Positive Material Identification (PMI) as it relates to refractory hardware

Transcription

1 Positive Material Identification (PMI) as it relates to refractory hardware

2 North American manufacturer and industry leader in the supply of metallic refractory hardware Established in 1966 Privately owned and operated We have been asked by the API to discuss our internal systems used to ensure PMI (Positive Material Identification)

3 Brief Description of Refractory Covers a broad range of metallic parts used in the refractory industry Used to anchor monolithic refractory linings (both castable and plastic) and secure refractory type tile in roof and wall construction for elevated furnace temperature applications Hardware

4 Material Processing Cycle PMI Procurement Production

5 Order processing Customer PO is reviewed and entered into our MRP system listing all requirements needed to manufacture complete. Order Acknowledgement is generated and sent to customer Traveller is generated and sent to purchasing

6 Purchasing At the time of purchasing raw materials, MTR s are requested with each and every order of Stainless Steel Every Jayne purchase order explicitly states the use of North American, European, or Japanese sources only. The Job Traveller then moves from Purchasing to the manufacturing manager

7 Receiving Upon receipt of raw material, a color coding system is applied to ensure that all materials are easily identifiable by material class (i.e. 304, 309, 409, etc.). This provides a quick and easy visual identifier. At the point of receipt, the vendor supplied MTR information is entered into a custom built Jayne materials database. Both the mechanical and the chemical results from the MTR are entered electronically into the database. If the results from the MTR fall outside of the acceptable ASTM ranges, the application flags the material as non-conforming and is presented to Purchasing for investigation and disposition. All MTR's are also filed in hard copy format for future reference.

8 Jayne MTR Database From the database the user is able to quickly find the min/max chemical and physical standards for any alloy used at Jayne

9 The materials database links the Jayne PO# with the material heat number. The heat number when requested may be used in the marking sequence during manufacturing to provide identification of each manufactured unit at the part level.

10 Material Identification Each receipt of raw material is also identified with a Jayne Purchase Order number as well as the Heat Number. This is written onto the material using a permanent paint marker and physical tag is affixed. The coil is tagged as "HOLD" and a coupon is taken for validation of chemical composition

11 Material Validation All coupons are validated using XRF (X Ray Fluorescent) technology to ensure that the material meets the grade shown on the Purchase Order. The XRF technique does not allow for accurate reading of low alloying elements such as Carbon. When requested, validation of Carbon content is performed by using a third party laboratory. The lab uses a Spectro Metal Analyzer to determine the chemical composition of the sample. The spark test accurately identifies many low alloying elements such as Carbon which are not achievable using XRF (X Ray Fluorescent) technology.

12 Upon successful results from PMI, the coils are transferred to a staging area for product processing

13 Jayne MTR Database Verification documents are scanned and stored in the database including the original mill material cert and any PMI cert linked to the heat number

14 Manufacture After material verification, the Job traveller is released by the plant manager to the machine operator. The machine operator requests the material grade & diameter required The machine operator records the grade and heat on the Job traveller. Manufacturing of the component can begin Once complete the operator signs off on the operation and sends the Job traveller to the next stage (ie:bsa (bright solution anneal), laser marking, etc

15 CNC Robotic Bending Machines

16 Comparison of different marking processes Laser marking Embossing Printing Inkjet Mechanical engraving Etching Environmental compatibility High + Average Average Average Average Low Quality High + Average High + Average High + High + Durability High + High + Average Average High + Average Material Stress Low + High Low + Low + High Average Flexibility High + Average Low Average Low Low Maintenance and Wear Low + High High High High Low +

17 Jayne Marking Option Laser etching advantage Reliability Versatility Legibility Durability The marking process option from Jayne Customer requests our marking option The marking option is incorporated into the job requirements at order entry The material grade and HT# from the MTR database is programed and etched into each anchor affiliated with the customer order.

18 Conclusion Thank you for the opportunity to discuss our internal process for PMI. Questions