adopting the most appropriate standard (use of
reinforcement gusseting for up to 1 1/2 in. branch)

The reforming was restarted after three days following to maintenance and inspection work.
We are continuing our investigations on the matter.

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Ce document est la proprit de TOTAL et rserv un usage interne
This document is TOTAL property and is reserved for an internal use