Bulging of outlet pigtail

14/10/2016
MGC Shoma Honda

I propose to METOR about additional inspection item, regarding bulging was

detected at reformer outlet pigtail in 2016 STA.

Inspection item
The inspection for reformer outlet pigtail in 2016 STA was carried out the below items.
・Outer diameter measurement (for 196 pigtails)
Outer diameter measurement was carried out south side of radiant box.
Measurement position was decided by 2011 STA result
→Bulging was found at six pigtails.
・PT inspection(for 196 pigtails)
Inspection is conducted same pigtails as the outer diameter measurement.
Inspection was conducted three points. Welding line with short piece/bend/welding
line with hot collector.
→The all inspections are not completed, but pigtail which bulging is detected does
not have the crack.
・SUMP inspection (7)
Seven pigtails selected by METOR, pigtail number is R2-T41,48、R3-T47、
R10-T50、R12-T49、R13-T50、R14-T48
→Waiting an inspection report

I received the inspection result. MGC selected 6 pigtails which bulging was occurred
and other 15 healthy pigtails (7 pigtails which SUMP test is conducted are included).
Every pig tail measured outer diameter 5points(①③④⑤are added).
In order to confirm detailed bulging condition of pigtails, and confirm the bulging
condition of connecting short pieces.
 ① ② ③ ④ ⑤ ※Bulging(%)
R2-37 42.2 42.6 42.5 42.4 42.4 0.9%
Catalyst Tube ☆ R2 - 3 9 42.2 4 8 .4 4 4 .8 4 4 .1 4 6 .3 1 4 .7 %
○ R2-41 42.2 43.4 42.9 42.8 42.8 2.8%
○ R2-48 42.2 42.5 42.6 42.6 42.6 0.9%
○ R3-47 42.2 42.5 42.8 42.4 42.4 1.4%
① Short Piece ☆ R3 - 4 8 42.2 5 2 .6 4 7 .4 4 7 .6 4 8 .2 2 4 .6 %
R3-49 42.3 43.2 42.6 42.8 42.9 2.4%
② ☆ R3 - 5 0 42.4 4 4 .5 4 4 .5 4 3 .5 4 3 .4 5 .5 %
R4-47 42.2 42.6 42.6 42.8 42.9 1.7%
⑤ ☆ R4 - 4 8 42.3 4 9 .2 4 4 .8 4 4 .0 4 4 .0 1 6 .6 %
☆ R4 - 4 9 42.2 5 0 .8 4 9 .8 4 5 .0 4 6 .7 2 0 .4 %
R4-50 42.3 42.7 42.5 42.7 42.0 1.2%
R7-1 42.3 42.4 42.0 42.3 42.3 0.5%
③ R7-2 42.2 42.4 42.0 42.3 42.3 0.5%
④ RT-3 42.2 42.4 42.4 42.2 42.2 0.5%
Hot Collecter R9-49 42.2 42.2 42.0 42.2 42.2 0.0%
☆ R9 - 5 0 42.2 4 8 .4 4 4 .4 4 5 .6 4 4 .7 1 4 .7 %
Outlet Pig Tail ○ R10-50 42.2 42.8 42.8 42.6 43.0 1.9%
○ R12-49 42.2 42.2 42.1 42.2 42.2 0.0%
○ R13-50 42.2 42.3 42.1 42.3 42.2 0.2%
○ R14-48 42.2 42.3 42.1 42.1 42.2 0.2%
☆；Point of bulging occurred
○；SUMP enforcement point
※Calculated 42.2 as standard。

measurement point measurement result

After measurement,I got the following tendencies.
・In six pigtails which bulging occured, bulging occured all surface of pigtail, and
connected short piece did not occur bulging.
・With six of them which bulging occured, all mesurement result indicate ② is bigger
than ⑤.

Why bulging occurred ?

There are usually two points of following causes for bulging.
① Abnormal increase in temperature
② Stress with more than assumption
The cause of stress is
・Stress by operation condition
・Stress by thermal expansion
In addition, short piece connected to pigtail which bulging occured not having
abnormality. Bulging of pigtail occurred only after 2013 STA.
③ There was an abnormality in materials of six pigtails
In total three possibility is assumed.

Additional inspection
METOR plans additional inspection by founding bulging of six pigtails.
・Outer diameter measurement (all outlet pigtails)
・PT inspection
・SUMP inspection
・Hardness measurement
・Destructive inspection

Suggestion from MGC

Other than the inspection mentioned above, I want to recommend the following
additional inspection for a root cause investigation into bulging occured.

Inspection during STA

・Confirmation of a cold position of spring hanger supporting outlet pigtail and the
fixed situation.
→To take in the thermal expansion stress appropriately at the time of the operating,
and avoid abnormal thermal stress on pigtail.
・Confirmation the catalytic loading condition of catalyst tube of 6 pigtail in 2013 STA
(especially, whether pressure difference is under 5% or not is each line is
important).
→If the filling situation had a problem, run a fever while operating, and pigtail
might become the abnormal high temperature.

The inspection and confirmation that is necessary after the STA end immediately
・Creep destructive inspection of the R3-T48 (Bulging rate is largest) and R3-T50
(Bulging rate is smallest).
→Pigtail whose bulging rate is over 5% will be replaced, and under 5% Pigtail
It will continue use. In order to predict remaining life of pigtail whose bulging rate
is under 5%, conduct creep destructive inspection.
・For pigtail which has a big bulging tendency, you counduct metal analysis.
→The confirmation of used materials accord with drawing.

Inspection and measures necessary after shift to steady operating

・You confirm that spring hanger supporting outlet pigtail moves to the normal
position.
→You confirm that thermal expansion stress of outlet pigtail is absorbed
appropriately.
・You carry out monitoring of the skin temperature of catalyst tube periodically.
→When abnormal fever is detected at catalyst tube, bulging may occur again.
In that case, confirmation and adjustment of the combustion state of burner
neighborhood is needed.