(104e) Lessons Learned from an Unusual Hydrogen Reformer Furnace Failure

On January 30,2005 a high-energy pressure impulse occurred within several radiant tubes of a steam/ methane reformer furnace during startup after a partial shutdown. This impulse caused the simultaneous rupture of 5 tubes with sufficient force to eject portions of the tubes out through the roof of the furnace. All of the failures occurred near the inlet of each tube in the headspace above the catalyst and the 5 tubes were clustered toward the centre of the furnace in four rows.

Approximately 41 additional tubes were destroyed as a result of impacts from ejected tube segments and the subsequent pressure wave. Extensive damage to the refractory also occurred.

As a result the furnace internal structure was condemned and a complete retube required. This paper will describe the investigation process, outcomes, and lessons learned.