2. 2. Results Table 4
Visual observation found a leaky transverse Linear indication characteristic found by ultrasonic test
crack with 40 mm in length on CW 2 as shown in Fig.
2 below. The crack position was 100 mm in distance Length Depth from
Position Height (mm)
(mm) surface (mm)
after south side thermowell nozzle (180o orientation).
This result agreed with the result from infrared camera 30o 30 5 43
observation and explosive gas level measurement that
showed the area around the south side thermowell The manufacturing records indicated that the CW
nozzle suffered leakage. By looking the crack 2 was subjected to local PWHT using heating elements
characteristic, it is obvious that hoop stress was the around the OD of the vessel. The local PWHT was
major contribution for crack propagation. For TWPV performed for 10 hours at 660oC.
which is applied internal pressure, the maximum hoop
stress occurs on ID surface. Then it can be deduced that
crack start from ID surface of CW joint. Maximum
hoop stress, high temperature and direct contact with
hydrogen gas are the major factors for crack initiation
and propagation.
Liquid penetrant testing found another crack
indication on HAZ of CW2 at 100o orientation with 20
mm in length, as shown in Fig. 3 below. This crack had
irregular characteristic and completely different with the
leakage one. This indication disappeared after grinding
up to 4 mm depth from surface.
Positive material identification using XRF
method shows that the WM and BM are made from
2.25Cr–1Mo steel. This result agreed with the vessel’s
material specification and it is shown in Table 2.
As outlined in introduction above, hardness is the
primary indication to assess the WM condition for
CW-2
N
(0o)
100 mm
(180o)
S
Surface Crack
60 mm
Height of the Hole
After Leak’s
Gouging
Fig. 3. Another surface crack found by penetrant testing
Heating 2 Incoloy
2nd NDT Final stage Final stage elements Plate
preheat welding 3 Monitoring
4 Thermocouple
Controlling
Thermocouple
50 mm
Weld
Final NDT Final PWHT 3rd NDT
3. 2. Results
The final preheat was performed by increasing
Hydrogen removal is intended to remove the temperature of CW 2 into 250 oC ± 10 oC. The final
absorbed hydrogen atoms in CW 2. This is done by stage welding was performed up to full thickness of the
using heating elements which were attached from OD shell. Then, the final PWHT was applied to this repair
zone by increasing temperature into 740 oC ± 10 oC (for 4. On-Stream Assessment
WM) and 650 oC ± 10 oC (for BM) for 4 hours, and
finally the temperature decreased into 200 oC.
Non destructive testing such as hardness testing, HTCUT performed after one year since the
high temperature penetrant testing, magnetic particle repair time. This testing conducted on-stream to vessel
testing, conventional ultrasonic testing, and TOFD were with outer surface temperature reach 240 oC. The gain
applied during and after weld repair. setting for this testing was 80-85 dB. In this gain range,
Final hardness test result is presented in Table 5 this testing is not suitable for detection of defects that
while the non destructive test results in Table 6. Fig. 7 may occur within the outer 0-25 mm range due to high
shows the shell repair after weld up to 50 mm and its level noise during testing. The accuracy of the defect’s
ToFD result respectively. depth measurement is likely within ± 10% accurate
meanwhile the height of defect is greater than actual.
Table 5 High temperature ultrasonic ToFD was also
Average hardness number of different zones of the performed in order to solve the weaknesses of HTCUT
vessel after repair for estimating the defect’s height. Same as conventional
one, high temperature ToFD is also not suitable for
Zone BM WM HAZ detection of subsurface defect and give high level noise
up to 20 mm due to gain adjustment as shown in Fig. 9
BHN 140 170 175 below.
HTCUT and high temperature ToFD results
Table 6 shown that all indications found were acceptable. It
Non destructive result during vessel repair means that CW2 in good condition. The results are
shown in Fig. 6 and 7 respectively. The indication found
Stage PT MT UT ToFD from HTCUT is summarized in Table 7.
1st NDT --- --- Acc ---
2nd NDT Acc Acc --- Acc
3rd NDT Acc --- Acc Acc
Outer surface
Depression
Indication
Inner surface
(b)
Fig. 7 (a). Shell repair (b) ToFD result after 1st Fig. 9. Indications found by high temperature ToFD
PWHT stage
Table 7 higher temperature with two stages PWHT was intended
Detail of indications found by HTCUT to reach the ID surface of shell because this surface has
direct contact with synthesis gas and decrease its
Height sensitivity to high temperature HA.
Indication no. Depth (mm)
(mm)
#1 50 2 6. Conclusion
#2 60 4
#3 75 10
#4 24 3 The failure of this TWPV is caused by HA. WM
#5 ID Surface <3 is critical location due to various microstructures and
#6 ID Surface <6 high level of residual stresses that created during
welding. The tendency for failure caused by HA can be
5. Discussion decreased with PWHT if it is done properly. Proper
PWHT can decrease the residual stress level inside
weldment. Repair procedure that had been performed is
based on this principle. From the on-stream vessel’s
The TWPV had failed after 2 years in operation. assessment after one year since its repairing time using
The failure occurred was a leaky transverse crack on HTCUT and high temperature ToFD showed the CW2
CW2 which had applied local PWHT during vessel in good condition. This successful repair procedure is
fabrication. The similar failure with short operating time very dependent on very controlled and careful step
after put in service also happen in petrochemical related during repair stage.
facilities such as in heat exchanger. The repair had also
been done using temper bead welding techniques
combined with local PWHT such as outlined by Firt 7. References
[10].
Hardness test from OD surface shown that CW2
around the leakage zone have hardness value above the [1]. Heuser, Albert., ”Repair of a Thick-walled
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according to NACE standard MR0175 and API 942 [4, AIChe., USA., 1991.
5]. This is most caused by improper local PWHT during [2]. Prescott, G. R., Shannon, Brian., ”Process
fabrication, such as: Equipment Problems Caused by Intercation with
Hydrogen”., Ammonia Plant Safety & Related
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of temperature during PWHT. [4]. ____., ”Petroleum and Natural Gas Industries—
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time during PWHT. Oil and Gas Production Parts 1, 2, and 3”, NACE
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with hydrogen gas with operating temperature around Refinery Equipment to Prevent Environmental
300 oC. With improper local PWHT applied, not all Cracking”, API 942.
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in two years operating time of this vessel. [7]. Fujibayashi, S., Kawano, K., Komamura, T.,
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order to decrease the sensitivity to high temperature HA Steel Shield Metal Arch Wedment”., ISIJ
by transformed all bainite structure into tempered International, Vol 44 (2004), No. 3, 581-590.
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zone, two times PWHT had applied, those were after Metals: A Primer for the Failure Analyst”., Journal
weld up to 50 mm and after weld into full thickness 110 Failure Analysis and Prevention (2008) 8:289 – 307.
mm. The PWHT temperature 740 oC ± 10 oC was higher [9]. ____., ”Rules for Construction of Pressure
than ASME recommendation on 677 oC [9]. This is Vessels”., ASME Sect. VIII Divison 1&2., 1998.
because from simulation using carbon steel plate 100 [10]. Firth, D. M., Keen, D., Jones, C., Kartensen, A.,
mm thickness found the different temperature of 100 ”Cracking and Repair of Closing Welds in
o
C–120 oC between two contact and non contact 2.25 Cr1Mo Steel Vessels Operating in High
surfaces with heating elements. Because the repair only Temperature Synthesis Gas”., Ammonia Plant
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8. Biographies