Escolar Documentos
Profissional Documentos
Cultura Documentos
BY
P.SUNDARAMOORTHY
BHEL – TRICHY
Crept components after completing their
designed life are examined for their “Fitness for
the Purpose
Purpose” or “Life
Life Extension Programme
Programme” as
per the code requirements.
MATERIALS IBR ASME Sec I 2001(PNo) ASME B31.1 2001 BS 1113/ 1999 BHEL's Practice
9Cr 1 Mo Steels (T9/P9) ‐‐ ‐‐ ‐‐ 740‐780 ‐‐
9Cr 1 Mo ¼V 0.1 Nb 0.05 745°±15
‐‐ 704 min(P5B‐2) 700‐760 735‐780
N Steels(T91/P91) 760°±10
½ Cr ½ Mo¼V ‐‐ ‐‐ ‐‐ 680‐720
12 Cr1Mo¼V½Ni
‐‐ ‐‐ ‐‐ 720‐760 750°±10
750 ±10
(X20CrMoV121‐ DIN 17175)
Replication:
p Test Method ASTM E1351
The component
p to be examined is fine g
ground
using emery grits ranging from coarse to fine.
Fine Grinding Using Emery Grits (Flapper Wheel) Under Progress at Site
The microscopical appearance of slight creep
damage may be strongly influenced by the
surface preparation. i.e. mechanical or
electrolytical polishing, and etching.
Replication:
p Cellulose acetate film / p
paper
p of
thickness 25µm and acetone.
Cellulose Acetate Film After Blackening
Gold sputtering
p g at lab to further improve
p the
reflectivity of the film and for viewing at
higher
g magnifications
g in OM as well as SEM.
X-axis:
X axis: For a particular level of Spheroidisation and
service hours
(4)
(3)
(2)
Ref: High Temp Component life Assessment By G.A. Webster & R.A. Ainsworth
REMAINING LIFE ASSESSMENT (RLA)
REPLICATION AND METALLURGICAL EVALUATION
CREEP DAMAGE CLASSIFICATION SYSTEM PROPOSED BY WEDAL AND NEUBAUER
Five levels of creep cavitation are related to an
“A-parameter”
A-parameter which is commonly used as one of
the quantitative creep damage parameter.
The g graph
p in the next slide shows the remaining
g
life fraction as a function of A-parameter.
Reference: Sri.R.Viswanathan, Journal of Pressure Vessel Technology, vol.107, August 1985
Tests to estimate the Remnant Life of Serviced
Tubes:
1. Visual Examination
2. Dimensional measurements
3. Chemical composition
p & Deposit
p Analysis
y
4. Macro Examination: Steam-side oxide scale
measurement ((in-situ at site))
5. Hardness measurement
6. Flattening
g Test to detect damageg due to
Hydrogen embrittlement
7. Micro Examination: Microstructure – Other
Damages
8. Tensile Test if required
q
9. Creep Test for RH and SH Tubes.
Visual examination for any macro level damage,
deposits, presence of oxide scales etc.
L
Logx = 0.00022(T+460)
0 00022(T+460) / (20+logt)-7.25
(20+l t) 7 25
x scale thickness in mils
x-
T- Temp in °Rankine (T°R=T°F+460)
t – Service in Hrs.
Hrs
Hardness Measurement:
Vickers Hardness with 10 kg load as per ASTM
E92 on the wall thickness of the tube after due
specimen preparation.
Hardness values reflects the Tensile strength of
the material related to microstructure.
Fl
Flattening
i Test
T as per ASTM A450
A4 0 / A370:
A3 0
Height H = (1+e)tD
( ) / (e+t)
( )
Cracked specimen
indicating damage due to
H d
Hydrogen embrittlement.
bi l
Micro examination
Mi i i conducted
d d through
h h out the
h
section of the specimen for any defects and
microstructure
i using
i OM and d SEM.
SEM
The level
Th l l I L microstructures
i t t off various
i t b
tube
materials is shown in the next two slides.
SA210 A1 850X SA213T11 – 340X
Weld
HAZ
C - Migration
ORIGINAL MICROSTRUCTURE
OVERHEATING STRUCTURES OF WW TUBES
ORIGINAL MICROSTRUCTURE
OVERHEATING STRUCTURES OF WW TUBES
ORIGINAL MICROSTRUCTURE
H2 DAMAGE IN WW TUBES
ID
ID
Tube Microstructure
CORROSION FATIGUE IN WW TUBES
ID
THERMAL FATIGUE CRACKS ON OD
Cu
Weld
TUBE HAZ