A General Survey on NDT in the Chemical Industry

LudwigshafenVerbund Site

n professionaln customer focusedn cost aware

A General Survey on

NDT in the Chemical Industry

ECNDT 2006Berlin, 25.-29. September 2006Fr.1.2.1

Dr.-Ing. Andreas HechtDipl.-Ing. Peter RostPlant Inspection / Materials Engineering

Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 2

LudwigshafenVerbund SiteChemical Industry:

Different Plants for all Sorts of Purposes


LudwigshafenVerbund SiteThe BASF Site Ludwigshafen –

the world’s largest integrated chemical complex



Rock salt

About 8.000 commercial productsAbout 8.000 commercial products

Major basic products and intermediatesMajor basic products and intermediates

Raw materialsRaw materials

about 200about 200

Natural gasSulfurPhosphate Water Air

Cruide oil Ores

The “Chemis-Tree”BASF Products


LudwigshafenVerbund SiteInvisible contribution. Visible success.


LudwigshafenVerbund SiteFrom Naphtha to Napkins:

Superabsorbers from BASF

Super-absorbersNaphtha Propylene Acrylic acid

pureAcrylic acid

crude


LudwigshafenVerbund SiteObjects in Chemical Plants

Subject to NDT

Storage Tank

High-Pressure Reactor

Sphere for Pressurized Gas Storage

Process Piping

Column



Economy(no down-time) Safety

Legal Requirements

- European- National

Why are Inspections of Chemical Equipment Necessary ?


LudwigshafenVerbund SiteFocus on Pressure Equipment

(Vessels, Process Piping)

Design and Manufacture

EU - Pressure Equipment Directive (PED)n mandatory for the EU-member-statesn essential safety-requirements of PEDn harmonized standards: e.g. EN 13445-5n national codes: e.g. AD-2000, CODAP 2000n pressure vessels of cat. IV are subject of NDT

in any casel typically good-workmanship criterial 3rd party is involved

n responsibility of manufacturer

OperationManufactureDesign


LudwigshafenVerbund SiteFocus on Pressure Equipment

(Vessels, Process Piping)

Operation (German View)

national BetrSichV (safe operation of plants)n inspection periods established by ownerl max. values by BetrSichV (e.g. 5 years)

n national accredited surveillance organizationsn experienced persons (e.g. owner)n amount and type of NDT settled by owner and

surveillance organization / experienced personl depends on type of potential damage

n responsibility of owner / operator

ManufactureDesign Operation


LudwigshafenVerbund SiteExample 1

Shell & Tube Heat-Exchanger of Cat. IV


consists ofn shelln 2 end-covers (bonnet, hood)n at least 4 nozzlesn 2 tubesheetsn tubes


LudwigshafenVerbund SiteShell & Tube Heat-Exchanger

NDT of Semi-Finished Products

n design & materials selection by manufacturerbased on owner´s specs

n design - approval by notified body (3rd party)n ordering of semi-finished products

l rolled partsl forged parts (e.g. tubesheet)l tubes: seamless or weldedl flanges, screws, etc.

n NDT carried out at steel-mill acc. to l EN-standards l customer specs. (manufacturer / operator)

n materials certificates & incoming goods inspectionn positive materials identification




NDT of Welded Vessel (shell, end-covers, nozzles)

n acc. to PEDn harmonized standard EN 13445-5n national codes, e.g. AD-2000 HP 5/3n NDT carried out at manufacturers siten EN-standards for NDT of weldsn good workmanship criterian fitness for purpose criteria may be considered

n responsibility of manufacturern NDT results reviewed by notified body




NDT of Tube-to-Tubesheet Welds

detection of porosity (potential leakage)n NDT not required by codes or standardsn fitness-for-purpose NDT l to be specified by owner / operatorl carried out at manufacturers sitel RT

– isotope– X-ray-tube

l UT

n responsibility of owner / operator




Leak Test (LT)

n not required by PED or by harmonized standard

n pressure test is no leak testn fitness-for-purpose NDTl bubble testl tracer gas methods (e.g. He)

n it has to be specified early, if LT is under responsibility ofl manufacturerl owner / operator




Final Inspection – Acceptance (cat. IV, Modul G)

final inspection for acceptancen manufacturer provides

l CE-marking on the heat-exchangerl declaration of conformityl technical documentation

n notified body carries out „unit verfication“l examination of technical documentation

– verify approval of NDT personnel– examine NDT test reports– ..........

l final inspectionl certificate of conformity

n final acceptance by owner




In-Service-Inspections (German View)

BetrSichV (safe operation of plants)n internal inspection at least every 5 yearsn internal inspection may be replaced or

complemented by NDT

n amount and type of NDT depends on type of potential damage

n settled by 1. owner 2. owner and experienced person3. owner and surveillance organization (ZÜS)


1 2

3

vessel for gas - fluid group 1




amount and type of NDT depends on type of potential damage

n LT of complete structure if necessaryn outer shell typically UT

l wall-thickness measurement (corrosion)l main welds (cracking)

n tube-to-tubesheet welds typically PT or MTn tubes typically ET, VT, UT-IRIS

baseline inspection during fabrication recommended




Who carries out NDT ?

n Annex I, 3.1.3 of PED requires approved personnel for NDT of welds at cat. III -and cat. IV – vessels

n approval of personnel by recognized third-party organizations (article 13)actual list:http://ec.europa.eu/enterprise/newapproach/nando

n harmonized and supporting standards require personnel certified acc. to EN 473

n no accreditation of NDT-company required

n PED does not applyn national regulations applyn NDT based on

l NDT EN-standardsorl NDT qualification procedure

n NDT personnel certified acc. to EN 473 if required

n accreditation of NDT-company based on EN ISO 17025 recommended / required ?




Who carries out NDT ?

n Annex I, 3.1.3 of PED requires approved personnel for NDT of welds at cat. III -and cat. IV – vessels

n approval of personnel by recognized third-party organizations (article 13)actual list:http://ec.europa.eu/enterprise/newapproach/nando

n harmonized and supporting standards require personnel certified acc. to EN 473

n no accreditation of NDT-company required

n PED does not applyn national regulations applyn NDT based on

l NDT EN-standardsorl NDT qualification procedure

n NDT personnel certified acc. to EN 473 if required

n accreditation of NDT-company based on EN ISO 17025 recommended / required ??



LudwigshafenVerbund SiteExample 2

Process Piping

n transport of fluids, steam or gases

n typically pressurizedoften hot and insulated

n 3 categories acc. to PED

n process piping consists ofl tubesl bendsl welded seamsl flangesl valvesl gasketsl ......



LudwigshafenVerbund SiteProcess Piping

NDT of Pressure Equipment Parts


n materials selection by owner based onstresses and corrosivity of media

n ordering of pressure equipment partsby fabricator / manufacturerl tubes (seamless or welded, EN 10216 or EN 10217)l flangesl valve-housingsl gaskets, etc.

n NDT carried out at steel-mill acc. to l EN 10246, part 1 - part 18 (UT, ET, MT,..)l customer specs à options of EN 10216/10217

n materials certificates & incoming goods inspection (e.g. PMI)



NDT of Welds (mainly circumferential)


n acc. to PEDn harmonized standard EN 13480-5n national codes, e.g. AD-2000 HP 5/3n NDT carried out at fabricators /

manufacturers siten EN-standards for NDT of weldsn good workmanship criterian fitness for purpose criteria may be

considered

n fabricator(s) à manufacturern responsibility of manufacturer



Final Acceptance & Leak Test


final inspection for acceptancen manufacturer provides

l declaration of conformityl technical documentation

n for category IIInotified body carries outl examination of technical documentation

– verify approval of NDT personnel– examine NDT test reports– ..........

l final inspection (incl. pressure test)l certificate of conformity

n final acceptance by owner

n LT not required by PED or by harmonized standard

n pressure test is no leak testn fitness-for-purpose NDT

l bubble testl tracer gas methods

(e.g. He)

n it has to be specified early, if LT is under responsibility ofl manufacturerl owner / operator



BetrSichV (safe operation of plants)n visual inspection at least every 5 yearsn pressure test at least every 5 yearsn pressure test may be replaced or

complemented by NDT

n amount and type of NDT depends on type of potential damage

n settled by 1. owner 2. owner and experienced person3. owner and surveillance organization (ZÜS)

Process Piping



process piping for inflammable and hazardous gases

1

2

3



In-Service-Inspections (Selection of Methods)

n amount and type of NDT depends on type of potential damage (ID or OD)l wall-thickness reductionl localized corrosionl crackingl deposits, blockagel .......

n off-stream methods require removal of insulation

n on-stream methods are appliedduring service (media, temperature,through insulation, etc.)


UT wall-thickness measurement off-stream

RT wall-thickness measurement on-stream



In-Service-Inspections (Methods)


Detection of defective insulationby infrared – testing on-stream

Detection of blockage byAcoustic Ranger Blockage Detectoroff-stream

Verification of valve-seat positionby RT and Phosphor Imaging Plateon-stream



In-Service-Inspections (on-Stream Methods)


Detection of corrosionunder pipe-supportMagna-Tec

VT corrosion scanningCorrScan

Detection of corrosionunder insulationIncotest

Detection of corrosionover long distancesTeletest


LudwigshafenVerbund SiteMethods and NDT-Equipment

used for In-Service-Inspections Validation / Qualification

n routine-NDT is typically based on EN-standardsl if an EN-standard applies,

NDT-validation is not required or neccesary

n on-stream NDT methods / systems are typically not covered by standards:l in this case:

validation / qualification of an NDT system is required acc. to EN ISO 17025

l CEN technical report CEN/TR 14748:2004Methodology for qualification of non-destructive tests



LudwigshafenVerbund SiteNDT in the Chemical Industry

Summary

n NDT in the chemical industry is NDT of equipment (e.g. vessels, tanks, piping)

n NDT during manufacturing is different from NDT during operation

n NDT during manufacturing has to follow provisions of European PED with respect to future operation conditions

l good workmanship criteria apply

l NDT acc. to well known codes and standards (RT, UT, PT, MT)

n NDT during operation has to follow provisions of national regulations

l NDT depends on type of defect estimated

l acceptance criteria depend individually from type of object

n Qualification / Validation of new methods required


Documents

A General Survey on NDT in the Chemical Industry