After Burning Phenomenon

as the cause of
HP and MP Steam Superheater Tube Burst
during Plant Start Up 2002

Setiyadi dan I Dewa Gede Bayu N.

Process Engineering, PT Medco Methanol Bunyu
Jl. Dermaga no.1 P. Bunyu Kalimantan Timur, 77181, Indonesia
e-mail: [email protected], [email protected]

Abstract

Medco Methanol Bunyu is a methanol producer whose plant is located in Bunyu island, East
Kalimantan, Indonesia. The plant has been in operation since 1986 using Lurgi Low Pressure Methanol
Synthesis technology with design capacity of 330,000 mt /year. Low sulphur natural gas from Medco
E&P Indonesia and Pertamina E&P is used as the raw material and source of fuel.

PT Medco Methanol Bunyu faced a failure in the plant start-up in October 2002. The failure was initially
indicated by rupture in HP and MP steam super heater tubes. The first indication that showed
abnormality was the unusual temperature profile at the reformer flue gas channel. Moreover, the inability
of the steam system to reach its operating pressure (steam lost) confirmed the failure in the steam
superheater.

According to material analysis conducted by B4T (an independent organization for testing and material
research) and Department of Metalurgy (Bandung Institute of Technology), the tubes failure was caused
by local overheating that decreased the material hardness and tensile strength. Based on the operation
data of the second start-up (22 October 2002), and field inspection, the overheating was caused by after
burning phenomenon.

able to achieve natural gas consumption per ton

Introduction MeOH below the performance test value.
Natural gas consumption for the period of April
to July 2003 was in average 33 MMBTU/MT at
Medco Improves the Plant Performance production volume of 950 MT/d. Up to three
years after that Turn Around, the plant still
Medco Methanol Bunyu, a subsidiary of shows good performance with average natural
Medco Energi International Co, operates gas consumption 35 MMBTU/MT at 80%
Pertamina’s (Indonesian State Oil Company) production capacity. As the comparison, in
methanol plant since 1997. The current plant 1996, natural gas consumption of the plant was
capacity is 1000 MT/d with natural gas around 36-37 MMBTU/MT.
consumption at the performance test (conducted
on July 1986) of 34.13 MMBTU/MT (design: Steam System Overview
32.77 MMBTU/MT).
Methanol Bunyu Plant generates both HP
Under Medco Methanol Bunyu operation, and MP Steam used for driving steam turbines.
plant performance has been improved. After Saturated HP-Steam (105.5 Bar and 315°C) is
Plant Turn Around 2002 with methanol generated in the reforming system, mainly by
synthesis catalyst replacement and some waste heat recovery of the process gas from
optimizations in plant operation, the plant was reformer (reformed gas). An additional Boiler

2005 306 AMMONIA TECHNICAL MANUAL

connected to the reformer flue gas system has
mainly a start-up and balancing function during
which abnormal steam requirement occurs.
Saturated HP Steam is then superheated in TI
1035
TI
1034
TI
1039
TI
1038

superheater E-102 I/II to about 505°C, utilizing TI TI TI

1025 1029
heat from flue gas, see figure 1. A quench cooler 1028

B-101
controls the outlet temperature of the steam. REFORMER E-105/II E-105/I

Saturated MP Steam (40 bars and 250°C) is S-101

Stack
E-101 E-102/II E-102/I E-103/II E-103/I E-104
generated in the methanol synthesis reactors, C-101
using the heat of methanol synthesis reaction. E-116
Boiler
Flue Gas Blower

All MP Steam is superheated to approx. 485°C TI

1014
Samping

in the MP Steam Super heater E-103 I/II E-106

installed in the flue gas waste heat system of the Waste Heat Boiler
Reformed Gas
KETERANGAN:
E-101: Pemanas Umpan
reformer. During start-up operation, when the E-102: Superheater Steam HP
E-103: Superheater Steam MP
methanol synthesis reactor is not yet in E-104: Pemanas Air Umpan Boiler
E-105: Pemanas Udara Pembakaran
full/stable operation, saturated MP Steam is
: Pendingin quenching untuk
produced by let down of saturated HP-Steam. Kontrol Temperatur Steam

Fig 2. Flue Gas Heat Recovery

F-101
HP Steam Drum
HPS Header
The following step is to start using process
Jalur MP steam
Start-Up By Pass steam, in which superheated process steam
(Press: approx. 15 – 20 Bars, and Temp 3000C)
to SPP

E-103/I E-103/II
is introduced into the Steam Reforming Catalyst
E-106
Waste Heat Boiler E-116
tube. The step is usually done when the flue gas
Additional Boiler
E-102/II E-102/I
temperature has reached approx. 325°C. The
objective of this step is to eliminate catalyst
F-201
impurities and to utilize the heat released by
MP Steam Drum
MPS Header
combustion in the steam reforming unit for
steam generation. At that time, the waste heat
boiler (E-106) begins to generate steam and the
R-201
total steam production of the plant is
significantly increased.
Jalur Heating up
Methanol Reactor Reaktor

900
TEMP. oC

fig 1. Steam Generation System

800

700
Normal Start-Up
600
Start-up in Plant PT MMB is initiated by firing
the reformer and heating up the flue gas 500

system. The rate of firing is set to achieve flue 400

gas temperature (TI-1025) increase of 10°C per
300
hour until the flue gas temperature reaches
100°C. This condition (100°C) is then held for 200
10 hours. After this holding time is successfully 100
maintained, the firing rate is increased to 20 –
30 °C per hour. The additional boiler (E-116) is 0
0 20 40 60 80 100 120 140
activated for steam production when the flue
gas temperature reaches 150°C. The load of the TIME, HOUR

additional boiler is gradually increased to reach

the steam temperature and pressure to the
setting value. Start Cut in steam Start Cut in Start Syn-Ga
Add. to reforme power start? Compressor
Boiler T > 300°C turbines Nat. Gas
Tfg >150oC P>15 bar Ts >450°C Trector >200°C
What is cut in P >34 bar ROT> 700°C
steam?

AMMONIA TECHNICAL MANUAL 307 2005

When the pressure of the MP Steam has reached The damaged tubes were located in the row
35 Bars and the temperature is 450°C, the steam closer to the additional boiler flue gas line. This
is ready to energize the HP-BFW pump turbine indicated that flue gas temperature distribution
and the Main power generation turbine. The next in E-102 or E-103 was not uniform.
step is heating up of the methanol synthesis
reactor and the desulphurization unit. The Failure Analysis of Start-Up October
temperature rise is set to 10 – 15°C per hour. 2002

When the reformer outlet temperature has The normal operating temperature of the flue
reached approx. 700°C and natural gas contains gas upstream E-102 I is 856°C at 100% load,
only traces of sulphur, natural gas is ready to be and 777°C at 50 % load. E-102 consists of three
fed to the reformer gradually (Cut in Gas). The different materials: 1.4922 (83 tubes), 10 Cr Mo
last step of the start-up sequences is starting the 9 10 (83 tubes) and 15 Mo 3 (83 tubes), with
synthesis gas compressor when the temperature HP-Steam temperature design 570°C and
of methanol synthesis reactor is already 200°C. pressure of 116 Bar.
The normal operating temperature of the flue
Start-Up failure Indication gas upstream E-103 I is 651°C at 100% load,
and 590°C at 50 %. E-103 I consists of three
Start-Up October 2002
different materials: 13Cr Mo44 (83 tubes), 15
PT Medco Methanol Bunyu conducted an Mo3 (83 tubes), ST.358.I (83 tubes), with MP-
annual Turn Around on September 20, 2002 Steam temperature design 550°C and pressure
with the primary agenda: replacement of of 44 Bar.
Methanol Synthesis Catalyst, replacement of
Primary Reformer Catalyst, and replacement of
Abnormal Flue Gas Temperature Profile
pure methanol Reboiler. All the works were
executed within 21 days, followed by plant start- The abnormality of flue gas temperature profile
up and Methanol Synthesis Catalyst reduction. was indicated by the higher temperature of the
down stream HP Steam Super heater (indicator:
TI-1027) than the upstream temperature
Start up failure in October 2002 was identified
(indicator: TI-1028). Another indication was the
just 10 hours after Cut in?? Steam. The load of
extreme temperature drop of HP and MP Steam
the additional boiler was almost 100 %
after the quenched cooler (desuperheated).
(equivalent to 30 t/h steam production), however,
HP and MP Steam pressure did not reach the
The following Table describes the temperature
normal pressure (setting) even as HP Steam
profile of the flue gas and the steam during the
production gradually increased. There was a
plant start up October 2002:
significant steam loss in the steam system. Our
prediction was a leakage occurred in superheater Para TI- TI- TI- TI- TI- TI- TI-
E-102 II and E-103 I/II, and we decided to stop meter 1027 1028 102 1034 1035 1038 1039
23/10 Inlet Inlet 9 HPS HPS MPS MPS
the start-up. / E-102 I E-103 II Outl Pre- Post- Pre- Post-
2002 et quench quenc quench quenc
The field inspection after first start-up showed E-103 h h

that 2 tubes in E-102 I (no. 69 and 70) and 2 13:00 440 470 706 478 464 441 446
tubes in E-103 I (no.73 and 74) were broken. 18:00 460 495 574 498 333 540 505
These tubes were then plugged and Hydrostatic 23:00 490 502 497 525 235 527 234
test was done to all steam lines. However the Normal 572 388 347
same failure took place again in the second start Design 856 651 550 - 550 -
up. Field inspection after second start-up
showed that three more tubes in E-102 I (no. 68, The abnormal temperature profile occurred after
71, 72) were ruptured and a couple of tubes near the additional boiler was activated.
the formerly damaged tubes were highly
deformed, see picture number xx. Two more
tubes in E-103 I (no.19 and 79) were also
ruptured. The broken tubes were then plugged.

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 Temperature Indications at Start-Up October 2002
The abnormality of the temperature profile in
the flue gas system was caused by combustion
650 of excess fuel from the additional boiler with the
550 excess air from the steam reforming unit. The
combustion occurred near the damaged tubes
Temperature, C

450 and generated local overheating which in turn

made the tubes burst. The operating
350
temperature indications of flue gas around the
250 TI 1025
damaged tubes and steam pressure in the tubes
TI1028 were still under the normal operation and
150 TI1029 design values.
50
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 The combustion system of the reformer and the
Time, Hours additional boiler are controlled by a control
system that guarantees the operating condition
Fig 3. Flue Gas Temperature Profile fail S/U
will not damage the plant equipment. However,
in some cases, several instrumentations didn’t
work properly, especially after plant-shut down.
The false indications of instrumentation often
800
lead to serious incidents. The damage of the
700 superheater tube during plant start up 2002
600
was caused by false indication of the Additional
Boiler combustion air flow. Combustion air and
500 natural gas fuel ratio in additional boiler burner
400 is controlled by a flow ratio control system FFIC-
1011B which is mounted cascading to the
300 natural gas fuel control valve. It is normally set
200 to approximately 12 - 15 % excess air for
optimum combustion condition.

Indicator The phenomenon of combustion taking place

No rmal Temperature P ro file (1No v 2002 jam 21.00) outside the combustion chamber/ burner
A bno rmal Temperature P ro file (23 Okt 2002 jam 13.00) indicated an inappropriate combustion air and
fuel ratio supplied to the additional boiler
burner. It led to poor air combustion or
Fig 4. Temperature Profile of Flue Gas moreover possibility of lack of air flow supply
(below combustion stochiometric requirement).
The excess fuel from the additional boiler
550
chamber then flowed into the flue gas duct and
500 reacted with excess air from the reformer
Temperature (C)

450 burner around the damaged tubes surface.

400 Unfortunately, no laboratory data was available
350 to describe the actual combustion condition.
300 This afterburning phenomenon was further
250
confirmed by the carbon formation on the water
tubes and flue gas duct of the additional boiler.
200
TI-1034

TI-1035

TI-1038

TI-1039

Examination of the Combustion Air control

valve and the flow indication (FR-1011) shows a
Normal Temperature Profile (2 Nov 2002 jam 09.00)
Indicator failure in the control indication system. At 20 %
Abnormal Temperature Profile (23 Okt 2002 jam 23.00) valve opening, the indication shows airflow 80 %
(20.000 Nm3/h) leads to 15% excess air. At the
normal operation, that opening should indicate
Fig 5. Temperature Profile of HP and airflow 20 – 25 % (4000 – 5000 Nm3/h) or
MPSteam minus 70% excess air.

AMMONIA TECHNICAL MANUAL 309 2005

 After repairing and calibrating the control The failure caused Medco Methanol Bunyu
valve to the right correlation, the third start-up the loss of 23 operation days and a reduction of
could be carried out successfully and the plant the heat transfer area of E-102 I/II by 12 %.
was in normal operation until next plant-shut
down. However, as the result of the plugged Suggestion
tubes, the superheated HP-Steam can never
reach the design temperature (505°C) and Plant Start Up is a crucial operation.
consequently decreases the over-all plant Unfortunately, many instrumentation frequently
efficiency, especially the steam consumption for do not work properly after long shut down.
turbine generator. Thus, to prevent failures from taking place, any
abnormality of the temperature profile given by
temperature indicator instruments should be
analyzed immediately and comprehensively.
Laboratory analysis (O2 content in flue gas) is
also needed to ensure the combustion is
FIC 1011

Combustion A ir
running properly.

Attachment:
1. Picture of Damage Tubes Super Heater
FFIC 1011
2. Picture of Carbon Layer on Additional
Boiler Tubes
HIC 1010

FIC 1010

Nat Gas Fuel

B urner

Is there no safeguard on low O2 conc. At the outlet of

the additional burner?

Fig 7 Combustion System of Additional Boiler

Conclusion

The damage of the HP and MP-steam super

heater E-102/E-103 during Plant Start-up
October 2002 in Methanol Bunyu Plant was
caused by after-burning phenomenon that led to
local overheating of several superheater tubes.
The excess fuel gas from the Additional boiler
was burnt with the excess air from the steam
reformer around the burst tubes. This was
confirmed by the abnormality of the flue gas
temperature profile and visual inspection in
which carbon layer covering evaporation tube
and part of flue gas wall was found in the
additional boiler. This indicated insufficient O2
combustion.
Material analysis of the damaged tubes
showed that plastic deformed tube material had
experienced hardness and tensile strength
decrease. Loss of tensile strength was caused by
decarburization which was favored by extreme
local overheating.

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