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CENTRIFUGALLY CAST TUBES FOR ELEVATED TEMPERATURE SERVICE NOVEMBER 1990 PAGE 1 of 8 EGE 00-B-24 -- 1990 TABLE OF CONTENTS 1. Scope 2. References 3. General 4. Definitions 5. Material 6. Tube Machining and Evaluation 7. Welding 7. General 8. Tube-to-Tube Welds 8. Inspection 8. General 9. Repair 10. Special Requirements for Reformer Furnace Assemblies 10. Inlet Flange and
CENTRIFUGALLY CAST TUBES FOR ELEVATED TEMPERATURE SERVICE NOVEMBER 1990 PAGE 1 of 8 EGE 00-B-24 -- 1990 TABLE OF CONTENTS 1. Scope 2. References 3. General 4. Definitions 5. Material 6. Tube Machining and Evaluation 7. Welding 7. General 8. Tube-to-Tube Welds 8. Inspection 8. General 9. Repair 10. Special Requirements for Reformer Furnace Assemblies 10. Inlet Flange and
CENTRIFUGALLY CAST TUBES FOR ELEVATED TEMPERATURE SERVICE NOVEMBER 1990 PAGE 1 of 8 EGE 00-B-24 -- 1990 TABLE OF CONTENTS 1. Scope 2. References 3. General 4. Definitions 5. Material 6. Tube Machining and Evaluation 7. Welding 7. General 8. Tube-to-Tube Welds 8. Inspection 8. General 9. Repair 10. Special Requirements for Reformer Furnace Assemblies 10. Inlet Flange and
CENTRIFUGALLY CAST TUBES FOR ELEVATED TEMPERATURE SERVICE
NOVEMBER 1990 PAGE 1 OF 8 EGE 00-B-24 1990
TABLE OF CONTENTS 1. Scope 2. References 3. General 4. Definitions 5. Material 6. Tube Machining and Evaluation 7. Welding 7.1 General 7.2 Tube-to-Tube Welds 8. Inspection 8.1 General 8.2 Hydrostatic and Pneumatic Testing 9. Repair 10. Special Requirements for Reformer Furnace Assemblies 10.1 General 10.2 Outlet Couplings 10.3 Bottom End Cap 10.4 Inlet Flange and Coupling 11. Shipping and Handling 1. SCOPE This Guide covers requirements for materials, fabrication, inspection, and testing of centrifugally cast, heat resistant, high alloy tubes for reformer furnaces and ethylene cracking furnaces. 2. REFERENCES The following publications form a part of this Guide. Unless otherwise specified herein, use the latest edition. Mobil Engineering Guides EGE 00-B-1 Direct Fired Process Heaters Design and Fabrication EGE 00-B-21 Pressure-Containing Equipment Welding and Weld Inspection ASME (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code Section VIII, Pressure Vessels, Division 1 Section IX, Welding Qualifications ASTM (American Society for Testing and Materials) Standards A608 Centrifugally Cast Iron-Chromium-Nickel High Alloy Tubing for Pressure Application at High Temperatures B408 Nickel-Iron-Chromium Alloy Rod and Bar 3. GENERAL Requirements shall be in accordance with the applicable codes and standards as supplemented and modified by this Guide. Specific attention should be given to EGE 00-B-1 for requirements related to heaters. Where conflict exists, the more stringent requirements shall control. MOBIL ENGINEERING GUIDE EGE 00-B-24 1990 PAGE 2 OF 8 NOVEMBER 1990 4. DEFINITIONS Sound Wall Thickness Sound wall thickness is defined as that thickness which remains when (1) all porosity and roughness associated with the internal surface is removed by concentric machining (or honing), or (2) roughness associated with external cast surfaces (exceeding a specified level) is taken into account. Alternative Alloys or Materials During the past few years, many foundries and suppliers have listed new alloy compositions for heat resistant, centrifugally cast, and weld filler metals. These alloys are not covered by ASTM materials specifications even though, in many cases, they may have similar generic compositions (such as 25 Cr-34 Ni). Provision has been made herein to permit the use of patented or proprietary alloys in place of standard ASTM alloys, provided the conditions stipulated herein have been satisfied and that Mobil has approved. 5. MATERIAL 5.1 Only foundries approved by Mobil shall be considered as qualified suppliers of centrifugally cast high alloy tubing. 5.2 Chemical composition and mechanical properties shall conform to the applicable standard (ASTM 608) unless alternative alloys are proposed. 5.3 For all centrifugally cast alloys, the following additional maximum chemical compositional limitations shall be imposed: (a) Pb 0.005% (b) Sn 0.005% (c) N 0.100% (d) V 0.100% (e) P 0.03% (f) S 0.03% (g) Cu 0.20% 5.4 If alternative alloys are proposed, the composition and high temperature strength properties of such alloys shall be approved by Mobil. Vendors submitting alternative alloys shall provide the following data for acceptance: (a) Chemical composition. (b) Physical properties. (c) Stress rupture properties for a short time at elevated temperature. (d) Long-term stress rupture data. (e) Typical welding procedure. (f) Fabrication and inspection sequence. MOBIL ENGINEERING GUIDE NOVEMBER 1990 PAGE 3 OF 8 EGE 00-B-24 1990 (g) Complete list of users. 5.5 Stress rupture testing shall be in accordance with ASTM A608 (supplementary requirement S3). Test conditions and acceptance criteria are shown in Table 1. Prior to the order being placed, the manufacturer and Mobil shall agree on a suitable basis for notification of test results. As a minimum requirement, the owner should be notified of results on the first three heats. A heat shall be rejected if it fails the rupture requirements of Table 1. Rupture ductility data should be provided for information purposes. 6. TUBE MACHINING AND EVALUATION 6.1 The vendor shall provide evidence in the form of ring samples removed from the cold end (opposite the pour) that sufficient sound wall will remain following machining to final dimensions. 6.2 One ring sample shall be removed from each heat and examined in accordance with ASTM A608 (supplementary requirement S7). The minimum sound wall thickness shall be measured from the root of the deepest OD surface irregularity. 6.3 For ethylene cracking furnace tubes, the inside surface of the as-cast tube shall be machined to ensure removal of unsound material. The amount to be removed shall be a minimum of 3 mm (1/8 in.) or 15% of the as-cast tube wall thickness, whichever is smaller. (Similar requirements may be imposed for steam reformer tubes, based on design requirements.) 6.4 For all centrifugally cast tubes, the internal machined surface shall have a roughness not to exceed 3.2 m (125 RMS). Tooling marks shall be cleared, leaving a surface finish equal to or better than the surrounding area. A sample surface shall be prepared by the manufacturer for approval by Mobil, and this surface shall be used as a reference for examining the complete batch of tubes. 6.5 Tube ends shall be beveled for welding using a joint design consistent with the metal thickness and welding procedure to be utilized in fabrication. 6.6 Tube section outside surfaces shall be machined to remove surface irregularities for a distance of a half-inch from the edge of the bevel. 6.7 Machined surfaces shall be suitable for dye penetrant inspection. They shall also be free of macroshrinkage and other injurious defects. 6.8 After machining, the thickness of each tube section shall be checked at each end and at the approximate center of the tube section in four spots 90 degrees apart. 6.9 Bowing of tubes or tube sections shall be restricted to 1.5 mm (0.060 in.) over a 2000 mm (78 in.) length. The deviation from the true axis over a completed reformer tube shall not exceed 6 mm (1/4 in.) after welding. Straightening of assemblies is not permitted without Mobil's permission. If permission is granted, a suitable method of inspection, such as liquid penetrant examination of the outer surface, shall be required to ensure the integrity of the tubes after straightening. MOBIL ENGINEERING GUIDE EGE 00-B-24 1990 PAGE 4 OF 8 NOVEMBER 1990 TABLE 1 MINIMUM TIME TO RUPTURE REQUIREMENTS Alloy Type Specimens kPa (psi) Life (Hours)* C F Number of Test Applied Stress Minimum Rupture Test Temperature HK-40 The larger of one per 1052 (1925) 21,000 (3060) 50 (25 Cr-20 Ni) heat or five per order. HP Modified The larger of one per 1100 (2012) 16,620 (2420) 100 (25 Cr-35 Ni heat or five per order. with Additions) 20 Cr-32 Ni The larger of one per 1038 (1900) 20,340 (2950) 100 Low C with Nb heat or five per order. * All test specimens shall meet this requirement. 6.10 Overall dimensions shall be within the tolerances specified on the purchasers drawing. The minimum segment length shall be 3 m (10 ft). A layout of each tube assembly, showing heat identification for each tube section, shall be provided. 7. WELDING 7.1 General 7.1.1 Welding procedures and performance qualifications for each alloy shall be in accordance with both the ASME Code (Section IX) and EGE 00-B-21. 7.1.2 Weld procedures and joint preparation details shall be submitted for review by Mobil. 7.1.3 Deposited weld metal from each heat of consumables shall be analyzed for chemical composition to verify compliance with requirements. In accordance with a new procedure qualification requirement (PQR), microsections shall be taken from qualification welds and examined by Mobil to verify freedom from microfissures. 7.2 Tube-to-Tube Welds 7.2.1 Misalignment of adjacent surfaces to be welded shall not exceed 0.6 mm (0.025 in.). 7.2.2 All root passes should be made by gas tungsten arc welding (GTAW). Alternative weld procedures may be considered. However, these shall be submitted to, and must be approved by, Mobil prior to the start of welding. Backing rings are not permitted. 7.2.3 Root passes for centrifugally cast tubes should be autogenous (without filler metal) or have filler metal added. 7.2.4 During GTAW and gas metal arc welding (GMAW), the weld shall be protected by inert gas shielding (99.5% pure argon). 7.2.5 Root passes shall be backpurged on the inside surface with a suitable inert gas. MOBIL ENGINEERING GUIDE NOVEMBER 1990 PAGE 5 OF 8 EGE 00-B-24 1990 7.2.6 Root passes shall be inspected with liquid penetrant in accordance with the ASME Code (Section VIII, Division 1, Appendix 8). Root passes shall also be inspected with a boroscope for cracks and lack of penetration. Crack bleed-through of penetrant, root undercut, or lack of penetration shall not be permitted. 7.2.7 The final weld pass, including the tube surface, shall be liquid penetrant inspected for a minimum of 13 mm ( in.) on each side of the weld. 7.2.8 All completed welds shall be 100% radiographed. 7.2.9 Filler metal shall be in accordance with Table 2. 8. INSPECTION 8.1 General 8.1.1 Liquid penetrant examination shall be in accordance with the ASME Code (Section VIII, Division 1, Appendix 8). 8.1.2 Radiographic examination shall be in accordance with the ASME Code (Section VIII, Division 1, Paragraph UW57). The following defects are sufficient cause for rejection of welds represented on a radiograph: (a) Any crack or zone of incomplete fusion. (b) Incomplete penetration. (c) Piping or undercutting. 8.1.3 Before welding is started, Mobil shall: (a) Approve the weld procedure. (b) Approve chemical analysis and results of mechanical testing. (c) Visually examine all bore surfaces of ethylene cracking furnace tube sections and the outer surfaces of all tube sections. 8.1.4 All weld preparations and the outside surface of machined sections shall be liquid penetrant examined. Each machined tube section shall be examined internally for a distance equal to two tube diameters. 8.1.5 Tube ring samples shall be visually examined. 8.1.6 Bore and outer surfaces of tube sections shall be visually examined. 8.2 Hydrostatic and Pneumatic Testing 8.2.1 Hydrostatic Testing Each complete tube assembly shall be hydrostatically tested in the presence of Mobil's Inspector as indicated below: (a) Test pressure shall be at least 6984 kPa gage (1000 psig) or that pressure which results in an applied stress equal to 75% of the minimum room temperature yield strength (of the lowest strength material involved). MOBIL ENGINEERING GUIDE EGE 00-B-24 1990 PAGE 6 OF 8 NOVEMBER 1990 TABLE 2 FILLER SELECTION Base Metal (Note 1) HK-40 to HK-40 HK-40, HP-50 HK-40, HP-50 20 Cr-32 Ni HP-50 to HP-50 25 Cr-35 Ni-Nb 25 Cr-35 Ni-Nb (ASTM B407 and B408) 25 Cr-35 Ni-Nb to to to to CS, Cr-Mo 20 Cr-32 Ni-Nb 20 Cr-32 Ni 25 Cr-35 Ni-Nb + 18 Cr-8 Ni (ASTM B407 and B408) (ASTM B407 and B408) Filler metal for Matching composition A 5.14 A 5.14 A 5.14 GTAW root pass to base metal Er Ni Cr Mo-3 Er Ni Cr Mo-3 Er Ni Cr Mo-3 fill passes (Note 2) or or or Er Ni Cr-3 Er Ni Cr-3 Er Ni Cr-3 Filler metal for Matching composition A 5.11 A 5.11 A 5.11 SMAW fill passes to base metal E Ni Cr Mo-3 E Ni Cr Mo-3 E Ni Cr Mo-3 or or or E Ni Cr-3 E Ni Cr-3 E Ni Cr-3 Filler metal for Matching composition A 5.14 A 5.11 A 5.11 GMAW fill passes to base metal Fr Ni Cr-3 E Ni Cr Mo-3 E Ni Cr Mo-3 (Note 3) or or or Fr Ni Cr Mo-3 E Ni Cr-3 E Ni Cr-3 NOTES: 1. Autogenous GTAW may be used for root pass. 2. GMAW spray transfer only. 3. For cast 20 Cr-32 Ni, filler metals of matching composition can be used. (b) Test pressure shall be held for 15 minutes or at least a time sufficient to permit the inspector to examine the entire tube length, assembly, or coil. (c) Hydrotest water shall contain no more than 25 ppm chlorides. 8.2.2 Pneumatic Testing Each completed tube assemblies shall be air tested by the foundry at an internal pressure of at least 517 kPa (75 psi) for at least one minute while submerged in clear water or covered with a soap solution. Any evidence of leakage shall be cause for rejection of the section being tested. 9. REPAIR 9.1 No repairs are permitted on centrifugally cast tube sections. Repair procedures on welds shall be submitted to Mobil. 9.2 Defective weld areas shall be removed by grinding or machining. Repair procedures shall be approved by Mobil. 10. SPECIAL REQUIREMENTS FOR REFORMER FURNACE ASSEMBLIES 10.1 General 10.1.1 All machined weld bevels shall be liquid penetrant inspected after machining and prior to welding. 10.1.2 All buttwelds shall be 100% radiographed. MOBIL ENGINEERING GUIDE NOVEMBER 1990 PAGE 7 OF 8 EGE 00-B-24 1990 10.1.3 All fittings and couplings to tube welds shall have, as a minimum, the root pass welded by GTAW. 10.2 Outlet Couplings 10.2.1 The outlet shall be fabricated from a forged weld fitting. The forged fitting shall be in accordance with ASTM B408 (UNS N08810). Grain size shall be ASTM No. 5 or coarser for this material (Alloy 800 H). 10.2.2 Couplings of this alloy shall be subjected to a weldability test [autogenous tungsten inert gas (TIG) bead followed by liquid penetrant test]. One coupling representing each separate heat shall be subject to this test. The presence of fissuring is cause for rejection of all couplings from that heat. 10.2.3 The root pass and final cover pass between the coupling and bottom end cap shall be 100% liquid penetrant inspected for all production welds. 10.3 Bottom End Cap 10.3.1 The bottom end cap shall be statically cast or centrifugally cast material. Static castings shall be made by either the shell molding, dry sand casting, or investment casting process. The chemical analysis and physical properties of the bottom end cap shall be as required by Paragraphs 5.2 and 5.5. 10.3.2 The bottom end cap shall be machined on all surfaces to the dimensions specified on the purchasers drawing. The inside diameter of the end cap shall be bored parallel to match the bore of the adjoining tube section for a minimum distance of 25 mm (1 in.) from the weld preparation. The machined bore shall be merged into the bore of the cap with a 1-to-4 taper. The outside machined cylindrical section shall also be blended into the profile of the cap with a taper of at least 1 to 4. 10.4 Inlet Flange and Coupling 10.4.1 The materials of the top flanges shall be suitable for the pressure and temperature conditions at the tube inlet. 10.4.2 The flange face finish on the reformer tube top flanges and the matching inlet coupling flanges shall be commercially smooth [3.2 m (125 RMS)]. 11. SHIPPING AND HANDLING 11.1 Because centrifugally cast tubes are relatively brittle and must be carefully handled, they shall be guarded against impact and shock loading. 11.2 Furnace tubes shall be cleaned free of grease, oil, weld spatter, and all other foreign deposits after testing. Handling defects shall be repaired in accordance with Paragraph 9.4 before shipping. 11.3 Before shipping, all tube openings shall be blanked off with wood or plastic plugs to prevent entrance of dirt. The plugs shall not be capable of passing into the bore of the tube. 11.4 For overland transportation, each reformer tube shall be boxed around the top flange and bottom end cap, including the outlet pigtail connection. 11.5 For long sea transportation, convenient numbers of reformer tubes shall be loaded into boxes. The boxes shall be lined with waterproof paper and clearly marked "Hold Storage" on the outside. 11.6 For air transportation, each reformer tube shall be lightly boxed around the top flange and the bottom end cap, including the outlet pigtail connection. 11.7 When a number of tubes are shipped in one box, they shall be packed so that they cannot move within the box and damage one another. MOBIL ENGINEERING GUIDE EGE 00-B-24 1990 PAGE 8 OF 8 NOVEMBER 1990 11.8 Catalyst support grids, studs with nuts, and gaskets shall be transported separately from the reformer tubes. These components shall be packed in boxes completely lined with waterproof paper. 11.9 All separate shipping lots and boxes shall be clearly labeled with the purchase order number and field receiving address. Boxes shall also be marked to indicate their contents. 11.10 The reformer tube manufacturer shall be fully responsible for the adequate support of tubes during transportation, the selection of suitable protective materials, the integrity of packing boxes, and lifting arrangements. 11.11 Exposure to chlorides (seawater, marine environment, and the like) during shipping and storage periods shall be avoided to prevent chloride stress corrosion cracking and pitting. 11.12 Tubes shall be guarded against contamination by carbon stress (abrasion), since carbon steel particles may form sites for pitting. 11.13 Contact with low melting metals and alloys (zinc, galvanizing) that may result in tube cracking shall be avoided.