evaluation of structural integrity a perspective of research activities at the csir-nml
TRANSCRIPT
Evaluation of Evaluation of Structural Structural
IntegrityIntegrity
a perspective of a perspective of research activities at research activities at
thethe
CSIR-NML
Higher Efficiency vs Increasing Costs
• Higher Stress Levels
• Higher Pressures
• Higher Temperatures
• Higher Speeds
• More Severe Environments
GRAVE CONSEQUENCES OF FAILURE
Cheaper Materials
Stronger Material
Lower Section Area
Lower Factors of Safety
Life Extension
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New CSIR for New IndiaNew CSIR for New India Demand on Engineering ComponentsDemand on Engineering Components
16 grades of creep resistance steels indigenised
Active interactions between users, producers, statutory and research organisations
1974 The Creep Laboratory set up for indigenization of high temperature alloys
Used for Remaining Life Assessment of high temperature components where creep is the main damaging mechanism
New CSIR for New IndiaNew CSIR for New India Initiatives at CSIR-NMLInitiatives at CSIR-NML
1974 The Creep Laboratory set up for indigenisation of high temperature alloys
1988 Research Group on NDT&E formally initiated
1992 Component Integrity Evaluation Programme started Facility development through loan from World Bank Subscribing sponsor industries
New CSIR for New IndiaNew CSIR for New India Initiatives at CSIR-NMLInitiatives at CSIR-NML
New CSIR for New IndiaNew CSIR for New India Material Evaluation Facility TodayMaterial Evaluation Facility Today
1974 The Creep Laboratory set up for indigenisation of high temperature alloys
1988 Research Group on NDT&E formally initiated
1992 Component Integrity Evaluation Programme started
2002 Advanced Centre for NDE Funded by the Dept. of Science & Technology +
CSIR Research on advanced techniques and protocols of
NDE Provide consultancy to Industry
New CSIR for New IndiaNew CSIR for New India Initiatives at CSIR-NMLInitiatives at CSIR-NML
1974 The Creep Laboratory set up for indigenisation of high temperature alloys
1988 Research Group on NDT&E formally initiated
1992 Component Integrity Evaluation Programme started
2002 Advanced Centre for NDE
2004 Networked research amongst CSIR Labs on Technology for Engineering Critical AssessmentTechnology for Engineering Critical Assessment 8 CSIR Labs; 6 tasks; 33 activities; ~30 scientists Industry oriented capacity building
New CSIR for New IndiaNew CSIR for New India Initiatives at CSIR-NMLInitiatives at CSIR-NML
1974 The Creep Laboratory set up for indigenisation of high temperature alloys
1988 Research Group on NDT&E formally initiated
1992 Component Integrity Evaluation Programme started
2002 Advanced Centre for NDE
2004 Networked research amongst CSIR Labs on Technology for Engineering Critical AssessmentTechnology for Engineering Critical Assessment
2008 Networked research proposal on Technology for Assessment and Refurbishment of Technology for Assessment and Refurbishment of Engineering Materials and ComponentsEngineering Materials and Components
7 CSIR Labs; Academic partners and target Industries
8 tasks; ~50 scientists; relevant deliverables
New CSIR for New IndiaNew CSIR for New India Initiatives at CSIR-NMLInitiatives at CSIR-NML
New CSIR for New IndiaNew CSIR for New India Elements of Structural IntegrityElements of Structural Integrity
In-service Critical Structural Components
Material Characterisation
Simulation &
Modelling
Non-destructive Surveillance
Experimental Evaluation
Documented information
Damage Resistance data
Qu
anti
tati
ve D
anm
age
Ind
ex
Ageing Parameter
Codes & Software
Validation
Full-scale Testing
New CSIR for New IndiaNew CSIR for New India Assessment of EngineeringAssessment of Engineering Materials & ComponentsMaterials & Components
In-service Critical Structural Components
Sensor Integration
Coatin
gs
Surface Engineering
New CSIR for New IndiaNew CSIR for New India Refurbishment of EngineeringRefurbishment of Engineering Materials & ComponentsMaterials & Components
Giant Magneto-Impedance based Sensing Device developed at NML
GMI based Sensing device
GMI Probe with nanostructured wire as
sensor element
In-water quenching system at NML & Nanostructured wires prepared
0% Martensite
12% Martensite17% Martensite
GMI sensor response on plastically deformed in 304 SS
Petrochemical Refinery Unit: Evaluation of damage in Johnson screen (321SS) : Carburisation during naptha cracking and becomes magnetic on long term exposure.
0 50 100 150 200 2500
200
400
600
Reactor-1
Reactor -3
BottomHeight from bottom (cm)
GM
I vo
ltag
e (
mV
)
Highly Carburise
d area
Johnson Screen
New CSIR for New IndiaNew CSIR for New India Giant Magneto-impedance Sensor Giant Magneto-impedance Sensor
700 750 800 850 900 950
80
90
100
110
120
Tempering Temperature (oC)
Ma
gn
etic
Co
erc
ivity
(O
e) 9Cr-1Mo Steel
0.20
0.25
0.30
0.35
0.40
0.45
MB
E V
olta
ge
(V
rms)
New CSIR for New IndiaNew CSIR for New India A Portable Magnetic SensingA Portable Magnetic Sensing Device (MagStar)Device (MagStar)
Magnetic Hysteresis loop (MHL) & Magnetic Barkhausen Emission (MBE) System
for NDE of damage assessment of steel structures/components
NLU parameters are more sensitive to structural damages (Fatigue, Creep, Corrosion etc…) than linear ultrasonic wave characteristics; velocity, amplitude or attenuation
Why NLU?
Initiatives at CSIR-NML
Establishment of correlation between NLU parameter with fatigue damage and pitting corrosion
Features: Portable with online NLU parameter determination/calibration software High S/N ratio with integrated pre-amplifier
Development of predictive model for damage quantification
Portable NLU device development for the integrity assessment of Industrial Components
Ultra
CSIR-NML
Globally First Portable Non-
Linear UT System
Developed at CSIR-NML, India
New CSIR for New IndiaNew CSIR for New India Non-Linear Ultrasonic forNon-Linear Ultrasonic for Structural Damage EvaluationStructural Damage Evaluation
High Alumina in Iron Ore Reduces Blast Furnace productivity Increases rate of coke consumption
300-375 kg more CO2 emission compared to International benchmark
Accept Ores
Reject Ores
Reduction of alumina % in the BF feed by rejecting high alumina rich iron ores through Infra-Red Thermal Imaging
Our Approach to Reduce Alumina %
Sorting Results
Feed Materials: Fe = 64.5% Al2O3 = 2.49%
Accept Ores: Fe = 65.95% Al2O3 = 1.45%
Feed Ores
New CSIR for New IndiaNew CSIR for New India Advanced Sensor based Advanced Sensor based Technique for Iron Ore SortingTechnique for Iron Ore Sorting