What aspects need to be considered when replacing furnace tubes in a converter?
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In a few months, the plant will need to shut down for maintenance; the furnace tubes in the hydrogen production unit’s converter are not up to standard and need to be replaced. I would like to ask those with experience: what aspects should be taken into consideration when replacing the furnace tubes as well as the inlet and outlet tail pipes?
When reinstalling the catalyst in the replaced furnace tube, it is important to ensure that the filling height and quantity of the catalysts of both specifications are the same as those in the previous furnace tube, and that the pressure difference across the furnace tube remains consistent. Also, pay attention to adjusting the positions of the spring hangers at the upper part and the supports at the lower part of the furnace tube. Pay attention to the welding quality of the upper and lower tail pipes with the gas collection pipe; thermal stress must be eliminated, as many problems occur in this area. Another point is to be mindful of safety precautions during disassembly and assembly: avoid touching other furnace tubes, do not place the scaffolding set up inside on top of the furnace tubes, and prevent any damage to the insulation.
I’m not sure whether you are replacing just a section of the furnace tube or the entire tube. When we replaced a section, we set up scaffolding inside the furnace and used wooden planks to secure it; we removed the hangers from the upper part of the tube in question and pulled it out from above. The catalyst was removed from the upper part as well, and after replacing the tube, it was put back in place. You don’t need to touch the upper and lower pigtail tubes; you can take that as a reference
Catalyst loading, spring supports, welding quality, etc