Lessons Learned from High Pressure Process Boiler Failure

摘要

After 13 months of service, a new 1500 psig (103 barg) secondary reformer effluent process boiler developed a severe leak. After stabilizing the plant, operators identified the nature of the issue. Precautions were taken during the shutdown that were successful in preventing catalyst damage in the secondary reformer and shift converters due to the leak of BFW into the process gas. The tube bundle was removed and replaced with a spare. The immediate cause of the failure was identified and a metallurgical analysis was performed on the failed and adjoining tubes. Possible contributing factors were considered. Metallurgical analysis results are consistent with the cause identified. Recommendations are shared on promptly recognizing this type of failure, shut down precautions, and prevention.