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

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Presentation on theme: "Evaluation of Structural Integrity a perspective of research activities at the CSIR-NML."— Presentation transcript:

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

2 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 New CSIR for New India Demand on Engineering Components Demand on Engineering Components

3  16 grades of creep resistance steels indigenised  Active interactions between users, producers, statutory and research organisations 1974The 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 India Initiatives at CSIR-NML

4 1974The Creep Laboratory set up for indigenisation of high temperature alloys 1988Research Group on NDT&E formally initiated 1992Component Integrity Evaluation Programme started  Facility development through loan from World Bank  Subscribing sponsor industries New CSIR for New India Initiatives at CSIR-NML Initiatives at CSIR-NML

5 New CSIR for New India Material Evaluation Facility Today Material Evaluation Facility Today

6 1974The Creep Laboratory set up for indigenisation of high temperature alloys 1988Research Group on NDT&E formally initiated 1992Component Integrity Evaluation Programme started 2002Advanced Centre for NDE  Funded by the Dept. of Science & Technology + CSIR  Research on advanced techniques and protocols of NDE  Provide consultancy to Industry New CSIR for New India Initiatives at CSIR-NML Initiatives at CSIR-NML

7 1974The Creep Laboratory set up for indigenisation of high temperature alloys 1988Research Group on NDT&E formally initiated 1992Component Integrity Evaluation Programme started 2002Advanced Centre for NDE Technology for Engineering Critical Assessment 2004Networked research amongst CSIR Labs on Technology for Engineering Critical Assessment  8 CSIR Labs; 6 tasks; 33 activities; ~30 scientists  Industry oriented capacity building New CSIR for New India Initiatives at CSIR-NML Initiatives at CSIR-NML

8 1974The Creep Laboratory set up for indigenisation of high temperature alloys 1988Research Group on NDT&E formally initiated 1992Component Integrity Evaluation Programme started 2002Advanced Centre for NDE Technology for Engineering Critical Assessment 2004Networked research amongst CSIR Labs on Technology for Engineering Critical Assessment Technology for Assessment and Refurbishment of Engineering Materials and Components 2008Networked 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 New CSIR for New India Initiatives at CSIR-NML Initiatives at CSIR-NML

9 New CSIR for New India Elements of Structural Integrity Elements of Structural Integrity

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

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

12 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% Martensite 17% 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. Highly Carburise d area Johnson Screen New CSIR for New India Giant Magneto-impedance Sensor Giant Magneto-impedance Sensor

13 New CSIR for New India A Portable Magnetic Sensing A 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

14 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 India Non-Linear Ultrasonic for Non-Linear Ultrasonic for Structural Damage Evaluation Structural Damage Evaluation

15 High Alumina in Iron Ore  Reduces Blast Furnace productivity  Increases rate of coke consumption  kg more CO 2 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% Al 2 O 3 = 2.49% Accept Ores: Fe = 65.95% Al 2 O 3 = 1.45% Feed Ores New CSIR for New India Advanced Sensor based Advanced Sensor based Technique for Iron Ore Sorting Technique for Iron Ore Sorting

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