Operations Manual for Kubota Carburization Detectors KCD100X Revision Dec 2008, Kyhota Kubota Corporation Kubota Metal Corporation[Table of Contentel Introduction How to Use the Kubota Carburization Detector 11 Calbation ofthe detector 42 Taking measurements with the oarbrzation dtecter 18 Meintainng your carburization detector 14 Aévonced uss of the carburization detector Determining where to outa tub fr repair wong ‘Conducting #earbceation suey 15 Footors which affest the accuraoy of the oxrbrzatin detectors {0 How to remove the Battery ist of Feros) Figaet+ Kobota KCDIO0K emburzation detector nits Figwe 2 Schomatic of tamary hase daram showing tantlon fom noo ‘magnetic to feromagrti Figure 8: Sohametio of operation of carburization detectr Figue Placement of probe on eabration block for X senor calibration, Figure: Placement of robe on calation block for Y sonsorealbvaton, Figure 6: ‘Schematic showing proper placament of KCDI00 probe Figure 7: ‘Table prepared fr carburization survey reags Figure 8; Average oxburzaion rndings in tubes 1 though 22 Figure 8: Average arbwieation roudings in tubes 1 hough 22. gure 10 Relatonchip of Mencring Valine and Carbursed Dapth on HP Alay Figur. Relationship of Measuring Valuos and Carburized Depth on HKAO CCaburizaton Measuramant curve of KHRASA Tube Fue 12, Fikwe 12 How to remove the BateryIntroduction ‘The Kubota carburization detectors KCD100X, shown in Figure 1, wore developed specifically to non-destructvely measure carburization in cast heat rosistant alloys The units work onthe principle that depletion of chromium in a localized region due to ‘de, nie, and carbide formation causes a change in the magnetic properties ofthat region. As iustrated in Figure 2, HP alloys are transformed from non-magnetic to {erromagnetic due to oxidation, niridation, and carburization, Figure 1: Kubota KCD100X carburization detector units ‘The use of a hand held magnet has long been used to qualitatWoly determine whore carburization has occurred these materials. The limitations ofthis method are: + grinding is necessary to remove the magnetic oxide layer + iis dificalt or impossible to completely remove the magnetic nitide layer, + a magnet may give a false reading when an oxide scale is present, + amagnot isnot sensitive; + amagnetis not consistent and repeatable. \With traning provided by Kubota metallurgical personnel, customers can use the instrument in many ways to achieve various benefits: ‘id in predicting furnace fe; + determine furnace temperature profiles and bumer behaviour, + identify hotspots; + determine best piacement fr thermocouples; + balancing the system; + distinguish between tube elongation due to creep and that due to carburization; + reduce time to conduct wold repairs by knowing where not to wold, + get an actual value for tho amount of carburization and not just a subjective fool ‘of low, moderate, or high.Figure 2: Schematic of terary phase diagram showing transition from non-magnetic to ferromagnetic. cr * caurzed ier © osoas ter esi oh Nd SARL \ AREA ‘Schama usta of change a to ee emis ave atten and eson. Fe’ Ni ‘The OD. surface oxide layer is thin, usually loss than 0.5 mm deep, and is formed ‘continuously due to heating in at. Below ths area a region i formed that contains nlrides. "This nitride layer is formed after a poriod of many months to years of ‘exposure. Both thase layers interfere withthe magnetic fx trough to the LD. carburized layer. Therefore Kubota has developed a probe containing two magnets. The first, X, determines the response through the entre wall thickness, while the second, ¥, a short range magnet, measures the magnetic response from the O.D. surface oxide and nie layers. The signal from the short range magnet is then electronically removed from that of the long range magnet, The resultant signal is then displayed at the unit. This processis shown schematically In Figure 3 For materials like HI40 and the more advanced high chromium, high nickel carburization resistant alloys the carburization works slightly diferently. As shown ‘above in Figure 2, these alloys do not develop a magnetic oxide layer, only a magnetic carburized layer. | This is because oxidation in these alloys dos nol generally deplete the surrounding matrix of enough chromium to cause the mati to become ferromagneticFigure 3: Schematic of poration of carburization detector. eo1a0K: Probe eer Using calibration curves these signal values can be converted ito the percent wall thickness that has beon carburized. Calibration curves must be developed for each Individual alloy and also for diferent wall thicknesses and tube diameters. The KCD100X unit was developed for use on tubes undor 10 mm wall thickness, How to Use the Kubota Carburization Detector “The Kubota carburization detector is simple in design and can be used with a minimum ‘amount of training. However certain procedures must be followed to achieve the best results. The fist step isto determine what alloy you willbe examining. The alloy type will determine how you calibrate, measure, and wat formula you will use to conver the ‘number shown on the detector into % wall carburized, 1H Calibration of the dotoctor While performing the callration ensure that no magnetic or electronic materials are close to the probe. Each carburization detectors supplied with a calibration black, Ths block must be used to calibrate tho unit everytime itis powered up. . When long carburization surveys are performed, the unit should be calibrated periodically to maintain consistency. ‘Step 1: Tum on the unit and set the positon indicator o "Xx". Use the supplied Jowollrs scroweliver to zero the indian Stop 2: Repeat the zeroing procedure fr the "Y* indicator. Step 3: Figures 4 and 5 show how the block is used to calibrate the two signals. Fist the X side of the probe is line up withthe X side ofthe calibration block. With the unit toggled to the X positon adjust *X cal" with the screwdriver untl the unit displays the value of 95, Step 4: Repeat the procedure wih the Y side of the probe, using the Y side of the calibration block, unt the reading shows 100 Step 5: For HP based materials, tum the indicator to X+Y, Ifyou are examining Hk or advanced materials such as KHR4SA, set the indioator to the X setting, ‘Step 6: Hold the probe in the air to make sure that the reading is O. 5Figure 4: Placement of probe on callbration black for X sensor calibration. Figure §: Placoment of probe on calibration block for Y sensor calibration. #2Taking measurements with the carburization detoctor Please note: The readings performed withthe Kubota carburization detector ar taken {rom the middle of the X sensor, ie: ust below the while circle inscribed onthe top of the X sensor. This is important if you are attempting to determine the amount of ‘carburization that has occurred in small area, For HP materials: Siep 1: After the unit has been calibrated, turn the indicator to "X +" and place the probe flat on the piace to be measured; Siep 2: Centre the middle ofthe X sensor diretly over the area to be measured 6‘Step 3: Record the X-¥ reading, ‘Stop 4: Calculate the actual depth of carburization using the equation or curves provided by Kubota Research and Development Department For HK and KHR&5A: Use the same procedures as above, except the indicator is to be set to the“ and only the X reading i to be recorded, position Figure 6: Schematic showing proper placement of KCD100 probe. a AR le +43 Maintaining your carburization detector Periodic maintenance is required forthe Kubota carburization detector. Two pieces {end to wear out, the Teflon probe base and the probe cable. The probe cable should be examined for loose connections and excessive abrasion, if either I present the Cable should be replaced or repaired. The Teflon base wears out due to abrasion from lube surfaces. Before the base wears through it should be replaced with afresh base ‘supplied as a spare vith your detector. Use the machine screws provided with your tector, They are non-magnetic and will not interfere with the probe. The use of ‘magnetic scrows can interfere with detector readings.14 Advanced uses of the carburization detector Determining wiere to cut a tubo for repair welding Replacing a heavily carburized tube with a repair pup is an easy process with tho carburization detector. ‘The proper use ofthe instrument wil allow maintenance personnel to remove a section and reweld a replacment section onthe fst alert. Placa the detector probe fat on the tube as shown in Figure 6. Slowly move the probe Up the tube length from the affected area untl the X-Y reading consistently shows Under a value previously determined as being acceptable for weld repair. Move the probe around tho circumference ofthe tubo as well fo ensure that tho entire wall is suitable for ewelding. Mark this area and repeat the procedure forthe tube below the affected area, ‘Conducting a carburization suey ‘One ofthe most informative uses ofthe carburization detectors the ability o chart the ‘operation of a fumace through the use of carburization measurements. Since the ‘amount of carburization is related tothe temperature of an area, the carburization ‘survey creates a furnace map with shows process hot spots. This ype of information ‘can help a process designer to optimize process efficiency and reduce the severly of trouble spots ina furnace. The complexity ofa carburization survey is dependent on the time available during shutdown. KUBOTA sales and research personnel have conducted numerous surveys ‘on which the folowing advice is based: 8) Prior to shuldown create a schematic ofthe fumace layout including all inlet tubes, ‘outlet tubes, bumers, and other ilems of interest. Indicate major directions on the diagram. 9. north, south, east, west. 'b) Determine the height ofthe furnace interior and estimate the number of readings {that willbe taken and the length of timo required to perform the survey. For example, ‘one furnace of 80 tubes, 40 foot high wil ake 2 to 3 shifts to complete a survoy it ‘measuromenis are taken on 4 sides every 2 feet. Create a blank form such as shown In Figure 7 on which to record carburization readings. ©) When the fumace has been scaffolded mark the tubes (using an approved maker only) at regular intervals, such as every two feet, fom a common reference point such 1a a tube to return bend wal. 4) Conduct the survey by taking readings at North, South, East, and West positions on every tube at every height interval, Have a second person record these readings in tho tablo previously created, €) When the survey is complete, develop a sproadshaet to calculato the percentage of ‘carburization that has occurred through the wal thickness. Present ths information in ‘graphical form such as shown in Figures 8 and 8. These figures represent 8‘carburization survey performed on a furnace with a serpentine coll arrangement. “Tubes 1 and 22 are nets, while tubes 11 and 12 are outa, 445 Factors which affect the accuracy of the carburization detectors 4) improper placement ofthe probe on the surface; 1) improper calibration ofthe unit; ©} use of KCD100X on tubes with heavy wall thickness (> 10 mm); «)_lack of calibration curves and equations for the particular alloy, wall thickness, and {ube diameter; {} use of magnetic screws in the probe rather than those supplied with the detector; 1) large bumps or weld deposits which interfore wih tho proper placoment of the dotector. ‘6 How to romove the Battery (Figure 13) Pressing atthe point shown inthe Figure 13, slide the Battery cover in the direction Indicated by te arrows. Press the spring withthe (-) ends of the Ballery and remove the Battry.Kubota, onounsnon saver tae Figure 7: Table prepared for carburization survey readings 10on ox lox box aos ros cox Figure 8° Average carburization In furnace tubes 1 trough 22. 1"sos Lo loon. eow How Joow. Figure 8: Average carburization readings in tubes 1 through 22. 30 forma 12ners ate) Figure 10: Relationship of Measuring Values and Carburized Depth on HP Alloys d Figure 11: Relationship of Measuring Values and Carburized Depth on HK40 Alloys, 13[Tube Thickness : 7.5mm x Readings Carburization Depth fom Inside (mm) Fgwo 12: Carwuzaion Measurement curve of KHRASA Tube aoe (Dssideans ope he bate cover remote bate cover @Remave te tatey Figure 13: How to remove the Battery 1"