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Evaluation of Structural Integrity

Evaluation of Structural Integrity. a perspective of research activities at the. CSIR-NML. Demand on Engineering Components. New CSIR for New India. Higher Efficiency vs Increasing Costs. Higher Stress Levels Higher Pressures Higher Temperatures Higher Speeds

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Evaluation of Structural Integrity

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

  2. Demand on Engineering Components New CSIR for New India Higher Efficiency vs Increasing Costs • Higher Stress Levels • Higher Pressures • Higher Temperatures • Higher Speeds • More Severe Environments Cheaper Materials Stronger Material Lower Section Area Lower Factors of Safety Life Extension GRAVE CONSEQUENCES OF FAILURE

  3. Initiatives at CSIR-NML New CSIR for New India 1974 The Creep Laboratory set up for indigenization of high temperature alloys • 16 grades of creep resistance steels indigenised • Active interactions between users, producers, statutory and research organisations • Used for Remaining Life Assessment of high temperature components where creep is the main damaging mechanism

  4. Initiatives at CSIR-NML New CSIR for New India 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

  5. Material Evaluation Facility Today New CSIR for New India

  6. Initiatives at CSIR-NML New CSIR for New India 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

  7. Initiatives at CSIR-NML New CSIR for New India 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 Assessment • 8 CSIR Labs; 6 tasks; 33 activities; ~30 scientists • Industry oriented capacity building

  8. Initiatives at CSIR-NML New CSIR for New India 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 Assessment 2008 Networked research proposal on Technology for Assessment and Refurbishment of Engineering Materials and Components • 7 CSIR Labs; Academic partners and target Industries • 8 tasks; ~50 scientists; relevant deliverables

  9. Elements of Structural Integrity New CSIR for New India FULL-SCALE STRUCTURAL TESTING ADVANCED MATERIALS & PROCESSING COMPUTATIONAL MODELLING DESIGN & PROTOTYPING MATERIAL CHARACTERISATION SOFTWARE & SERVICES MECHANICAL BEHAVIOUR OXIDATION, EROSION & WEAR NON-DESTRUCTIVE EVALUATION SURFACE ENGINEERING

  10. Assessment of Engineering Damage Resistance data Validation Quantitative Danmage Index Codes & Software Ageing Parameter Simulation & Modelling Non-destructive Surveillance Documented information In-service Critical Structural Components Material Characterisation Experimental Evaluation New CSIR for New India Materials & Components Full-scale Testing

  11. Refurbishment of Engineering New CSIR for New India Materials & Components In-service Critical Structural Components Sensor Integration Coatings Surface Engineering

  12. Giant Magneto-impedance Sensor 0% Martensite 12% Martensite 17% Martensite New CSIR for New India Petrochemical Refinery Unit: Evaluation of damage in Johnson screen (321SS) : Carburisation during naptha cracking and becomes magnetic on long term exposure. Johnson Screen Highly Carburised area In-water quenching system at NML & Nanostructured wires prepared Giant Magneto-Impedance based Sensing Device developed at NML GMI sensor response on plastically deformed in 304 SS GMI Probe with nanostructured wire as sensor element GMI based Sensing device

  13. A Portable Magnetic Sensing New CSIR for New India Device (MagStar) for NDE of damage assessment of steel structures/components Magnetic Hysteresis loop (MHL) & Magnetic Barkhausen Emission (MBE) System

  14. Non-Linear Ultrasonic for New CSIR for New India Structural Damage Evaluation NLU parameters are more sensitive to structural damages (Fatigue, Creep, Corrosion etc…) than linear ultrasonic wave characteristics; velocity, amplitude or attenuation Why NLU? Globally First Portable Non-Linear UT System Developed at CSIR-NML, India Initiatives at CSIR-NML Ultrab • Establishment of correlation between NLU parameter with fatigue damage and pitting corrosion CSIR-NML • Development of predictive model for damage quantification • Portable NLU device development for the integrity assessment of Industrial Components Features: Portable with online NLU parameter determination/calibration software High S/N ratio with integrated pre-amplifier

  15. Advanced Sensor based New CSIR for New India Technique for Iron Ore Sorting High Alumina in Iron Ore • Reduces Blast Furnace productivity • Increases rate of coke consumption • 300-375 kg more CO2 emission compared to International benchmark Our Approach to Reduce Alumina % Feed Ores Accept Ores Reduction of alumina % in the BF feed by rejecting high alumina rich iron ores through Infra-Red Thermal Imaging Sorting Results Feed Materials: Fe = 64.5% Al2O3 = 2.49% Accept Ores: Fe = 65.95% Al2O3 = 1.45% Reject Ores

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