Remaining Life Assessment of Refinery Furnace Tubes Using Omega Simulations

Jerry Wilks CITGO Petroleum Lemont Refinery

IR Scan of a Coker Furnace at Lemont Refinery

Summary
The Importance of Refinery Furnace Reliability in Processing Opportunity Crudes Causes of Poor Furnace Reliability Creep Damage and Creep as a Process Coking Furnace Operations and Why Coker Furnaces Are Difficult to Simulate Long-Term Changes in Process Conditions Results and Conclusions

The Importance of Furnace Reliability

The production of gasoline, diesel, coke, hydrogen, and other refinery products requires heating hydrocarbons to as high as 1400F (760C) during processing, and furnace reliability is an important aspect of refinery operations. As a result of the process temperatures, the metals used for furnace tubes are exposed to temperatures up to 1750F (950C). Furnace tube degradation occurs primarily due to corrosion, metallurgical changes, and creep. Furnace tube failures occur primarily due to creep. The highest process temperatures occur in catalytic cracking, 1350F (718C) in the catalyst regenerator and 1400F (760C) in methane-steam reforming. The coking process temperature is ~950F (510C) and 9Cr-1Mo tubes in a Coker furnace typically are heated to a maximum of 1250F (705C) when coked. Stainless tubes can be heated to a maximum of 1500F (815C).

Processing Opportunity Crudes

Why Cokers Are Important to Processing Opportunity Crudes
The opportunity crudes available in the Midwest come primarily from Canada. Many Canadian opportunity crudes are defined as synthetic crudes mined instead of pumped & pre-processed. The mined raw crude is processed to remove rock and produce usable products - crudes that refineries can process like natural crudes. This processing removes lighter distillates in Canada making the available synthetic crudes heavy. These synthetic crudes also contain sulfur and they are referred to as sour crudes. In general heavy, sour crudes are cheaper and are therefore considered opportunity crudes. Heavy, sour crudes result in significant resid production when they are refined. Resid is processed by US refineries into coke some can be cracked to produce more products, but there will still be more coke produced making Coker reliability important.

Coker Furnace Tube Reliability

Coker units operate 4-5 years between shut downs. Unscheduled Coker outages due to furnace tube failures are expensive, and the entire refinery can be impacted because crude rate may have to be cut or crude blends changed when the Coker is down or cut back. Therefore, being able to predict furnace tube life is essential to maintaining refinery furnace reliability and refinery profitability. Creep is the #1 cause of furnace tube failures. Creep is the time-dependent deformation occurring when metals are subjected to stress (internal pressure) at elevated temperatures. Predicting Coker furnace tube life using simulations is difficult because the process conditions change continuously due to the formation of coke in the tubes: tube metal temperature, pressure distribution, and flow characteristics change with time.

What a Tube Failure Looks Like

Tube Background
Unit: Alloy: Aromatics Hydrotreater 9Cr-1Mo

Rupture at the Bulge

Cause of Failure: Flame Impingement

Bulge

Characteristics of the Creep Phenomenon

Creep is the long-term deformation of metals that typically occurs at elevated temperatures. I
Strain (m/m)

II

III

Time

Creep deformation is rapid for a short time period when equipment is first put in service (primary creep). Then the deformation rate becomes constant and relatively low for a long time period (secondary creep). Toward the end of life the deformation again becomes rapid (tertiary creep) . Refinery furnaces typically operate in the secondary creep region.

Characteristics of the Creep Phenomenon

Creep is a combination of three mechanisms Diffusion Crystal boundary sliding or grain boundary sliding Dislocation motion dislocations are linear defects in metal crystals that cause deformation when they move through the crystal. Some Similarities between Creep and Chemical Processes: There is an activation energy for creep. Increasing temperature increases the rate creep occurs. Pressure or stress also effects the creep rate. Creep can be simulated and the simulation used to predict what will occur in the future the remaining life of a furnace tube.

Omega Creep Analysis

Background:
Technology developed by the Oil Industry in a joint industry project initiated in 1986 Project Omega. Materials Properties Council did the research funded by API (Refining) Martin Prager was the project leader. Omega analysis involves a metal database and applying Omega is geometry specific the geometry of the component at high temperature has to be included in simulation software.

Omega Definition: is a creep damage coefficient that is related to the strain and the strain rate: = ln/. Omega defines .the rate at which strain rate accelerates as a result of creep strain. See Development of the MPC Omega Method for Life Assessment in the Creep Range, 1994, Martin Prager, ASME for a complete explanation of Omega technology.

A Section of the Omega Database

= ln(1-0 t)/ = true strain (today) 0 = initial strain rate = a material property that is a function of temperature and stress. t = time elapsed
If you know the strain that occurs at rupture and the initial strain rate for new steel, you can use this equation to determine remaining life.

Whats Important in a Creep Simulation?

Temperature it has a major influence on the creep rate and the remaining life of equipment. Stress or Pressure The forces acting on the metal are also important to the rate at which the metal will creep. If the internal pressure is low a furnace tube can operate at higher temperatures before experiencing significant creep damage. Corrosion or Wall Damage since corrosion causes the equipment to lose thickness it influences the stress and therefore influences creep. Other mechanisms that reduce equipment wall thickness also play a role an example is provided later. Past Service unlike most types of refinery process simulations, what occurred in the past effects the creep phenomenon today and in the future.

Omega Software
MPC software & Equity Engineering software both contain the Omega database and equations to do Omega calculations MPC software is somewhat easier to use. Initially it was only available to companies that participated in the Omega project. Equity Engineering software is more sophisticated, and it does other types of engineering calculations.

A Simple Example New Boiler Superheater Tubes

Omega Remaining Life vs. Temperature for New Boiler Superheater Tubes
1000000

In a Boiler Temperatures and Pressures Remain Relatively Constant

0

Corrosion Rates mils per year Maximum Operating Temperature with No Corrosion 1042F - 561C

4 5

22.8 Years 11.4 Years

Remaining Life - Hours

100000

10000

Maximum Operating Temperature With 5 mpy (0.13mm/year) Corrosion 1019F - 548C

1.14 Years

Tube Alloy: Size: Temperature: Pressure:

1000

2Cr-1Mo 5.563OD - 0.25Wall 141mm OD - 6.35mm Wall 915F - 491C 775 psig 5343 kPa
1100 1125 1150

950

975

1000

1025

1050

1075

Temperature -F
525 550 575 600

Temperature -C

The Effects of Past Service

Omega Remaining Life vs. Temperature for New Boiler Superheater Tubes
1000000
Failure occurs at 20.92 years if the temperature isnt lowered.

Temperature Increased to 1025F - 551C

0 5 10 Tube Alloy: Size: Temperature: Pressure: 2Cr-1Mo 5.563OD - 0.25Wall 141mm OD - 6.35mm Wall 1025F - 551C 775 psig 5343 kPa

22.8 Years 11.4 Years

Remaining Life - Hours

100000 20

10000

Maximum Operating Temperature with No Corrosion After 20 Years at 979F - 526C

1.14 Years Maximum Operating Temperature with No Corrosion 1042F - 561C

1000

950

975
525

1000

1025
550

1050 1075 Temperature -F

575

1100
600

1125

1150

Temperature -C

What This Example of Omega Analysis Shows

The results of Omega analysis can be displayed with a curve that makes it possible to quickly evaluate what will happen in the future - a remaining life vs. temperature curve. Pressure vs. remaining life curves can also be generated. The future maximum operating temperatures depend upon the past operating conditions this ties into unit productivity & $$. The effect of corrosion on remaining life the corrosion effect is not linear with time. Longer design life means larger corrosion effect. How the design life chosen impacts the maximum operating temperature: longer design life lower max. operating temperatures. Past service effects remaining life by gradually lowering the maximum operating temperature. The relationship between the effect of past service and time of past service is not linear its an exponential relationship with damage occurring more rapidly as time passes.

The Coking Process Variables

Average Temperature and Pressure Trends in 13B-2 Furnace During 2005
1200

Best Correlation Between Temperature and Pressure Excluding Shutdowns & Startups: 0.9042

400

2750

600

1100

2500

550

1000

Average TI Temperature

350 2250

Temperature - C

500

Temperature - F

300 800

450

Pressure - psig

900

2000

400

700

250

1750

350 600

Inlet Pressure
200

1500

300

250

500

1250

Decoking Outages
150

400

Time

Decoking occurs when one of the tube TIs reads 1250F - 705C

Pressure - kPa

Improved Temperature and Pressure Correlation

When Instrumentation Errors and Ramp-Up Effects Are Removed

Temperature & Pressure Correlation for a Single Cycle

Pressure (kPa)
1300 1200 1400 1600 1800 2000 2200 2400 700

1200 Y = 2.1832X + 511.85 R2 = 0.957

650

Temperature - F

1100

600

550 1000

500 900

This correlation is good enough to use temperature to calculate pressure.

200 250 300

450 350

800 150

Pressure (psig)

Temperature - C

Important Aspects of the Coker Furnaces

Note that the temperature and pressure follow similar trends, but these variables dont correlate very well this is a process modeling problem it can be dealt with in the simulation by entering data frequently daily averages were used for this analysis. Decoking outages occur when any of the temperature indicators on the tubes reaches 1250F (705C). Only 12 tubes in a firebox have TIs 12 out of 50 tubes. Periodic infrared (IR) scans are used to help monitor tube metal temperatures and check for hot tubes and hot spots. Periodic IR scans ensure that the tubes we monitor are representative of furnace conditions. Coke is forming in the tubes and coke formation effects both the temperature and pressure distributions. Local hot spots due to coke also occur Throughput is maintained at a nearly constant level so inlet pressure increases as flow drops off due to coking. Outlet pressure also varies with coke build-up downstream of the furnaces. The changing pressure drop in the furnace due to coking makes it necessary to simulate individual tubes. Past service impacts the remaining life or the maximum operating temperature of the furnace tubes. There is a tradeoff between tube life and maximum operating temperature.

Major Process Changes

13B-2 Coker Furnace - Average Tube Metal Temperatures Coils 3 & 4
1250

Average of Readings from 12 TIs

Change in Operations Higher Temperatures Pigging Replaces SteamAir Decoking
650

1200

1150

Temperature -F

600
1100

1050

550
1000

950

500
900 J-91 J-92 J-93 J-94 J-95 J-96 J-97 J-98 J-99 J-00 J-01 J-02 J-03 J-04 J-05 J-06

Time - Years

Temperature -C

Important Aspects of Major Process Changes

In mid-1995 the maximum tube wall temperature reached each cycle increased by ~50F (27.8C). That magnitude of change in maximum temperatures has a major effect on creep life. In March of 1996 the decoking process changed from steam-air decoking to mechanical pigging. In the end this turned out the be the most important major process change. Due to the more rapid decoking, the overall furnace cycle time was shortened. In a given year the tubes would reach maximums more often. Also increased processing of opportunity crudes began in 1997 more on this later.

Before Major Process Changes

A Nearly Normal Distribution
13B-2 Daily Maximum Tube Temperature Distribution 5/1/91-5/1/95
250 Temperature Ranges (C)
482-496 496-510 510-524 524-537 537-551 551-566 566-579 579-593 593-607 607-621 621-635 635-649 649-662 662-677 677-691 691-704

Days in Each Temperature Range

Average 1131.6F 610.9C 200

150

100

50

900-925

925-950

950-975

1050-1075

1125-1150

1175-1200

1225-1250

1075-1100

1100-1125

1150-1175

1200-1225

1250-1275

975-1000

1000-1025

1025-1050

Temperature Ranges (F)

1275-1300

After Major Process Changes

Distribution Skewed to Higher Temperatures
13B-2 Daily Maximum Tube Temperature Distribution 5/1/95-5/1/06
600 Temperature Ranges (C)
482-496 496-510 510-524 524-537 537-551 551-566 566-579 579-593 593-607 607-621 621-635 635-649 649-662 662-677 677-691 691-704

Days in Each Temperature Range

500

Average 1133.5F 611.9C

400

300

200

100

900-925

925-950

950-975

975-1000

1225-1250

1050-1075

1125-1150

1175-1200

1200-1225

1250-1275

1075-1100

1100-1125

1000-1025

1025-1050

Temperature Ranges (F)

1150-1175

1275-1300

Before Major Process Changes

Maximum & Average Temperatures
Average & Maximum Temperatures Tend to Be Significantly Different
1300

700

1200

650

Temperature - F

600
1100

550
1000

500
900 5/1/91 5/1/92 5/1/93 5/1/94 5/1/95

Time - Years

Temperature - C

After Major Process Changes

Maximum vs. Average Temperatures
Average & Maximum Temperatures Were Closer After Readings from 12 TIs on Coils 3 & 4 the Process Changes
1300

Maximum & Average Tube Metal Temperatures from 5/1/95 to 5/1/99

700

Maximum Temperatures

Temperature- -F F Temperature

1200

650

1100

600

550
1000

Average Temperatures
900 5/1/95 5/1/96 5/1/97 5/1/98

500

5/1/99

Time Time -- Years Years

Temperature - -C Temperature C

Pressures Trends
History of Average Inlet Pressures from 10/27/96 to 5/1/06
400

350

Gradual Downward Pressure Trend Since the Process Changes Beneficial but Why?

2600

2400

2200

Pressure (psig)

300 2000

1800 250 1600

200

1400

Pressure Increased with 95-97 Process Changes

150
O-96 O-97 O-98 O-99

1200

The pressure distribution was a normal bell curve.

O-00 O-01 O-02 O-03 O-04 O-05

Time - Years

Pressure (kPa)

Petro-Chem Pressure Simulation of the Furnace with Coked Tubes

Tube Inlet Pressures vs. Tube Number
Y = 324.07-0.004X3 + 0.0636X2 -1.469X R2 = 0.9995 300 The red curve shows the result of polynomial regression of the Petro-Chem simulation data. 2000

Tube Inlet Pressures psig

250 The simulation results for pressure are plotted in blue. The data points are the tube inlet pressures. 1500

200

150

1000

100

The pressures used in the simulation for individual tubes were determined with ratios between the pressure drop across the entire furnace and the pressure drop in this simulation.
C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 C-12 C-13 C-14 C-15 C-16 R-15 R-16 R-17 R-18 R-19 R-20 R-21 R-22 R-23 R-24 R-25 R-26 R-27 R-28 R-29 R-30 R-31 R-32 R-33 R-34 R-35 R-36 R-37 R-38 R-39 R-40

500

50

Tube Identification

(C= Convection R= Radiant)

Note: Tubes C-15 & C-16 are actually roof tubes.

Tube Inlet Pressures kPa

The Corrosion Process Change

Coker Resid Sulfur Content Began Increasing in 1997 Increasing Sulfidic Corrosion Potential

Sulfur increased due to increased processing of opportunity crudes.

Analysis of Tube Inspection Data

Radiant Section Wall Loss Summary
1968-2006 3.42 mpy 0.0867 mm/year 1968-2002 2.50 mpy 0.064 mm/year 1968-1997 0.55 mpy 0.014 mm/year 1968-1994 -0.29 mpy -0.0074 mm/year
Negative corrosion due to changes in thickness measurement technology. Readings from inspections conducted in the 1980s indicated no corrosion.

1994-2006 11.80 mpy 0.299 mm/year 1994-2002 11.08 mpy 0.281 mm/year 1994-1997 7.61 mpy 0.193 mm/year

1997-2006 12.83 mpy 0.326 mm/year 1997-2002 13.59 mpy 0.345 mm/year

2002-2006 14.40 mpy 0.366 mm/year

Tube wall loss rate began increasing between the 1994 and 1997 inspections.

The Pigging Process Change

Contrary to what the companies doing pigging tell you, pigging operations sometimes do damage furnace tubes. Pigging impacts corrosion because protective corrosion product layers are removed during pigging. Pigging mechanically damages the tubes. Damage is not uniform so it is difficult to measure.

Whats a Pig?
Hard Rubber The pig fits snug in a furnace tube and is forced to move through the tube with water pressure

Tungsten Carbide Tips to Cut the Coke also cut the steel

What Happens at a Turn?

The Pig Spikes Dig in and Shave off Metal
The most severe damage occurred on the inside sweep of the return bends where the pig was forced into the return bend wall.

A return bend failed on the inside sweep during the spring of 2006 Wall loss increased significantly when pigging started & before sulfur content in resid began increasing

Grooves Cut in Return Bends

Failure occurred on the inside sweep of a return bend.

Other Evidence of Damage

9Cr-1Mo Steel Shavings Found in the Coke Debris after Pigging

So How Is This Process Simulated?

Use as much available data as possible to accurately represent the process information: 15 years of temperature data and 10 years of pressure data. Sample process data at high frequency daily maximums and averages used in this analysis. Divide the total 37 years of furnace tube life into sections at major process changes. Interview people who worked on the unit years ago to try to fill in time periods where electronic data is not available. Model each time period separately and link the time periods with creep damage. Include pigging damage with corrosion damage. Use the Petro-Chem pressure drop simulation to develop a relationship between the pressure in the tubes and the pressure drop across the entire furnace. Tie the tube pressures to the TI outputs to determine the remaining life of individual tubes.

Omega Analyses Results for the Most Damaged Tube

Omega Simulation Results for Tube C-16
1000000000

500

550

600

Temperature C
650 700

750

800

100000000

Remaining Life - Hours

10000000

Life Consumed by 1994 = 8.7%

1000000

Life Consumed by 1997 = 14.5%

100000 25 15 10

Life Consumed by 2006 = 25.6%

x
10000

5 3

1230F (665C)

1000

900

1000

1100

1200

1300

1400

1500

Temperature F

Remaining Life - Years

1217F (658C) is needed to continue current operations for 3 years till the next turnaround opportunity. Typically 25F is subtracted to provide a safety factor. Therefore, the 1230F maximum isnt high enough and it was recommended the tubes be replaced.

Conclusions
The tubes in this coker furnace needed to be replaced but they didnt need to be replaced right away. It was recommended that they be replaced within 18 months or at the half life of tube C-16. The furnace is being retubed in October 2006 over a year earlier. High temperature sulfidic corrosion did not appear to play a major role in tube wall damage. From 1968 to 1994 there was no significant wall loss. Wall loss began in 1996 when decoking with pigs began, and this was before the sulfur content of the resid increased. Consequently, the wall loss cannot be attributed to high temperature sulfidic corrosion because the increase in sulfur would not have resulted in the significant change in wall loss that occurred. Furnace tube simulations need to include past major process changes by dividing the Omega analysis into time periods starting at those major process changes. Changes to the decoking process should be considered significant process changes. Process variations can be accommodated in Omega simulations by taking into account all the factors effecting creep of the tubes: long term and short term temperature variations, long term and short term pressure variations, changes in corrosion, & changes that increase corrosion and other changes that increase wall loss. Use data collected over short time periods, i.e. averages of data collected during 24 hour time periods. Averages over longer periods could miss significant process variations.