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Use of Replication and Portable Hardness-With-Cover-Page-V2
Use of Replication and Portable Hardness-With-Cover-Page-V2
Use of Replication and Portable Hardness-With-Cover-Page-V2
Creep and fract ure behaviour of English Elect ric Mark III t ransit ion welds
Jonat han Parker
T he Performance of an Emergency Cold Weld Repair on a 2.25CR1MO Longit udinally Seam-Welded Pre…
H. Li, Druce Dunne
Seminar Power & Process Plant Issues
Lahore, Pakistan: May 2011
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Introduction
Life assessment based on calculational
procedures is conservative (use minimum
parent material properties, etc)
Difficult to account for welds
Metallographic methods assess the actual
material condition of the component/weld
Metallographic replication
Hardness assessment
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Metallographic Replication
Must be targeted at the areas most likely to show
creep damage
Normally welds and bends in pipework
High temperatures; end-loads on pipework; known
problems
Apply across Weld, HAZ and Parent material
Examine replicas at site optically before re-
lagging
Further examination in laboratory
Film
6) Film stripped from surface with record of
microstructure
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Replica Positions
Pipework
4 points round welds
Intrados, extrados of bends
Intersections - saddles and crotch
positions
Tubing
Hottest tubes - superheater, reheater
outlets
Swollen tubes to quantify remaining life
Headers
Antler/stub tubes – minimum grinding
Plain barrel if any signs of distress
Nozzles
Turbines
Rotor bores
Control
unit
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Sentencing of Replicas –
Quantifying the Damage
Several means of quantifying
damage:
‘A’ parameter depends on
counting the number of
cavitated grain boundaries
Gives numerical answer but
time-consuming
Normal use life based on
damage classification schemes
Action may be advised but
depends on
History
Future outage schedules
Operating practice
Best assessed individually
B: Isolated cavitation
C: Orientated cavitation
D: Microcracking <2mm
NDE non-detectable
E: Macrocrack >2mm
NDE detectable
European Technology Development Ltd.
After Neubauer
European Technology Development Ltd.
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Introduction to Hardness
Hardness is used in power,
petrochemical and process industry for:
quality control
life assessment
It is defined as the ability of a material
to resist permanent indentation or
deformation when in contact with an
indenter under load
European Technology Development Ltd.
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Introduction to Hardness
Basically a hardness test consists of
pressing an indenter of known geometry
and mechanical properties into the test
material
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Hardness – Life relationship
Hardness indentation technique is one
of the oldest testing methods applied to
analyse the materials properties
It gives the hardenability of a certain
component
Conversion charts can convert hardness
values to tensile strain and consequent
probability to type IV damage.
European Technology Development Ltd.
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Hardness changes and testing
Several investigators have developed
hardness models to calculate the
remaining life of piping and tubing
components.
Models based on hardness have been
developed for low alloy steels and
modern steels based on creep data.
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Portable hardness testing equipment
MIC 10
control unit
Vickers
5kgf Probe
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Hardness test for superheater header
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European Technology Development Ltd.
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Main steam line
Material Properties
Temperature, C
Pressure, Bar 95
530
Case Study from Recent ETD Work in Europe
Service time, hours* 180,071
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Main steam line (contd.)
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Main steam line (contd.)
BM HAZ WM
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Main steam line (contd.)
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Main steam line (contd.)
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Main steam line (contd.)
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Main steam line (contd.)
Hardness (HB)
Position Weld HAZ BM
12 O’Clock 203 204 126
4 O’Clock 202 195 128
Valve Pipe
8 O’Clock 204 198 132
Avg. Hardness 203 199 129
12 O’Clock 208 198 135
4 O’Clock 204 201 136
Valve Forging Side 8 O’Clock 206 195 140
Avg. Hardness 206 198 137
The hardness test results for the base materials, HAZ and
weld metals were within the expected range for P11 steel
after long-term operation at elevated temperature.
European Technology Development Ltd.
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Main steam line (contd.)
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Main steam line (contd.)
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Advantages of replication & hardness
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Limitations of replication & hardness
The technique only analyzes the microstructure of the
outer surface of a material/component.
In many cases the surface microstructure can be
different from the microstructure found in the interior
of the component
The replica only reveals the topographic features at
the surface; therefore it is impossible to analyse the
chemical composition of the elements
Contamination may be a problem in harsh or dusty
environments
Precision is required to operate the hardness probe
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Conclusion
It has been proved that replication and
hardness can be efficiently used to
perform life assessment
Sampling removal and analysis are
relatively simply and not time
consumable
Cost of performing these tests is lower
in comparison with other non-
destructive techniques
European Technology Development Ltd.
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Thank You very much for your
attention.
Questions?
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