Fire in a Steam-Methane Reformer Reactor of a Refinery
The accident happened in a refinery unit, constructed ten years before. A pigtail ruptured in a steam reformer for the production of hydrogen, and caused a major fire, which destroyed most of the tubes (54) in one quadrant of the large steam-methane reformer furnace. No personnel was hurt. Main causes were bad weld quality and shortening of pigtails over the life of the plant, which significantly increased the cyclic stress at the root of the weld from thermal expansion and tube bowing. After the failure of the pigtail, the downstream hydrogen flew back into the reformer and ignited together with the hydrocarbons present there. Changes done in design and operating procedures are described in the article mentioned among the references.
Event Date
June 12, 1984
Record Quality Indicator
Region / Country
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Causes
Cause Comments
Immediate cause was the failure of aged pigtails at the root of the weld, due to thermal expansion and tube bowing.
Facility Information
Application Type
Application
Specific Application Supply Chain Stage
Components Involved
steam reformer, pigtails
Storage/Process Medium
Location Type
Location description
Industrial Area
Lessons Learned
Lessons Learned
McCoy et al. (see references) reported the following lessons learned from the event:There are two general lessons to be learned from thisincident. These are lessons that have been learned beforeand unfortunately, will probably have to be learnedagain. They are:1. Small design modifications executed to solve an immediate problem, can compromise the basic safety design of a whole process equipment. Sometimes, as in this case, several suchchanges have an additive effect. 2. Operating procedures must aim in first instance at protecting people and equipment,and only secondarily at protecting the catalysts.At many years from this event, a more generic historical view can be concluded. Pigtails are a weak components of a reformer, and have initiated repeatedly similar accidents. However, improvement based on their whole lifetime, from material selections and metallurgy (micro-structure) to cycling behaviour up to inspections, have reduced significantly their negative effects on the reformer operation, as reported by the second article of 2014 among the references.
Event Nature
Emergency Action
Unknown
Release Type
Release Substance
Ignition Source
Detonation
No
Deflagration
No
High Pressure Explosion
No
High Voltage Explosion
No
Flame Type
Source Category
References
References
On line Journal Nitrogen+Syngas, 330, July - August 2014
Available at: https://www.questintegrity.com/assets/PDFs/Articles-2014/Improving-refo…
Accessed July 2020)