Material Inspection

MATERIAL INSPECTION

TABLE OF CONTENT: 1. Materials used in Saudi Aramco 2. Incoming Material Inspection 3. Visual Inspection – Rust Grades 4. Alloying elements and there effects 5. Special Materials (DSS, SDSS and P91) 6. Storage and preservation 7. Type of Inspection Documents 8. Review Of Material Test Certificate

MATERIAL USED IN SAUDI ARAMCO  

Pipes:I. Carbon Steel : - ASTM A53 Gr. A/B, ASTM A106 Gr. A/B/C, ASTM A333 Gr.1/Gr.6 II. Alloy Steel :- ASTM A335 Gr.P1/P2/P5/P7/P9/P11/P12/P22. III. Stainless Steel :- ASTM A312TP304/TP304L/TP304H/TP308/TP310/TP316/TP316L/ TP316H/TP317/TP321/TP321H/TP347/TP347H/TP348/TP348H. IV. Nickel Steel :- ASTM A333Gr.3/ Gr.8.

MATERIAL USED IN SAUDI ARAMCO Plates: I. Carbon Steel :- ASTM A285, ASTM A515, ASTM A516. II. Alloy Steel :- ASTM A387 Gr.2/Gr.5/Gr.7/Gr.9/Gr.11/Gr.12/Gr.22. III. Stainless Steel :- ASTM A240 TP410/TP405/TP430/TP304/TP304L/TP309/TP310S/ TP316/TP316L/TP317/TP321/TP347/TP348 IV. Nickel Steel :- ASTM A203 Gr.D/Gr.E, ASTM A353.

MATERIAL USED IN SAUDI ARAMCO Tubes:I. Carbon Steel :- ASTM A178/179/192, ASTM A334 Gr.1/6. II. Alloy Steel :- ASTM A161T1, ASTM A213T1/T2/T5/T7/T9/T11/T12/T22. III. Stainless Steel :- ASTM A213 TP304/TP304L/TP304H/TP310/TP316/TP316L/TP316H/ TP317/TP321/TP321H/TP347/TP347H/TP348/TP348H, ASTM A608 HK40. IV. Nickel Steel :- ASTM A334Gr.3/Gr.8

MATERIAL USED IN SAUDI ARAMCO Wrought Iron fittings :I. Carbon Steel :- ASTM A234Gr.WPA/B, ASTM A420 Gr.WPL6. II. Alloy Steel :- ASTM A234 WP1/WP5/WP7/WP9/WP11/WP12/WP22. III. Stainless Steel :- ASTM A403 WP304/WP304L/WP304H/WP309/WP310/WP316/ WP316L/WP316H/ WP317/WP321/WP321H/WP347/WP347H/ WP348. IV. Nickel Steel :- ASTM A420WPL6/WPL8.

MATERIAL USED IN SAUDI ARAMCO Forged Fittings : I. Carbon Steel :- ASTM A181. ASTM A105, ASTM A350 LF1/2. II. Alloy Steel :- ASTM A182F1/F2/F5/F7/F9/F11/F12/F22. III. Stainless Steel :- ASTM A182F6/F304/F304L/F304H/F310/F316/F316L/F316H/F321/ F321H/F347/F347H/F348. IV. Nickel Steel :- ASTM A350 LF3, ASTM A522.

MATERIAL USED IN SAUDI ARAMCO E. Cast Fittings: I. Carbon Steel :- ASTM A216, ASTM A352 LCB/C. II. Alloy Steel :- ASTM A217 WC1/WC6/WC9/C5/C12. III. Stainless Steel :- ASTM A217 CA15, ASTM A296 CA15, ASTM A351 CF8/CF3/CH20/ CK20/CF 8M/CF 3M/CF 8C/HK40. IV. Nickel Steel :- ASTM A352LC3.

INCOMING MATERIAL INSPECTION 1. Pipe 2. Plate 3. Tubes 4. Wrought Iron Fittings 5. Forged Fittings 6. Cast Fittings 7. Electrodes and Filler Wire 8. Paints 9. Hardware

VISUAL INSPECTION – RUST GRADES Rust Grade A- Steel surface largely covered with adhering mill scale with little or no rust. Rust Grade B: Steel Surface which has begun to rust and from which the mill scale has begun to flake. Rust Grade C: Steel Surface on which most of the mill scale has rusted away or from which it can be scraped and with slight pitting visible. Rust Grade D: Steel Surface on which mill scale has rusted away and on which heavy pitting is visible.

Rust Grade A

Rust Grade B

Rust Grades C

Rust Grades D

ALLOYING ELEMENT AND THEIR EFFECTS Element

Effects

Carbon

For strength

Manganese

For toughness

Silicon

< 0.3 % deoxidizer

Aluminium

Grain refiner, < 0.008 % deoxidizer + toughness

Chromium

Corrosion resistance

Molybdenenum

1% is for creep resistance

Vanadium

Strength

Nickel

Low temperature application

Copper

Used for weathering steels (Corten)

Sulphur

Residual element (can cause hot shortness)

Phosphorus

Residual element

Titanium

Grain refiner, used as a micro alloying element (S & T)

Niobium

Grain refiner, used as a micro alloying element (S & T)

S & T = Strength and Toughness

SPECIAL MATERIALS (DSS) Properties of Duplex Stainless Steels • • • • • • • • •

High resistance to uniform corrosion. High to pitting and crevice corrosion. Good resistance to stress corrosion cracking and corrosion fatigue. High mechanical strength. Good sulfide stress corrosion resistance. Good abrasion and erosion resistance. Good fatigue resistance high energy absorption. Low thermal expansion. Good weldability.

SPECIAL MATERIALS (DSS) Ferrite Readings 1. Point Count Method Purpose: Determines % ferrite Additional Details: • WPS and PQR generally uses point count method. • Check α–ϒ balance for entire weldment thickness. Optimal ferrite content between 35-60%

SPECIAL MATERIALS (DSS) 2. Hardness survey Purpose: Check maximum allowable hardness Additional Details: • Depends on DSS grade and service environment • Recommended not to exceed HV 10 310 • Caution: Conversion from Vickers hardness to Rockwell for DSS is not represented by ASTM E140. Refer to API-938C, Figure 2, for hardness conversions.

SPECIAL MATERIALS (DSS) 3. Impact Testing Purpose: Toughness measurement Additional Details: • Typically associated with minimum design temperature and engineering recommendations • EN specifies minimum 60J at room temperature • Frequent requirements for parent and weld metal are minimum 45J average at -46°C per ASTM A923 Method B. The narrow HAZ precludes accurate impact measurements in isolation.

SPECIAL MATERIALS (SDSS) Properties of Super Duplex Steel S32760 • • • • • • • •

Guaranteed corrosion performance. Excellent corrosion resistance in mineral acids such as hydrochloric and sulfuric acids. High resistance to pitting and crevice corrosion. Excellent resistance to stress corrosion cracking in both chloride and sour environments. High resistance to erosion, corrosion and corrosion fatigue. Excellent mechanical properties. Possibility for weight reduction over austenitic, standard duplex and nickel base alloys. Good weldability.

SPECIAL MATERIALS (P 91) Properties •

91 contains 9 % Chromium and 1 % Molybdenum compared to 2.5 % Chromium in the next best P22 grade. Chromium improves high temperature strength and increases oxidation resistance. Molybdenum increases the creep resistance. Also present are smaller quantities of Nickel and Manganese which increase the hardenability of the steel.

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Grade 91 exhibits high strength up to temperatures in the range of 600 °C. Also the oxidation temperature limits are higher.

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Higher thermal fatigue life of almost ten times. This allows them to increase the operating temperature to a higher level, increasing the efficiency of the plant.

STORAGE AND PRESERVATION OF THE MATERIALS Checkpoint during visit to storage areas. •

Based on the materials like CS, SS, wooden pallets, etc.

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Materials not to be placed directly on soil

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Desiccants

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Paint Storage

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Electrode Storage

TYPES OF INSPECTION DOCUMENTS Non – Specific Inspection

Inspection document type 2.1

Inspection document type 2.2

Specific Inspection

Inspection certificate type 3.1

Inspection certificate type 3.2

REVIEW OF MATERIAL TEST CERTIFICATE •Material Specification •Heat No. •Batch No. •Manufacturers name and Logo •Mechanical Properties •Chemical Analysis •Any special requirements

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