ME-04 - Moaddab T S (En)

A report on
Restoration
of hydrogen-heater
tubes
By: Moaddab Talebzadeh

Shiraz Oil Refining Company
Contents
1) Heater Properties
2) Tubes Repair and Restore Method
3) Confirmation of Research Institute of

Petroleum Industry (RIPI)
4) Additional Value Produced by This Method
1
Section 1
Heater Properties
Heater Properties
Hydrogen-heater of Shiraz
refinery was designed by
FOSTER WHEELER Company
and it has been worked since
1973.
2
Heater Properties
Number of tubes 74
Tube material ASTM A297
Tube positions HK40
Inlet flange material vertical
Outlet flange A 182 F11
material A-105
Filler material ER-INCONEL
Flange type RTJ WN
Heater Properties
In designing of this heater,

the outlet flanges was put
outside the combustion
chamber to make their
temperature near ambient
temperature.
3
Heater Properties
In the other hand, gas and

vaporized water inside the
tubes permeate in this zone
and they make corrosion in
weaker metal.
Heater Properties
As the outlet flange was made by carbon
steel, heat affected area of weld (HAZ)
between flange and tube is susceptible to
be corroded and from this area the weld
become weaker and consequently holed.
4
Heater Properties
Because of complicated
designing of heater and
difficult access to damaged
point , repairing of downer
flange in site is not possible.
Heater Properties
Necessarily, from 1973 until 2006
,62 tubes of this heater had been
changed because of corrosion in
weld in downer flanges and in
some cases these welds became
holed due to corrosion.
5
Heater Properties
These 62 tubes were keeping

in salvage yard.
Heater Properties
The number of new tubes in
our company decreased to a
small quantity and buying new
tubes made too much costs.
So we decided to restore
tubes which just affected by
corrosion in their flange welds.
6
7
8
9
Section 2
Tubes Repair and

Restore Method
10
Tubes Repair and Restore Method
1 ) At first radiographic test

applied to welds to gain
confidence that there wasn't
any other fault in welds
besides above mentioned
corrosion.
11
2 ) Hydrogen relieve operation

was done on welds.
12
3 ) Internal face of welds was

cleaned and penetrant test
applied on them.
13
14
4 ) After the welds were

confirmed by PT & RT, weld
area heated to 50c. Then
welding and supporting weld
between flange and tube
from inside part of tube was
done.
15
5 ) Welding was done by using

E-INCONEL (E-NICRFE3 )
filler.
16
6 ) Then the face of weld got

cleaned until it became flat
and the internal face of tube
became flat and smooth.
17
18
7 ) Again, PT was applied after

smoothing the internal face
of each tube.
19
8 ) RT was applied and

confirmed.
20
21
9 ) After confirmation of PT &

RT,
RT position of ring in faces
of both flanges ,which
affected by corrosion, lathed
and corrected by FLANGE
FACER machine.
machine
22
10 ) Then, hydrostatic pressure

test did for each tube to 40
kg/
cm2 . The results were okey.
23
11 ) After confirmation of weld,

faces of two coupling on tube
were corrected by grinding.
24
12 ) By installing wooden plug,

plug
inner parts of coupling were
protected.
13 ) To prevent corrosion during

keeping tubes in stoke, face of
flanges was greased and
covered by galvanized plates.
plates
25
Section 3
Confirmation of Research
Institute of Petroleum
Industry (RIPI)
26
Confirmation of Research Institute of
To get confidence about this

repairing method, one restored
tube was sent to RIPI .
Confirmation of Research Institute of

The RIPI confirmed this

repairing method by relying on
results of RT,
RT PT and
hydrostatic test.
test
27
Section 4
Additional Value
Produced by This Method
Additional Value Produced

by This Method
According to RIPI report, these

tubes will have 50,000 working
hours life regarding to creep
phenomena, carborizing and
changing in metallurgy of metal
irrespective of flange corrosion.
28
by This Method
New tubes are designed with

100,000 working hour life.

by This Method
A new HK 40 tube approximately

costs 11,000, in 2006.
So, for 50,000 working hour of a
new tube,5500 Euro should be
paid.
29
by This Method
Repairing and restoration cost of

each tube, including inspection
costs, repairing costs, welding,
tests and consumer goods and
,is equal to 16,500,000Rials.

by This Method
So, for 62 tubes economic saving is

equal to:
70,000,000 - 16,500,000 = 53,500,000Rials
53,500,000 62 = 3,317,000,000Rials
30
by This Method
Economic saving
=
261,000
according to prices of 2006
Questions?
31
Thanks for your
attention
32

ME-04 - Moaddab T S (En)

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A report on

By: Moaddab Talebzadeh

2) Tubes Repair and Restore Method

3) Confirmation of Research Institute of

4) Additional Value Produced by This Method

In designing of this heater,

In the other hand, gas and

These 62 tubes were keeping

Tubes Repair and

1 ) At first radiographic test

2 ) Hydrogen relieve operation

3 ) Internal face of welds was

4 ) After the welds were

5 ) Welding was done by using

6 ) Then the face of weld got

7 ) Again, PT was applied after

8 ) RT was applied and

9 ) After confirmation of PT &

10 ) Then, hydrostatic pressure

11 ) After confirmation of weld,

12 ) By installing wooden plug,

Tubes Repair and Restore Method

13 ) To prevent corrosion during

To get confidence about this

Confirmation of Research Institute of

The RIPI confirmed this

Additional Value Produced

According to RIPI report, these

New tubes are designed with

Additional Value Produced

A new HK 40 tube approximately

Repairing and restoration cost of

Additional Value Produced

So, for 62 tubes economic saving is

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