Section 7 Materials Inspection Scanned with CamScanner7 Materials Inspection 7.1 General One of the duties of the visual/welding inspector is materials inspection and there are a number of situations where this will be required: = At the plate or pipe mill ® During fabrication or construction of the material. = After installation of material, usually during a planned maintenance Programme, outage or shutdown. A wide range of materials can be used in fabrication and welding and include, but is not limited to: Steels. Stainless steels. ‘Aluminium and its alloys. Nickel and its alloys Copper and its alloys. Titanium and its alloys. Cast iron. ‘These materials are all widely used in fabrication, welding and construction to meet the requirements of @ diverse range of applications and industry sectors. There are three essential aspects to material inspection that the Inspector should consider: = Material type and weldability. = Material traceability. = Material condition and dimensions. 7.2 Material type and weldability A welding inspector must understand and interpret the material designation to check compliance with relevant normative documents. For example materials standards such as BS EN, API, ASTM, the WPS, purchase order, fabrication drawings, quality plan/contract specification and client requirements. A commonly used material standard for steel designation is BS EN 10025 ~ Hot rolled products of non-alloy structural steels. A typical steel designation to this standard, S355)2G3, would be classified as follows: s Structural steel. 355 Minimum yield strength: N/mm? at t < 16mm. 32 Longitudinal Charpy, 27Joules 20°C. G3 Normalised or normalised rolled. Commonly used materials and most of the alloys can be fusion welded using various welding processes, in a wide range of thickness and where applicable, diameters. Reference to other standards such as 150 15608 Welding - Guidelines for @ metallic material grouping system and ste! producer and welding consumable data books can also provide the inspector with guidance as to the suitability of a material and consumable type for a given application. hte) Scanned with CamScanner73 2.4 7.41 Alloying elements and their effects Iron Fe Carbon C Strength Manganese Mn Toughness Silicon Si < 0.3% deoxidiser Aluminium Al Grain refiner, <0.008% deoxidiser + toughness Chromium Cr Corrosion resistance Molybdenum Mo 1% is for creep resistance Vanadium V- Strength Nickel Ni Low temperature applications Copper Cu Used for weathering steels (Corten) Sulphur S Residual element (can cause hot shortness) Phosphorus P Residual element Titanium Ti Grain refiner, used as a micro-alloying element {strength and toughness) Niobium Nb Grain refiner, used as a micro-alloying element (strength and toughness) Material traceability Traceability is defined as the ability to trace the history, application or location of that which is under consideration. With 2 welded product, traceability may require the inspector to consider the: = Origin of both parent and filler materials. = Processing history - for example before or after PWHT. = Location of the product - this usually refers to a specific part or sub- assembly. To trace the history of the material, reference must be made to the Inspection documents. BS EN 10204 Metallic products ~ Types of inspection documents is the standard which provides guidance on these types of document. According to BS EN 10204 inspection documents fall into two types: Non-specific inspection Cerried out by the manufacturer in accordance with his own procedures to assess whether products defined by the same product specification and made by the same manufacturing process, comply with the requirements of the order. = Type 2.1 are documents in which the manufacturer declares that, the products supplied comply with the requirements of the order without inclusion of test results. = Type 2.2 are documents in which the manufacturer declares that the products supplied comply with the requirements of the order and includes test results based on non-specific inspection. Scanned with CamScanner7.4.2 Specific inspection Inspection carried out before delivery according to the product specification on the products to be supplied or test units of which the products supplied are part, to verify that these products comply with the requirements of the order. = Type 3.1 are certificates in which the manufacturer declares that the products supplied comply with the requirements of the order and in which test results are supplied. = Type 3.2 are certificates prepared by both the manufacturer's authorised inspection representative independent of the manufacturing department and either the purchaser's authorised representative or the inspector designated by the official regulations and in which they deciare that the products supplied comply with the requirements of the order and in which test results are supplied. Application or location of a particular material can be carried out through @ review of the WPS, fabrication drawings, quality plan or by physical inspection of the material at the point of use. In certain circumstances the inspector may have to witness the transfer of cast numbers from the original plate to pieces to be used in production. On pipeline work it is @ requirement that the inspector records all the relevant information for each piece of linepipe. On large diameter pipes this information is usually stencilled on the inside of the pipe, On smaller diameter pipes it may be stencilied along the outside of the pipe. Eas Prete cer Ae) Scanned with CamScannerBS EN 10204: Metallic materials Summary of types of inspection documents. Non-specific inspection* May be replaced by specific inspection if specified in the material standard or the order. Inspection document Type 2.1 Inspection document Type 2.2 Deciaration of compliance with Test report. the order. Statement of compliance with Statement of compliance with the order, with indication of the order. results of non-specific Validated by manufacturer. inspection. Validated by manufacturer. Specific inspection Quality management system of the material manufacturer certified by a competent body established within the community and having undergone a specific assessment for materials. Inspection certificate Type 3.1 Inspection certificate Type 3.2 = Statement of compliance with ||] = Statement of compliance with the order with indication of the order with indication of results of specific inspection. results of specific inspection. Validated by manufacturer's ||] = Validated by manufacturer's authorised inspection authorised inspection representative independent of representative independent of the manufacturing department. the manufacturing department and either the purchaser's authorised inspection representative or the inspector designated by the official regulations. Scanned with CamScanner7.5 Material condition and dimensions The condition of the material could have an adverse effect on the service life of the component so is an important inspection point. The points for inspection must include: General inspection. Visible imperfections. Dimensions. Surface condition. General inspection This takes account of storage conditions, methods of handling, number of plates or pipes and distortion tolerances. Visible imperfections Typical visible imperfections are usually attributable to the manufacturing process and include cold laps which break the surface or laminations if they appear at the edge of the plate. Ultrasonic testing using 2 compression probe may be required for laminations which may be present in the body of the material Figure 7.1 Cold Figure 7.2 Plate lamination. Dimensions For plates this includes length, width and thickness. For pipes this includes length and wall thickness and also inspection of diameter and ovality. At this stage of inspection the material cast or heat number may be recorded for validation against the material certificate. Surface condition ‘The surface condition is important and must not show excessive millscale or rust, be badly pitted or have unacceptable mechanical damage. Rte} Scanned with CamScannerThere are four grades of rusting which the inspector may have to consider: Figure 7.3 Rust Grade A. Steel surface largely covered with adherent miliscale with little or no rust. Figure 7.4 Rust Grade B. Steel surface which has begun to rust and from which mill scale has begun to flake. Figure 7.5 Rust Grade C. Steel surface on which the mill scale has rusted away or from which it can be scraped. Slight pitting visible under normal vision. Figure 7.6 Rust Grade D. Steel surface on which mill scale has rusted away. General pitting visible under normal vision. CZs Scanned with CamScanner7.6 Summary Material inspection is an important part of the inspector's duties and an understanding of the documentation involved is key ta success. Material inspection must be approached in a logical and precise manner if material verification and traceability are to be achieved. This can be difficult if the material is not readily accessible, access may have to be provided, safety precautions observed and authorisation obtained before material inspection can be carried out. The quality plan should identify the level of inspection required and the point at which inspection takes place. A fabrication drawing should provide information on the type and location of the material. If material type cannot be determined from the inspectian documents available or the inspection document is missing, other methods of identifying the material may need to be used. These methods may include but are not limited to: Spark test, spectroscopic analysis, chemical analysis, scleroscope hardness test, etc. These types of test are normally conducted by 2n approved test house but sometimes on- site and the inspector may be required to witness them to verify compliance with the purchase order or appropriate standard(s). ‘EN ISO 9000 Quality management systems ~ Fundamentals and vocabulary. Scanned with CamScannerMaterial Inspection Ty Material inspection Objective ents presen nas been cited ou case ny Material Inspection A materia amvng on ste sould be tage ive ie 1 ptt In aceition other elements may need to be cconsicered depending en the rratenils form or shape. rw Pipe Inspection Condition (corsson, dersage, wall thickness, vat, {amiratiane ana ena) Welded sea spuctenton ‘other checks may nee foearee, norber ep ny Pir napection Condition (corresion, mechanical damage, lsps bands end lems tions) Specification ‘Other checks may need to be made such as distortion tolerance, number of plates end storage TW Roting Tmperfections exer tng ein conta Lamination Segregation Scanned with CamScannerie Parent Material Imperfections aches damage P: Lam nation Segregation Ine Laminations are caused in the parent plate by the steel making process, originating fram ingot easting defects ‘Segregation bands occur in the contre of the plate and are low ‘meking paint impurities such as sulphur and phosphorous, Laps are caused during roling when overlapping metal does nat fase to the base material, Lamination | [EWI Lamination Plate lemination Scanned with CamScannerAny Questions ? 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