Reformer Heater Inspection – Aramco Mechanical QC Questions

Reformer Heater Inspection: A Comprehensive Guide

A reformer heater is a critical component of many industrial processes that use high-temperature catalytic reactions. Over time, these heaters can deteriorate and develop problems that can lead to inefficiencies, safety hazards, and production downtime. To avoid these issues, regular inspections of reformer heaters are necessary.

Here is a comprehensive guide for conducting a reformer heater inspection:

1. Check the heater drawing and materials: The first step is to review the heater drawing and inspect the material of radiant and convection tubes, tube support/tube guide, refractory, thermo well, damper plates, and other applicable components. This inspection includes measuring the dimensions of individual items like diameter, length, and thickness. Additionally, check the burner assembly and orientation of the burner tip and material.
2. Review the heater file: Review the heater’s history to note any corrosion, tube failures, over-heating incidents, re-tubing frequency, and other replacement or repair history. This information can help identify potential issues or weaknesses in the system.
3. Conduct a joint inspection: Before entering the heater for internal inspection, verify that blinds, ventilation, lighting, and scaffolding are provided. Obtain an entry permit to ensure that the heater is safe to enter and inspect. Always keep a man watch for safety during the inspection.
4. Conduct an external inspection: Primarily, inspect the external components of the heater for external flue gas leaks, external damage to the heater casing and structure, burner blocks, and fuel leaks. It is recommended to perform an infrared survey before shutting down the heater to identify hotspots, hot tubes, and any refractory damage to the heater casing.
5. Gas tests the heater: Before entering the heater for an internal inspection, test the gas levels to ensure that the heater has adequate venting and is free from any foul smell/toxic gas release while scales or deposit are disturbed. Check for adequate lighting and scaffold as required for inspection. At the time of vessel entry, ensure that a man stand by is available for your safety and company loss prevention.

By following this comprehensive guide, you can ensure that your reformer heater is thoroughly inspected, maintained, and optimized for safe and efficient operation.

Inspecting the internal components of a reformer heater is a crucial task to ensure safe and efficient operation of the equipment. In this article, we will discuss the steps involved in carrying out a preliminary visual inspection of the heater’s internal components, with a focus on the floor, burner assembly, burners, snuffing steam connections, and refractory walls. We will also cover the process of tube inspection, including numbering, examination for overheating, bulging, bowing, surface discontinuities, and creep measurement.

1. Start with a Preliminary Visual Inspection Before inspecting the tubes, it is essential to conduct a preliminary visual inspection of the heater’s internal components. Pay particular attention to the heater floor, burner assembly, burners, snuffing steam connections, and refractory walls. This step will help to identify any visible damage or anomalies that may require further inspection.
2. Number the Tubes Number the tubes per cell starting from north to south or west to east vice versa. This numbering system helps in tracking the location of each tube during the inspection process and record keeping.
3. Inspect Individual Tubes Inspect each tube individually, focusing on areas opposite to the burner or flame area. Look for overheating, bulging, bowing, surface discontinuities such as micro fissuring, cracks, and other signs of damage. It is essential to inspect each tube carefully, as even minor damage can lead to significant problems if left unchecked.
4. Carry Out Creep Measurement Creep is a critical parameter that determines the remaining life of the tube. Carry out creep measurement on all tubes and compare the results with the previous creep measurement results. Evaluate the creep behavior of each tube and recommend all tubes with creep above 3.5% for renewal.
5. Arrange for Non-Destructive Testing (NDT) Arrange for Magnetize, LOTIS or H-scan to carry out creep measurement and evaluate the results aided by computer, which will give the tube renewal criteria based on creep and crack initiation in the tube. Crack indication above 30% should be considered for renewal if not sooner.

In conclusion, a thorough inspection of the reformer heater’s internal components is critical to maintaining safe and efficient operation. By following these steps, plant operators can identify potential issues before they become major problems, helping to prevent costly shutdowns and ensuring the safety of personnel and equipment.

Inspection of a reformer heater is a critical task that ensures the safe and efficient operation of the equipment. It involves various steps that should be carried out with precision and attention to detail. In this article, we will discuss the steps involved in the inspection of a reformer heater.

Step 1: Preliminary Visual Inspection: The first step in the inspection process is to conduct a preliminary visual inspection of the heater’s internal components. This involves checking the burner assembly, burners, snuffing steam connections, and refractory walls. Pay attention to the heater floor and look for any signs of damage or wear and tear.

Step 2: Tube Inspection Next, inspect the heater tubes by numbering each tube per cell and evaluating them for overheating, bulging, bowing, and surface discontinuities like micro fissures and cracks. Pay attention to areas opposite the burner or flame area. Carry out creep measurement on all tubes and compare the results with previous measurements. Evaluate the creep behavior and recommend tubes with creep above 3.5% for renewal. Consider renewing tubes with crack indications above 30%.

Step 3: Cleaning for Inspection Evaluate if the heater tubes are adequately cleaned for inspection. If cleaning is not sufficient, request adequate cleaning.

Step 4: Inspection after Adequate Cleaning Check tube surfaces externally for any significant corrosion, mechanical damage, bulge, tube distortion or bowing, and fissuring. Get thermo-wells removed and cleaned for visual and DP tests and evaluate the results. Check snuffing steam nozzles/connection for plugging and corrosion. Inspect the floor bricks, refractory, and wall refractory for bulge or any significant damage. Request repairs if required. Inspect the bottom transfer/pigtail pipe for overheating and crack damage externally. Carry out PT test on all weld joints for cracks. Inspect the inlet pigtail pipe for crack damage at the weld joints at inlet header and catalyst tube. Open the blind nozzle flanges on the inlet header and check for fouling. If required, get it cleaned free of the foulant. Inspect the steam generator, economizer, and superheater coils visually and by UT gauging. Check the dampers and their operability. Inspect the stack where accessible for cleanliness and refractory damage.

Step 5: Documentation After completing the inspection, document the findings and recommend necessary repairs or replacements. Make sure to keep a record of the inspection results and use them to plan future maintenance and inspections.

Maintenance and Inspection Guidelines for Heaters in Saudi Aramco Facilities

Heaters are a crucial part of any petrochemical industry as they are responsible for providing the required heat for various processes. To ensure the safe and efficient operation of heaters, regular maintenance and inspection are necessary. In this article, we will discuss the guidelines for the maintenance and inspection of heaters in Saudi Aramco facilities.

1. Full Inspection and Request for Cleaning and Repairs Upon completion of a full inspection, the first step is to request any cleaning, repair, or re-tubing if needed. The inspection should follow Saudi Aramco standards, codes, ASME, and API. The assessment should be carried out thoroughly to determine the necessary repairs to ensure the heater’s optimal performance.
2. Follow-up on Recommendations and Related Repairs The next step is to follow-up on the recommendations and related repairs based on the inspection findings. The repairs should comply with Saudi Aramco standards, codes, ASME, and API. Any deviations from these standards should be approved by the appropriate authorities.
3. Final Inspection After Repairs and Cleaning Once the repairs and cleaning are completed, a final inspection should be carried out to assess the heater’s condition for operation during the next EIS period. If the inspection reveals that the heater does not comply with the findings, a Fitness-for-Service (FFS) assessment should be carried out. If the heater is not fit for further service, it should undergo a partial or full re-tubing with spare tubes on hand for replacement.
4. Testing the Heater On completion of inspection and repairs, the heater should be tested from the tube side at its test pressure. The test pressure should be Design pressure x 1.5 for heaters built before 1999 and 1.3 x after 1999. The nameplate and SIS should be referred to for the test pressure. Any tube leaks at hydrostatic test should be renewed and retested. In cases where hydrostatic testing is not practical due to the catalyst and the refractory, the heater should be pneumatically tested with prior approval or leak tested with a waiver in lieu of hydrostatic testing.
5. Applicable Standards and Codes: The maintenance and inspection of heaters should comply with the following standards and codes:

• SAEP-20
• SAES-W-010
• ASME SEC VIII D1
• API STD 530
• API STD 510

Any repairs to the heater should be hydrostatically tested per SAES-A-004 and ASME SEC.VIII D1. If a waiver is required, it should be processed, and a leak test should be performed at the available plant nitrogen pressure. Test procedures should be provided by the operation engineer of the unit, or waivers should be submitted per SAEP-20 in advance. All test or waiver documents should be filed for reference.

Conclusion In conclusion, regular maintenance and inspection of heaters are essential to ensure their safe and efficient operation. The guidelines discussed in this article are crucial for ensuring compliance with Saudi Aramco standards, codes, ASME, and API, and for maintaining the optimal performance of heaters in petrochemical industries.