Evaluation of Structural Integrity a perspective of research activities at the CSIR-NML

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 Material Evaluation Facility TodayMaterial Evaluation Facility Today



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





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





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 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

Documents

Evaluation of Structural Integrity a perspective of research activities at the CSIR-NML