Failure Analysis of Reformer Tubes: Technicalarticle-Peer-Reviewed

J Fail. Anal. and Preven.
(2013) 13:731–736
DOI 10.1007/s11668-013-9731-0
TECHNICAL ARTICLE—PEER-REVIEWED
Failure Analysis of Reformer Tubes

S. Al-Shahrani • A. Al-Meshari • M. Rabie
Submitted: 7 May 2013 / in revised form: 23 June 2013 / Published online: 4 September 2013
Ó ASM International 2013
Abstract This paper presents a failure analysis per- recommendations aimed at preventing the reoccurrence of
formed to investigate cracking observed in reformer tubes. similar failure.
Thorough investigation showed that the tubes failed by
thermal shock. No signs of advanced creep failure could be Technical Background
observed near the ruptures or across the microstructure.
Also, no material-related abnormalities were observed in The reformer is a furnace containing catalyst filled vertical
the tube microstructure. The reformer tube material is tubes. These tubes are supported at the bottom and free to
suitable for the application, and there is no need for met- expand at the top. The natural gas and steam mixture enter
allurgy upgrade. It is recommended that reformer the tube top end at 450–500°C and 10 kg/cm2, and the
operating, start-up and shut down procedures be followed reformed gas leaves the tubes at 800–840°C and 6 kg/cm2.
to ensure safe and sustainable operation. The condition of The reformer tube outer surface metal temperature mea-
un-replaced tubes that had been exposed to the extreme sured by manual thermograph is in the range of 890–
thermal cycles has to be frequently monitored. 930°C. The reformer tubes had been in operation for about
5 years. The design data of the reformer are as follows
Keywords Reformer tubes GX40CrNiSi25-20 [1]:
Thermal shock
Fuels used for main Natural gas
burners:
Introduction Reformer tube material: GX40CrNiSi25-20
I.D. (inner diameter): 130.6 mm
The DRI plant tripped due to an instrumentation problem. Reformer tube thickness: 7.0 mm
During plant start-up, the reformer tube ruptured. Twenty- Design temperature: 985°C
four tubes ruptured (Fig. 1). The balance tubes were Inlet medium: Superheated steam and desulfurized
inspected by automatic eddy current test, and as a result, it natural gas
was recommended to replace nine more tubes due to crack
indication of more than 30% of wall thickness. The
objectives of the subject investigation include identify-
ing the failure mechanism of the tubes and providing
Investigation
Visual Examination
S. Al-Shahrani (&) A. Al-Meshari M. Rabie
SABIC Technology Centre – Jubail, Saudi Basic Industries
Corporation, P.O. Box 11669, Jubail 31961, Saudi Arabia
Three tube samples were received from the plant for failure
e-mail: shahranisa@sabic.com analysis (Fig. 2), namely fractured piece (a), longitudinally
123
732 J Fail. Anal. and Preven. (2013) 13:731–736
Fig. 1 A close up view of the ruptured tubes
ruptured tube (b) and un-ruptured tube (c). Numerous

cracks can be seen on the surface of fractured piece (a) as
shown in Fig. 2. Samples (a) and (b) were cut longitudi-
nally for internal examination (Fig. 3). Dye penetrant
(DPT) was applied on each half to examine both internal
and external surfaces. Small cracks adjacent to the rupture
zone were identified on the inner surface of longitudinally
ruptured tube (b) after DPT (Fig. 3). No cracks were
observed in un-ruptured tube (c) as it can be seen in
Fig. 3c.
Generally, there was no evidence of either general or
localized wall thinning in all specimens studied.
Material Verification
Chemical composition of the tubes was confirmed by X-ray

fluorescence (XRF) and LECO carbon and sulfur (C/S)
analyzer, and results are presented in Table 1. This table
also shows the specified chemical composition of
GX40CrNiSi25-20.
Metallographic Examination
Metallographic observations were made using light opti-

cal microscope and scanning electron microscope (SEM) Fig. 2 Samples submitted for analysis: (a) fractured piece; (b)
equipped with energy dispersive X-ray (EDX) analysis longitudinally ruptured tube; (c) un-ruptured tube
system. For metallographic observations, small cubical
samples were cut from fractured piece (a), longitudinally
ruptured tube (b) and un-ruptured tube (c) locations of the figure, the microstructure consists of equiaxed austenitic
reformer tubes. These samples were next mounted and grains with network of primary and secondary metal
mechanically polished. Polished faces were etched using carbides precipitated mainly at the grain boundaries typ-
glycergia etchant. The metallographic examinations are ical of healthy, thermally aged centrifugally cast heat
revealed in (Figs. 4, 5, 6, 7, 8, 9). The microstructure of resistant alloy. Multiple interdendritic cracks initiating
the tubes is illustrated in Fig. 8. As can be seen in this from the tube ID and OD were observed (Figs. 7, 9). No
123
J Fail. Anal. and Preven. (2013) 13:731–736 733
Fig. 3 Photographs of samples

submitted for analysis after DPT
test: (a) longitudinally ruptured
tube; (b) close up photograph
showing cracks adjacent to the
ruptured zone; (c) un-ruptured
tube showing inner side; (d) un-
ruptured tube showing outer
side
Table 1 Chemical composition (wt%) of GX40CrNiSi25-20 grade

alloy and tube material [6]
Elements ISO 11973 GX40CrNiSi25-20 Tube SAMPLE
C 0.3–0.5 0.49
Al 0.0377
Si 1.0–2.5 0.75
P 0.4 max 0.03
S 0.03 max 0.02
Ti 0.08
V 0.04
Cr 24–27 25.42
Mn 2 max 0.16
Fe Balance Balance
Ni 19–22 19.98
Cu 0.03
Nb 0.74
Mo 0.5 max 0.01
Fig. 4 SEM micrograph showing OD surface of fractured piece
revealed oxides containing concentrations of Cr, Ni, Al

signs of advance creep activities (e.g., micro voids or and Nb.
internal fissures) could be observed near the cracks or
across the microstructure (Figs. 7, 9). According to EDX
results, the dark second phase was confirmed to be Discussion
chromium-rich carbide (Fig. 6), whereas the whitish phase
(Fig. 6) was identified as niobium-rich carbide. Scale Visual and microstructural examinations as well as the
analysis of both inner and outer surfaces (Figs. 5, 7) information provided by the plant indicate that the reformer
123
Fig. 5 SEM micrograph of

microstructure and EDS
analysis of chemical
composition of OD surface of
fractured piece

microstructure and EDS
analysis of chemical
composition of area close to OD
surface of fractured piece
tubes had been subject sudden and sharp fluctuation in expansion between matrix and carbides at the grain
temperature and load that resulted in shattering and tearing boundaries, cracks propagated through the interface of
of the tubes. This fluctuation creates extremely high ther- carbide and matrix [2, 3].
mal stresses as the tubes attempt to contract under restraint The failure happens during start-up because of the
and as a consequence led to cracks and ruptures. This abnormality of operation. This is one of the root causes of
phenomenon is normally called thermal shock. reformer tubes failure. Conditions during shut downs and
Thermal shock is known to be produced by high and start-ups are so transient that they generate additional
non-uniform thermal stresses developed over a relatively stresses due to the high rate of temperature changes.
short time, and because of the difference in thermal Regular visual inspection of reformer tubes is necessary
123
J Fail. Anal. and Preven. (2013) 13:731–736 735

crack in cross-section sample
(Fig. 4) at the ID region with
EDX analysis of chemical
composition within the crack
and the microstructure front of
the crack
during start-up and shut down. It gives clear picture of what

is going on inside the reformer and that the tubes are not
being overheated [4, 5].
Conclusions
The following conclusions can be drawn from this

investigation:
1. The failure mechanism is thermal shock.
2. No material-related abnormalities were observed in the
tube microstructure.
3. No signs of advance creep failure (e.g., micro voids,
internal fissures) could be observed near the ruptures or
across the microstructure. Fig. 8 An optical micrograph showing the microstructure of the tube
123
Recommendations
1. No tubes material upgrade is recommended.
2. Safe and sustainable operation must be maintained and
avoid the abnormality of operation.
3. The condition of un-replaced tubes that had been
exposed to the extreme thermal cycles has to be
frequently monitored.
References
1. Documents provided by the plant

2. Damage Mechanisms Affecting Fixed Equipment in the Refining
Industry API Recommended Practice 571 Second Edition, April
2011
3. Failure Analysis and Prevention. Metals Handbook, vol. 11.
(American Society for Metals, Metals Park, 2002)
4. U.-H. Anwar, H.M. Tawancy, A.I. Mohammed, N.M.
Abbas, Failure analysis of furnace radiant tubes exposed
to excessive temperature. Eng. Fail Anal. 13, 1005–1021
(2006)
5. S. Jaganathan, G. Krishna, G. Manojkumar, R. Prabirkumar, G.
Rabindranath, Failure analysis and remaining life assessment of
service exposed primary reformer heater tubes. Eng. Fail Anal. 15,
311–331 (2008)
6. Schmidt ? Clemens Centracero. Centralloy 4848 micro. Material
Fig. 9 An optical micrograph showing: (a) crack in cross-section sample Data sheet; Revision No. 10-02, Schmidt ? Clemens GmbH ?
(Fig. 4) at the ID region; (b) cracks in cross-section sample (Fig. 3a) Co.KG, February 2010
123

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What caused the failure of the reformer tubes?

What failure mechanism was identified?

J Fail. Anal. and Preven.

Failure Analysis of Reformer Tubes

Fig. 1 A close up view of the ruptured tubes

ruptured tube (b) and un-ruptured tube (c). Numerous

Chemical composition of the tubes was confirmed by X-ray

Metallographic observations were made using light opti-

Fig. 3 Photographs of samples

Table 1 Chemical composition (wt%) of GX40CrNiSi25-20 grade

revealed oxides containing concentrations of Cr, Ni, Al

Fig. 5 SEM micrograph of

Fig. 6 SEM micrograph of

Fig. 7 SEM micrograph of

during start-up and shut down. It gives clear picture of what

The following conclusions can be drawn from this

1. Documents provided by the plant

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