Primary Reformer F101 Tee Collector and Transfer Line

Primary Reformer (F-101) Tee Collector and Transfer Line Problems Muhammad Waqas Younas (Mgt. Associate) Projects-TSD

OBJECTIVE The objective of my presentation is to discuss the replacement plan and problems associated with; a)Primary Reformer (F-101) outlet Tee Collectors b)Transfer Line (F-101 to C-102)

CONTENTS • Introduction • Brief history • Problems observed • Way Forward • Replacement Project • Recommendations

F-101 Piping Inlet Pigtails Top Flanges C-102 Inlet Miter Elbow Riser Tee Collector Transfer Line Bottom Flanges Catalyst Tubes Outlet manifold

F-101 Transfer Line Plan View North West Header North East Header South West Header South East Header C-102 Inlet

TEE COLLECTOR PROBLEMS

Background 1966 At LCA : One Manifold each chamber, connected by a tube Material A-297 1972 Two manifolds each chamber Material : Incoloy 800 Grade 2 (800 H) Design life 100, 000 Operating Hrs 1991 Cracks observed in both cells outlet manifold Cracks repaired by Welding as per FW procedure 1997 At PQA : Hair line cracks observed in Bull head tee weld joints 1998 At FFBL : Procurement of Bull Head Tees and Manifold initiated FW regret to provide Bull Head Tess of Incoloy 800 H 2000 Bull Head Tees and manifolds replaced with upgraded material New material 2032 Nb

Tee Collector Component Material Replacement Year Outlet manifold Wiscolloy 2032 Nb Replaced in 2000 Bull head Tee Wiscolloy 2032 Nb Replaced in 2000 Expander Incoloy 800 H Replaced in 1972 Cone C - 1/2 Mo Replaced in 1972 Cone Bull Head Tee Expander

Outlet Manifold Tee Collector Crack • Severe circumferential cracks in weld toe of all four bull head Tee to expander joints. Bull Head Tee (20 Cr-32 Ni-1 Nb) Cracked weld Joint Expander (Incoloy 800 H)

Outlet Manifold Tee Collector Crack Grinding of crack

Short Term Remedial Actions for Cracks Repair • Stabilization Heat Treatment was carried out prior to welding – Heating @ 125˚C/hr above 425˚C to 980 ˚C – Soaking temperature 980 ˚C @ 5 hrs – Followed by rapid air cooling • Root pass : Inconel 82 • Weld completion : Inconel 182 • Stage wise DPT and 100 % RT (Root + Final)

TRANSFER LINE PROBLEMS

Transfer Line Refractory Hot Face Cold Face Greencast 94 • High Alumina, Low Silica, Outstanding abrasion resistance • Thickness 3” • Max Temperature 1870 ˚ C • Thermal Conductivity @ 870˚ C 2. 03 W/m. K Kaolite 2300 LI • Backup Insulation, Light weight, Low thermal conductivity • Thickness 5” • Max Temperature 1260 ˚ C • Thermal Conductivity @ 870˚ C 0. 26 W/m. K

Riser Edge Diffuser and Pipe Junction

Transfer Line Refractory Problems • Partly refractory damages observed in TA-2011, 12 & 13 • Location : Approximately 7. 0ꞌ eastwards from manway center • Approximately ~ 2ꞌꞌ thick refractory missing from a band of 2. 5” from 8 O’clock to 11 O’clock 7’ 0 Eastwards from manway center Refractory damage

Transfer Line Refractory Damages TA-15 East Leg Opposite the Riser Crack 5 mm wide and 10 cm Long Refractory damage in Junction of Diffuser and Pipe (West Leg) Refractory detached at East Side about 1. 5’ above Riser edge

Transfer Line Access Problem • Visual inspection to access health of 1998 vintage refractory not possible due to access problem • Thermo-graphic inspection was carried out Riser Tee Access Manway

Transfer Line Skin Temperature Problem • Gradual rise in skin temperature is observed in the past few years (130˚C ~ 230˚C)

Scope of Project Material Up-gradation for complete scope Refractory evaluation and upgrade Flexibility analysis of process gas for complete circuit Refractory and component joint design Material Supply VSM Services for Project execution monitoring

AMEC-FW Response Proposed material: Part Description Existing Material New Material Bull Head Tees 20 -32 Nb (Centrifugally Cast) Expanders Incolloy 800 H 20 -32 Nb (Centrifugally Cast) Transfer Line Tee Collectors C - 0. 5 Mo 1. 25 Cr – 0. 5 Mo Transfer Line Fabrication: Transfer line to be supplied in 22 no. pre-lined and fully heat cured section due to dry out problem at site.

Proposed Assemblies of Tee Collector AMEC-FW proposed to provide 2 X complete assembly as shown below: Centrifugally Cast Bull Nose Tee Transfer Line Fabricated Tee Spun Cast Cone

Transfer Line Inspection Points AFW Proposal: • 1 peephole in each horizontal straight section. • Total Peepholes: 9 ID 508 mm • FFBL proposed 4 manways instead of peep holes in TL ID 406 mm

Cost Break Down of Project Sr. No Description Cost Currency 01 Design Services 76, 800 GBP 02 Additional Engineering Cost if required 50, 000 GBP 03 Material Cost CFR Karachi 1, 423, 145 GBP 04 Sub Total 1, 549, 945 GBP 05 AFW VSM Cost 337, 078 GBP 06 FFBL Execution Cost 142, 898 GBP Total cost in GBP 2, 029, 921 Total cost in PKR with 5 % Contingency 346, 355, 270

Tentative Timeline Task Start Date Duration End Date Budget Approval CAPEX 2016 1 - Oct - 2015 2 months 1 - Dec - 2015 VSM Visit Plantsite 4 - Jan - 2016 6 days 09 - Jan - 2016 Contract and PO 10 - Jan - 2016 1 months 10 – Feb - 2016 Kick Off Meeting 25 – Feb - 2016 2 days 26 – Feb - 2016 Design Work 01 – Mar - 2016 2 months To be confirmed with AFW 01 – May - 2016 Material Arrival 01 – May - 2016 7 months 01 – Nov - 2016 Pre-fabrication 01 – Nov - 2016 2 months 01 - Jan - 2017 Execution in TA-2017 08 – Jan - 2017 22 days 30 – Jan – 2017

Gantt Chart Complete execution of the project (Replacement of 2 X Tee Collectors and Refractory Lined Transfer line) will be carried out in TA-2017 planned in Jan-17.