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Evaluation of
Structural
Integrity
a perspective of
research activities at
the
CSIR-NML
Demand on Engineering Components
Higher Efficiency
• Higher Stress Levels
• Higher Pressures
• Higher Temperatures
• Higher Speeds
• More Severe Environments
vs
New CSIR for New India
Increasing Costs
Cheaper Materials •
Stronger Material •
Lower Section Area •
Lower Factors of Safety •
Life Extension •
GRAVE CONSEQUENCES OF FAILURE
Initiatives at CSIR-NML
1974
New CSIR for New India
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
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
Material Evaluation Facility Today
New CSIR for New India
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
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
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
Elements of Structural Integrity
New CSIR for New India
Assessment of Engineering
Materials & Components
New CSIR for New India
Validation
Quantitative Danmage
Index
Damage
Resistance data
Full-scale Testing
Codes &
Software
Simulation
&
Modelling
Ageing Parameter
Non-destructive
Surveillance
Documented
information
In-service Critical
Structural Components
Material
Characterisation
Experimenta
l Evaluation
Refurbishment of Engineering
Materials & Components
New CSIR for New India
In-service Critical
Structural Components
Sensor Integration
Surface Engineering
Giant Magneto-impedance Sensor
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
600
exposure.
Reactor -3
Johnson
In-water quenching system at NML &
Nanostructured wires prepared
Giant Magneto-Impedance based Sensing Device
developed at NML
GMI voltage (mV)
Screen
400
Highly
Carburise
d
area
200
Reactor-1
0
Bottom 0
50
100
150
200
Height from bottom (cm)
250
GMI sensor response on plastically deformed in 304
SS
17% martensite
GMI Probe with
nanostructured wire as
sensor element
GMI based
Sensing device
Sensor(mV)
400
300
12% martensite
200
0% martensite
100
1
80
)
(mm
40
n
atio
Loc
60
2
20
3
0
A Portable Magnetic Sensing
Device (MagStar)
New CSIR for New India
120
9Cr-1Mo Steel
0.45
0.40
110
0.35
100
0.30
90
0.25
80
0.20
700
750
800
850
900
950
Tempering Temperature (oC)
Magnetic Hysteresis loop (MHL) &
Magnetic Barkhausen Emission (MBE) System
MBE Voltage (Vrms)
Magnetic Coercivity (Oe)
for NDE of damage assessment of steel structures/components
Non-Linear Ultrasonic for
Structural Damage Evaluation
Why NLU?
New CSIR for New India
NLU parameters are more sensitive to structural damages
(Fatigue, Creep, Corrosion etc…) than linear ultrasonic
wave characteristics; velocity, amplitude or attenuation
Initiatives at CSIR-NML
 Establishment of correlation between
NLU parameter with fatigue damage
and pitting corrosion
Globally First Portable
Non-Linear UT System
Developed at
CSIR-NML, India
 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
Advanced Sensor based
Technique for Iron Ore Sorting
New CSIR for New India
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
Reject
Ores
Feed Materials:
Fe = 64.5%
Al2O3 = 2.49%
Accept Ores:
Fe = 65.95%
Al2O3 = 1.45%