Introduction. 2. Incoming QA/QC Assurance that the material you receive matches the order

Transcription

1 PMI and Fabrication Playbook September 2016

2 Index Introduction... 3 Feature / Benefit... 4 In-process material identification: PMI... 5 Oil and Gas... 6 Refineries and Petrochemical Plants... 6 Power Generation: Fossil, Gas and Nuclear... 6 Power Generation: FAC Application Other Chemical Plants... 7 Pipeline Operations Inspection Companies... 8 Contractors... 8 Foundries and Mills... 9 Stainless and Low Alloy Steel Mills... 9 Steel Mills and Foundries... 9 Low Alloy Steel and Iron Foundries...10 Stainless Steel Foundries...10 Non-ferrous Foundries...10 Forging Plants...10 Fabricators...11 Heat Exchanger Manufacturers...11 Pressure Vessels...11 Pharmaceutical Valves...12 Pumps...12 Stainless Steel Pipe Seamless...12 Stainless Steel Pipes, Bends and Flanges Standard...12 Welding Rod and Filler Manufacturers...13 Turbine Manufacturing and Repair...13 Cryogenic Equipment Manufacturing...13 Automotive Industry Aerospace Equipment Manufacturing...14 Fasteners...14 Additional Resources

3 Introduction The verification of metal alloys for manufacturing quality assurance and control has never been more important for product and process reliability and safety. From metal production to service centers and distributors, from component fabrication to final product assembly the potential for material mix-ups is very real, and the need for traceability is now a top priority. There are multiple areas where material inspection can be useful: 1. In-process material identification Routine Inspection of piping systems and other process components to ensure that there are no incompatible alloys present in the processing stream (Retro PMI) 2. Maintenance and fabrication-related material identification Provide assurance that no incompatible alloys are inserted into the process stream during construction and maintenance procedures (new pipes, valves, etc.) 2. Incoming QA/QC Assurance that the material you receive matches the order 3. Outgoing QA/QC Final inspection and certified shipments to the client 2. Inventory Management & Recovery Ensure that segregation of material is kept in check Recover lost materials for proper re-insertion into the supply chain Thermo Scientific Niton XL2, XL3 and XL5 series Thermo Scientific Niton XRF analyzers provide alloy grade identification and chemical analysis in seconds. They re used in fabrication shops, foundries, service centers, and petrochemical refineries to verify incoming alloys, recover lost material traceability, and confirm finished products and it s all done nondestructively. Our customers have determined that they can no longer rely on mill test reports (MTRs) and have literally taken matters into their own hands to confirm material composition. From low alloy steels to stainless steels to super alloys, red metals in titanium alloys to exotic elements Niton alloy analyzers provide the material confidence you just can t get from a piece of paper. Why Thermo Scientific Niton XRF Analyzers? 1. Our internal tests show that the Niton analyzers make the correct grade ID much more often than the competition (Including SDD). 2. Our internal tests show that Niton XRF analyzers are much faster in alloy identification than the competition (including SDD). 3. Niton analyzers are robust and therefore capable of performing without failure from harsh environmental conditions or the instabilities of a Windows CE platform used by our competitors. 4. Niton offers the world s smallest, lightest, highest performing HHXRF on the market and returns lab quality results for virtually every type of metal alloy. 3

4 Feature / Benefit Feature Benefit Advanced alloy library Thermo Scientific Niton NDT Software Suite Rugged design Thermo Scientific Niton integrated calibration feature Integrated CPU and display Integrated Bluetooth and USB technology Available GOLDD technology Color tilt screen display Optional CCD camera Optional small spot collimation feature Accessories The comprehensive alloy library gives you the confidence that what you are measuring is correctly identified by your analyzer. Continuing our heritage of working closely with our metals industry customers and partners, we regularly update our library to include the alloys you need to identify The user friendly NDT software allows users to run the analyzer from their PC, download and manipulate data, print reports, and customize their own alloy library. Raw data is secured in a tamper-proof format, ensuring the integrity of original measurements. The Niton analyzer will withstand the elements and extreme conditions often found in the harshest working environments. Don t waste time looking for the calibration standard it s built into the system! Simply push a button and the system will self calibrate whenever and wherever you want. Get faster analysis and results displayed on a stable platform that is not susceptible to slow processing, lock-ups or crashes common in competitors Windows CE-based systems. Easily connect to your PC to run your analyzer and download data for further analysis and certificate printouts. Connect wirelessly to peripheral devices such as printers, GPS systems and bar-code scanners. A combination of advanced design features coupled with new Si Drift Detectors (SDD) provide the ultimate in element detection limits and light element sensitivity. Adjust the display to easily see your results in a variety of lighting and working conditions. Take out the guess work. Focus in on exactly where you want to measure and record images for future traceability (only available on Niton XL3t series) Zoom in to a small area (3 mm) for weld analysis or analyzing very small samples. Based on our internal testing, Niton XL3t integrated collimator provides the most precise small spot analysis in the market. (Available for Niton XL3t series) Zoom in to a small area (3 mm) for weld analysis or analyzing very small samples. Based on our internal testing, Niton XL3t integrated collimator provides the most precise small spot analysis in the market. (Available for Niton XL3t series) 4

5 In-process material identification - Positive Material Identification (PMI) Positive Material Identification (PMI) has grown dramatically over the past years and is today an essential inspection protocol at petroleum refineries for the prevention of catastrophic failures. PMI is a method of nondestructive testing, which uses analysis and identification of alloy materials based on their chemical composition. Today, in critical petroleum, oil, or gas operations, every pipe, tank, flange, valve, welding seam and other component is verified to confirm that it matches the engineering specification. Typically PMI is in-process material identification to accept or reject the material used - not to adjust its properties in the process Requirements Verify that used alloy is correct The alloy has the expected chemistry Verify possible impurities (unwanted elements) In some cases, only alloy grade name is required Main Drivers API RP 578, recommended practice is widely implemented in the US and increasingly in other regions as well Local/national laws and regulations like the American Society of Mechanical Engineers (ASME) codes for pressure vessels or Pressure Equipment Directive (PED) in the EU The PED pressure equipment directive in the EU requires material traceability, but it doesn t require PMI Companies internal policies for quality and/or safety reasons Key Contacts Depending on the site, plants do PMI by themselves or it is outsourced. Outsourced PMI is very common in the US and EU area; in Asia in-house PMI by asset owner is more common. In some cases an asset owner has their own analyzers, but they primarily use inspection companies. In large refineries there is often a non-destructive testing (NDT) coordinator who purchases the services of an inspection company Additionally, plant metallurgists, material inspector, chief of inspection department, QC managers, reliability engineer, maintenance manager can also be the right points of contact Pre-demo Questions What are the most important alloy grades? What elements and at what accuracy level are important to measure? What kind of samples? Pipes, pumps, shafts, welding seams, etc. Who is performing measurement? Inside NDT or outsourced? Frequency of need? Instrument of Choice Typically Niton XL3t series, as small spot analysis is frequently required Niton XL3t 980 GOLDD+ or 985 Ultra if light element or trace element analysis is needed, such as flow accelerated corrosion (FAC), residual elements, low Si application has Niton XL5, the smallest, lightest, fastest HHXRF on the market, is the optimal choice for retro-pmi where size reduction pays direct dividends to the client increasing overall number of access points Niton XL5 recommended for advanced applications such as Low-Si, residual and trace element detection including microalloy (high strength low alloy) steels. 5

6 Oil and Gas Refineries and Petrochemical Plants Analyzers are typically used to verify existing material on pipes and process equipment (retro PMI) or to verify the new incoming / maintenance material. OSHA National Emphasis Programs (NEPs) for refinery CPL and chemical CPL enforced in 2009 & 2011 to protect workers from catastrophic releases of highly hazardous chemicals. OSHA 29 CFR (j) PSM Mechanical Integrity equipment shall be suitable for process application, proper material, identify, inspect, document - includes vessels, tanks, piping systems, valves, pumps. - Residual elements Cr, Cu, Ni to predict corrosion susceptibility in alkylation plants - Furnace bricks and anchors to verify that correct material has been used - Detection of surface Hg contamination - Identification of different deposits and sludges Power Generation: Fossil, Gas and Nuclear Typical application is PMI of heat resistant, low alloy pipes, minimum diameter ½ Typically used grades are T11, T22, T91, P9, P91, SS304/316 etc. Zirconium alloys, primarily Zircaloy-2 and Zircaloy-4, are used in nuclear reactor cores Nuclear power plants have their own really stringent quality criteria requirement (must have) traceability of material back to mill certificate Carbon is often important because of welding and mechanical strength, by knowing the carbon content can avoid costly and time consuming pre-heating of parts to be welded Typically, it is enough if grade name is according to the specification Typically used grades are carbon and low alloy steels, SS304/316, SS321, Duplex 2205, various Ni alloys such as Inconels and Incoloys PMI often complements other NDT techniques like ultrasonic or eddy current Both HHXRF and mobile Optical Emission Spectroscopy (OES) used; OES mainly to measure carbon (stainless steel L-grades) HHXRF is increasingly used also for advanced PMI applications such as: - Retro-PMI piping surveys at process temperatures typ F, up to 900 F - Si in carbon steel for sulfidation corrosion Power Generation: FAC Application Detecting the pipes that are susceptible for Flow Accelerated Corrosion (FAC) can reduce costs and improve safety Inspection of the piping system to determine their exact chemistry provides essential information for predicting the FAC rate 6

7 Typically used material is plain carbon steel like A106B Cr is known to be the most influential element on FAC, but also Cu and Mo contents effect on the FAC rate Cr < 0.06% g risk of accelerated corrosion Cr > 0.15% g no corrosion Cu and Mo have a lesser effect to corrosion resistance Another potential application is the maintenance of the pipeline compressor stations; the compressor stations may have several gas turbines and they are used 24/7. Other Chemical Plants The value proposition for the chemical plants is exactly the same as for refineries The materials used may vary depending on process conditions; Stainless steels, Nickel alloys and Ti alloys are commonly used The most critical processes for PMI are those where corrosive liquids and gases are handled under high pressure and high temperature Offshore/Subsea Upstream crude oil and natural gas, exploration and production (E&P) sector Often use microalloy steels with additions of Nb, V, Ti, Al for added strength Carbon equivalency key for weldability and resisitance to cracking (SSC, HSC) The National Association of Corrosion Engineers (NACE) MR0175/ISO standard for specifying parent metal properties for materials used in sour H2S-containing environments in O&G production NACE guidelines may limit nickel content <1% for carbon Pipeline Operations Oil, petroleum or gas networks Important pipeline networks in the US, Canada, Russia, Middle East Typical application is to verify carbon content in steel prior to welding and after welding to verify the filler material Carbon analysis is often required, but there is need for handheld XRF as well Verification of carbon steel residual elements such as Cr, Cu, Ni, Mo, V, Ti, which can significantly affect material properties is a new, important HHXRF opportunity 7

8 and low alloy steels Duplex and Super Duplex material offer greatest resistance to pitting and crevice corrosion, ex: 2205, 2507, Ferralium 255, Zeron 100 Det Norske Veritas and Germanischer Lloyd (DNV GL) international certification body ~65% of world s offshore pipelines are designed and installed to these technical standards ex: DNV GL-OS-B101 Contractors PMI is required by their customers PMI is required by regulations (like an ASME pressure vessel code) - Pressure vessels - Heat exchangers - Boilers - Valves, flanges and pipes - Pumps - Welding of components Examples: Foster Wheeler, GE, Fluor, Bechtel Inspection Companies Inspection companies are doing PMI projects for Petrochem and power generation and fabricators - Typically located next to big plants and factories - Examples: Mistras, Acuren, US Inspection, Iris NDT, Oceaneering, Setsco, EPRI Used in very demanding conditions of temperature, moisture, dirt and must be very rugged for many measurements Use both handheld XRF and mobile OES intensively Inspection companies charge per hour g reliable unit and fast service highly valued (High measurement capacity) The end product is measurement report g Must be easy to produce Basically need to measure all possible alloys, however 75% of measurements is stainless steel or high-temp steels Stainless steel L-grades are the driver behind carbon analysis due to the welding requirements 8

9 Foundries and Mills A metal production mill, typically blast and Electric Arc Furnace (EAF), is a continuous casting operation. A foundry is a metal casting operation. Steel is typically produced in a two-stage process. First, iron ore is reduced or smelted with coke and limestone in a blast furnace, producing molten iron, which is either cast into pig iron or carried to the next stage as molten iron. In the second stage, known as steelmaking, impurities such as sulfur, phosphorus, and excess carbon are removed and alloying elements such as manganese, nickel, chromium and vanadium are added to produce the exact steel required. Steel mills then turn molten steel into blooms, ingots, slabs and sheet through casting, hot rolling and cold rolling. Requirements - Limited number of alloys to check - Typically focused on one alloy family - Chemistry is very important Key contacts - Scrap buyer - Production manager - QA/QC manager Main drivers - Verification of incoming metals Buy scrap at the right price Predetermination of melt chemistry - Predicts furnace output Reduces production waste - Inventory control of finished product Prevents stock mix-ups Pre-demo questions - What kind of metal is produced? - Why need a mobile unit? - What elements and at what accuracy level are important to measure? - Do you analyze raw material or end product, or both? - Is carbon analysis required? Stainless and Low Alloy Steel Mills They always have Wavelength Dispersive X-ray Fluorescence (WDXRF) and OES (SS mills) unit in the lab, often automated 24/7 operation. End products checked before delivery by XRF or OES Need high accuracy and repeatability HHXRF feasible for SS mills raw material (=scrap) Dominated by Thermo ARL and Spectro Steel Mills and Foundries XRF used to analyze raw material (=scrap especially stainless steel where 95% of raw material is scrap), OES is typically used for the end product - Most have OES, typically big lab unit(s) - Foundries we re looking at are producing: Stainless steel Nickel alloys Aluminum, titanium White cast iron 9

10 Low Alloy Steel and Iron Foundries Also scrap as raw material, but important elements are typically C, Si, P, Mn which makes this often OES application 80% of low alloy castings are gray cast irons (on aver. 3.4% C, 2.2% Si), requires re-melting of sample to measure with OES. Notice, Si in gray cast iron can be analyzed with the SDD instrument. White cast iron is typically OES application Another typical cast iron grade is ductile cast iron, typically used in car parts, can be measured with laboratory OES Generally cast irons are difficult to measure with OES, because of poor conductivity. High Mn and high Cr castings used in mining/rock crushing equipment For Copper foundries XRF applicable, can measure Al, Si & (P) on copper alloys. Typical grade names are - Al: 356, 319, 535 (Almag) - Cu: 115 (C83600), 245 (C92200), 415 (C94500) Forging Plants Typically, low alloy/carbon steels, some Al alloys Often supplier of the automotive industry - Strict quality control needed - Specifications stipulated by the car manufacturers Carbon is an important element in incoming inspection because it determines how the forging works In the outgoing inspection, the speed of non-destructive analysis is important because high throughput rates Stainless Steel Foundries Use SS scrap as raw material => Ni accuracy and speed of analysis are essential Need to know all elements on their end products with high accuracy (<50ppm all elements) Typically uses laboratory type OES like ARL3460 Typically used SS casting grades are CF3 (304L), CF8 (304), CF8M (316), CD3MN (Duplex 2205) Non-ferrous Foundries Mainly Al foundries, some Cu, Ni and Ti HHXRF practically useless on Al due to high accuracy for Al, Si, Mg 10

11 Fabricators A fabricator is a company that makes a value added product with a metal alloy as the primary raw material, for instance machine shops. Requirements - Typically focused on one or two alloy families - Alloy ID is most important - Chemistry is typically less important - Prefers non-destructive test (NDT) Key contacts - Owner (small company) - Inspection dept. manager - QA/QC manager - Scrap material manager Main drivers - Quality Assurance/Quality Control Minimize production errors Minimize material rework - Incoming inspection of raw material stock - Prevents production errors due to out-of-spec. / mislabeled raw material - Finished product inspection Pre-demo questions - What is the end product? - What are typical alloy grades? - Do you need carbon analysis? - Do you analyze raw material or end product, or both? - What is the driver behind the analysis? - Size and shape of samples? Heat Exchanger Manufacturers Heat exchanger is often classified as pressure vessel g certain rules and regulation applies, often country specific like the American Society for Testing and Materials (ASTM) codes in the US or PED in EU Carbon is important when welding used in manufacturing Some heat exchangers are made of Cu or Ti pipes, typical grades are Ti Gr.2 or 90/10 CuNi Every refinery, chemical and power plant has hundreds of heat exchangers and pressure vessels Pressure Vessels See Heat Exchanger Manufacturers section Many countries have their own specific codes Higher pressure, larger diameter pipes require greater quality control; fabricators must prove that their product meets specification Know what range of pressure the manufacturers products meet. Often carbon steel outside A with clad lining or internal weld overlay using SST 309, 316, 317, Inconel 625, 686, Hastelloy C276, C22 for corrosion barrier Pharmaceutical Almost always stainless steels grades like SS304 and SS316 Equipment = process vessels, reactors, mixers, piping, tablet makers/press It is essential that there is no contamination from pipes/ vessels. 11

12 Analytically easy application Occasionally measurements taken through plastic films covering parts/components Stringent quality control and reporting Alfa Laval, Niro, Linde Gas, Northland Stainless Valves The valve bodies are typically cast in China or other low cost countries and then assembled in the final manufacturing country with a known brand name. This means that incoming inspection is very important The ball valves sometimes have hard Cr-coating, valve manufacturers are potential customers for a coating thickness. All Niton instruments can effectively measure Cr coating In most cases, the end users require PMI before delivery, especially for stainless steel valves Sulzer, Goulds, KSB, Weir, Cryostar Stainless Steel Pipe - Seamless Seamless pipes manufactured through extruder most often requires online inspection system due to the nature of the process Good accuracy needed to separate similar SS grades from each other, separation based on Ni, Cr, Mo, Ti, Cu, Nb Many plants use automated system operating 24/7 Typical grades used in oil refineries and chemical plants Stainless Steel Pipes, Bends and Flanges - Standard Standard welded from cold-rolled steel Labeling process at the same time as welding Occasional quality control with HH XRF Typical grade names same as in refineries and chemical plants Bends and flanges often manufactured in the same facility as standard tubes Similar PMI requirements as pipes Pumps The value proposition is the same as for valve manufacturers The most critical components are the blades, corrosion there quickly deteriorates the pump efficiency Many pump manufacturers have the casting plants as well; sometimes they need to buy the scrap from new sources and normally they are in a hurry when they do; no time for lengthy lab analysis Pump manufacturers are normally big with multiple manufacturing locations. 12

13 Welding Rod and Filler Manufacturers Welding rods are analyzed by customers who need to avoid the welding seam The typical diameter of the rod is 1.6mm and higher g hard to do with OES due to Argon sealing, requires special adapters Rods and fillers have their own grade names; see typical examples, in the table below Grades of rod are close to the grade pieces being welded together, but normally over alloyed e.g. higher content doping alloys Turbine blades are made of several different materials, Ti in the inlet and more precious alloys (Ni/Co s e.g. Inconels and Incoloys) in the second stage The present requirement for lower fuel consumption has resulted in higher (over 1100 C) operating temperatures. This has resulted in developing alloys doped with exotic elements like Rh or Ru OES is typically not used due to destructive nature Limited number of manufacturers all have multiple facilities; GE, Siemens, Alstom, Rolls-Royce, Pratt & Whitney Base metal Welding rod SS304L E/ER 308L SS316L E/ER 316L 904L E/ER 385 SS410 E/ER PH E/ER 630 Alloy 20 E/ER E/ER E/ER 2553 Inco625 E/ERNiCrMo-3 Cryogenic Equipment Manufacturing Only few alloys used, but PMI is often required (similar to pressure vessels) Typical application is PMI on liquid natural gas (LNG) tanks either on board a ship or as a storage container Typical alloys are SS304L, 9% Ni steels (A553Gr1) or Al5083 Turbine Manufacturing and Repair Practically all components in the turbine need to be verified Turbine is a very complex structure and the blades are the most critical components, up to 40 different alloys used Automotive Industry Modern automotive industry sets really high standards for quality, every car assembly plant has an extensive quality organization for their own production and also for incoming inspection Large parts used engines, power transmission and suspension are castings due to higher volumes and cost requirements Material verification is typically done before machining of 13

14 castings, either at car assembly plants, but more often at the supplier s plant which can be either machine workshop or foundry Typical alloys include carbon and low alloy steels, but also increasingly aluminium alloys Another potential application is coatings, most common is Zr based passivation coatings used for corrosion resistance Aerospace Equipment Manufacturing Wide selection of alloys used: Ti and Al alloys, stainless steel and some Ni alloys Stringent quality control, everything is reported Both the incoming material and the final product have to be checked Fasteners Aerospace industry - Serious mix-ups in the past have resulted in airspace companies that require 100% PMI from all fastener suppliers Automotive industry and its supply chain - Typically, steel rods and wires are used in bolt/nut manufacturing and are analyzed when the material is taken in, not for finished products. In this case, carbon analysis is needed as well. Stainless steel (and Ni, Ti) fasteners manufactured for the critical areas in high-temp, high-corrosion processes undergo rigorous quality control by the manufacturer Sometimes different alloy names are used; see examples in the table below: Common alloy name Bolt name (ASTM A193) SS304L B8 SS316L B8M SS347 B8C SS321 B8T SS410 B B7 Inco625 E/ERNiCrMo-3 14

15 Additional Resources Available in the Virtual Center of Excellence (vcoe), see Oil & Gas Launch, September 2016 Americas Boston, USA Europe, Middle East, Africa Munich, Germany India Mumbai, India Asia Pacific New Territories, Hong Kong Find out more at thermofisher.com/portableid 2016 Thermo Fisher Scientific Inc. All rights reserved. All trademarks are the property of Thermo Fisher Scientific and its subsidiaries unless otherwise specified