a general survey on ndt in the chemical industry · 2006. 11. 8. · andreas hecht + peter rost,...
TRANSCRIPT
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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
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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
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 3
LudwigshafenVerbund SiteThe BASF Site Ludwigshafen –
the world’s largest integrated chemical complex
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 4
LudwigshafenVerbund Site
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
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 5
LudwigshafenVerbund SiteInvisible contribution. Visible success.
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 6
LudwigshafenVerbund SiteFrom Naphtha to Napkins:
Superabsorbers from BASF
Super-absorbersNaphtha Propylene
Acrylic acid pure
Acrylic acidcrude
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 7
LudwigshafenVerbund SiteObjects in Chemical Plants
Subject to NDT
Storage Tank
High-Pressure Reactor
Sphere for Pressurized Gas Storage
Process Piping
Column
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 8
LudwigshafenVerbund Site
Economy(no down-time) Safety
Legal Requirements
- European- National
Why are Inspections of Chemical Equipment Necessary ?
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 9
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
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 10
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
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 11
LudwigshafenVerbund SiteExample 1
Shell & Tube Heat-Exchanger of Cat. IV
OperationManufactureDesign
consists ofn shelln 2 end-covers (bonnet, hood)n at least 4 nozzlesn 2 tubesheetsn tubes
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 12
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
OperationManufactureDesign
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 13
LudwigshafenVerbund SiteShell & Tube Heat-Exchanger
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
OperationManufactureDesign
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 14
LudwigshafenVerbund SiteShell & Tube Heat-Exchanger
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
OperationManufactureDesign
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 15
LudwigshafenVerbund SiteShell & Tube Heat-Exchanger
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
OperationManufactureDesign
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 16
LudwigshafenVerbund SiteShell & Tube Heat-Exchanger
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
OperationManufactureDesign
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 17
LudwigshafenVerbund SiteShell & Tube Heat-Exchanger
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)
ManufactureDesign Operation
1 2
3
vessel for gas - fluid group 1
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 18
LudwigshafenVerbund SiteShell & Tube Heat-Exchanger
In-Service-Inspections (German View)
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
ManufactureDesign Operation
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 19
LudwigshafenVerbund SiteShell & Tube Heat-Exchanger
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 ?
OperationManufactureDesign
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 20
LudwigshafenVerbund SiteShell & Tube Heat-Exchanger
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 ??
ManufactureDesign Operation
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 21
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 ......
OperationManufactureDesign
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 22
LudwigshafenVerbund SiteProcess Piping
NDT of Pressure Equipment Parts
OperationManufactureDesign
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)
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 23
LudwigshafenVerbund SiteProcess Piping
NDT of Welds (mainly circumferential)
OperationManufactureDesign
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
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 24
LudwigshafenVerbund SiteProcess Piping
Final Acceptance & Leak Test
OperationManufactureDesign
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
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 25
LudwigshafenVerbund Site
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
In-Service-Inspections (German View)
ManufactureDesign Operation
process piping for inflammable and hazardous gases
1
2
3
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 26
LudwigshafenVerbund SiteProcess Piping
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.)
ManufactureDesign Operation
UT wall-thickness measurement off-stream
RT wall-thickness measurement on-stream
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 27
LudwigshafenVerbund SiteProcess Piping
In-Service-Inspections (Methods)
ManufactureDesign Operation
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
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 28
LudwigshafenVerbund SiteProcess Piping
In-Service-Inspections (on-Stream Methods)
ManufactureDesign Operation
Detection of corrosionunder pipe-supportMagna-Tec
VT corrosion scanningCorrScan
Detection of corrosionunder insulationIncotest
Detection of corrosionover long distancesTeletest
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 29
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
ManufactureDesign Operation
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Andreas Hecht + Peter Rost, BASF AG ECNDT-Berlin, Sept. 2006, Fr.1.2.1 30
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
OperationManufactureDesign