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     * Refractory Encapsulating Coating
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NAPHTHA REFORMER PROBLEMS – A THING OF THE PAST

BACKGROUND | RETUBING TO REDUCE SCALE BUILD-UP

A Naphtha Pre-treater was retubed to improve metallurgy in order to reduce scale
build-up and other end of life factors. Besides the change in metallurgy, no
other changes were made. The cabin style heater is designed with horizontal
passes in a segmented serpentine pattern containing internal manifolds.

Follow up IR scans were taken of the newly installed tubes to ensure safe
operation.

PROBLEM

Operation over 200°F/93°C over the ROLH limit

SOLUTION

Shielding the tubes that are not getting enough flow to uniformly increase the
temperatures throughout the rest of the furnace

OUTCOME

Furnace is now operating with all available burners online at outlet
temperatures of >945°F/507°C

PROBLEM DISCOVERY | OVERHEATING

The IR scan revealed that the bottom pass in each set of manifolds was much
hotter than surrounding tubes. Due to overheating, rates were cut to reduce the
temperature to safe operating ranges. The furnace was modeled by a third party
to determine the source of the issues. The simulation showed that the bottom
passes had much lower flow rates leading to hotter fluid and hotter tubes.





SOLUTION | CETEK CERAMIC WRAP

Faced with the possibility of tube replacements, which would seriously increase
the length of the forthcoming short turnaround, the refinery was aware of
Cetek’s fired heater optimization experience and contacted Cetek for a solution.

Cetek quickly developed a shielding solution to prevent the overheating. It was
proposed that the problem tubes should be shielded with a high temperature
ceramic wrap and coated with Cetek’s proprietary ceramic coating to prevent
deterioration of the ceramic substrate in service.

Cetek’s fired heater experts calculated the effects on the process tubes and
estimated the reduction in temperature of the shielded tubes and the effect on
the temperature of the unshielded tubes. The refinery also decided to install
thermocouples on the problem tubes to monitor the temperature under the
shielding.

INSTALLING TUBE PROTECTION

Cetek’s Process Tube Protection was installed at the next short turnaround
during a catalyst regeneration. TI readings after startup were very similar to
the temperatures predicted by Cetek in the pre-project evaluation.

After 3 years in service, the shielding continues to perform as expected.

 



Inspection after 3 years in service

CATEGORIES:

Cetek
Fired Heater
Oil & Gas


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