Section_III_Bareiß-Baumann

VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

VBG R 109 Material specification for components under pressure

in fossil-fired power plants and quality assurance in the field of materials for

new power plants

Dr.-Ing. Jörg Bareiß, EnBW Kraftwerke AG, Stuttgart

Dipl.-Ing. Olaf Baumann, VGB PowerTech e.V., Essen

VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Target of the Specification

Creation of a uniform material specification

Creation of clear stipulations for ordering semi-finished products on the base of EN standards

Addition of ordering criteria in excess of EN standards

Collection of experience and recommendation of all parties

Acceptance for a general application

International application

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Structure1. Abbreviations

2. Terminology

3. Field of application

4. Basis of the material acceptance

5. Requirements on the material manufacturers or suppliers

6. Requirements on the materials for pressure equipment

7. Further processing within the component manufacturer

8. Test activities within the material inspection

9. Occurrences, deviations

10. Order placed with the material manufacturers or suppliers

11. Additional regulations

12. Castings

13. List of material data sheet13.1 til 13.12 – separately shown materials

14. Requirements on filler material3

VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Topics

General points

Abbreviations, Terminology, General

Requirements on the material manufacturers or suppliers

Requirements on the materials for pressure equipment

Further processing within the component manufacture

Test activities within the material inspection

Occurrences, deviations

Castings

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Topics

Description of order requirements for not separately listed Materials in the

specification

Sheet metal according to DIN EN 10028

Forged pieces according to DIN EN 10222 (Open-die forgings),

DIN EN 10273 (rods), DIN EN 10272 (rods) and

DIN EN 10254 (Closed-die drop forgings)

Welded tube according to DIN EN 10217 for the hot yield strength range

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Topics

Seamless tubes of stainless steel

hot yield strength range

creeping range

Seamless temperature – resistant tubes according to DIN EN 10216-2

hot yield strength range

creeping range

Binding stipulations options for specific semi-finished products depending on the

application area collected in the EN standards

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Topics

Additional regulations e.g.

Exclusions

Additional requirements for collected components

Marking of semi-finished products

Corrosion-protection measures

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

TopicsDescription of order requirements based on the respective mentioned material

depending on the knowledge according to the availability of semi-finished

product forms

General agreements

Additional requirements for

− flat products

− tubes and tube bends

− forged pieces8

VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Example – X10CrWMoVNb9-2General agreements

material expert opinion

manufacturing processes, quenching and tempering treatment

heat analysis, parts analysis

mechanical-technological properties

microstructure verification

hardness testing, surface examinations

acceptance test certificates9

VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Beispiel / Example – X10CrWMoVNb9-2- Werkstoffbegutachtung / material expert opinion -

1. Der Werkstoff P/T 92 kann, insoweit er noch nicht in der DIN EN 10216-2 aufgeführt ist, nur dann eingesetzt werden, wenn vor dessen Einsatz in Anlagen eine Begutachtung nach der Druckgeräterichtlinie 97/23/EG nach Anhang I Ziffer 4.2 in Verbindung mit DIN EN 764-4 vorliegt.

1. If not already listed in DIN EN 10216-2, the material P/T 92 can only be used, if prior to its use in plants an expert opinion is enclosed according to the pressure equipment directive 97/23/EC in accordance with Appendix I, Section 4.2 in connection with DIN EN 764-4.

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Beispiel / Example – X10CrWMoVNb9-2- Herstellungsverfahren / manufacturing processes -

2. Es dürfen nur überprüfte Erschmelzungsverfahren(Elektro-Lichtbogenverfahren mit Vakuum-Entgasung oder geeigneter Nachbehandlung) angewandt werden. Diese sind im Zeugnis aufzuführen.

2. Only controlled melting processes (electric arc process with vacuum degassing or appropriate after-treatment) may be applied. These must be listed on the certificate.

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Beispiel / Example – X10CrWMoVNb9-2- Schmelzanalyse / heat analysis -

3. Die Schmelzanalysen sind bezogen auf das Halbzeug im Zeugnis aufzuführen. - nahtlose Rohre nach

DIN EN 10216-2 - Schmiedestücke in Anlehnung

an DIN EN 10216-2 Der Analysengehalt für Cu ist auf max. 0,3 % begrenzt und in der Prüfbescheinigung auszuweisen.

3. The heat analysis relating to the semi-finished product must be listed on the certificate.- seamless tubes according to

DIN EN 10216-2- forged pieces in accordance

with DIN EN 10216-2The analysis content of Cu is limited to max. 0.3 % and must be shown on the test certificate.

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Beispiel / Example – X10CrWMoVNb9-2- Stückanalyse / parts analysis -

4. Die Stückanalyse erfolgt bei Rohren und Schmiedestücke über 142 mm Außendurch-messer an einem Teil je Schmelze.Für die Abweichungen von der Stückanalyse ist die Tabelle 5 der DIN EN 10216-2 heran-zuziehen.

4. The parts analysis is performed for one part per heat on tubes and forged pieces exceeding an outside diameter of 142 mm.

For the deviation from the parts analysis refer to Table 5 of DIN EN 10216-2.

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Beispiel / Example – X10CrWMoVNb9-2- Vergütungsbehandlung / quenching and tempering treatment -

5. Die Vergütungsbehandlung ist in Bezug auf die Temperatur-höhe, Haltezeit und das Abkühlmedium nach dem Normalisieren sowie in Bezug auf die Anlasstemperatur im Zeugnis anzugeben. Die Normalisierungstemperatur für Rohre und Schmiedestücke soll mindestens 1050 °C betragen.

5. On the certificate, the quenching and tempering treatment is to be listed with reference to the temperature, holding time and cooling medium after normalising as well as with reference to the tempering temperature. The normalising temperature for tubes and forged pieces should be at least 1050 °C.

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Beispiel / Example – X10CrWMoVNb9-2- mech.-techn. Eigenschaften / mechanical-technological properties -

6. Für die mechanisch-technologischen Eigenschaften gelten die Anforder-ungen der DIN EN 10216-2. Abweichend von der Liefernorm wird eine Kerbschlagarbeit von mindestens 41/68 J (Probenrichtung quer/längs) gefordert. Für Bauteile, welche im Zeitstand-bereich eingesetzt werden, ist je Schmelze und Abmessung die Ersatzstreckgrenze Rp0,2 bei 600 °C zu bestimmen. Die Prüfung erfolgt an Querproben. Rundproben haben den Vorzug vor Flachproben.

6. The requirements ofDIN EN 10216 2 apply to the mechanical properties.Deviating from the delivery standard a notched bar impact work of at least 41/68 J (transverse/longitudinal orientation of specimen) is required.For components used within the creeping range the offset yield strength Rp0,2 at 600 °C must be determined per heat and dimension. The test is carried out on transverse specimens. Round specimens are given preference to flat specimens.

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Beispiel / Example – X10CrWMoVNb9-2- Gefügenachweis / microstructure verification -

7. Je Abmessung, Schmelze und Wärme-behandlungslos ist durch einen Mikroschliff (200:1 und 500:1) zu dokumentieren, dass kein nichtange-lassener Martensit vorhanden ist.

Bei der Dokumentation ist mindestens eine Bildgröße des Originalphotos von 10,5 cm Breite und 7 cm Höhe bzw. bei digitaler Fotographie eine Mindestbild-größe von 10 cm Breite und 8 cm Höhe (Mindestauflösung der Mikroskop-kamera 600 x 480 Bildpunkte) einzuhalten. Der Maßstab muss im Bild enthalten sein.

7. For each dimension, heat and heat treatment batch, a microsection (200:1 and 500:1) must document that no untempered martensite is available.

The documentation requires a minimum image size of 10.5 cm width and 7 cm height for the original photo or a minimum image size of 10 cm width and 8 cm height for a digital photo (minimum resolution of the microscope camera 600 x 480 pixels). The scale must be included in the image. 16

VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Beispiel / Example – X10CrWMoVNb9-2- Härteprüfung / hardness testing -

8. An den metallographischenSchliffen wird eine Härte-prüfung HV10 über den Wanddickenverlauf erstellt. Folgende Härtewerte sindeinzuhalten:

- min. 190 HV10- max. 260 HV10

8. On the metallographic cross-sections a hardness testing HV10 is prepared over the wall thickness. The following hardness numbers must be observed:

- min. 190 HV10- max. 260 HV10

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Beispiel / Example – X10CrWMoVNb9-2- Oberflächenprüfungen / surface examinations -

9. Die Oberflächenprüfung auf Längs- und Querfehler erfolgt nach den halbzeug-abhängigen DIN EN Prüfnormen. - Rohre nach

DIN EN 10246-12 - Schmiedestücke nach

DIN EN 10228-1

Der Punkt 11 (a) unter „Zusätzliche Bestimmungen“ dieser Spezifikation ist dabei zu beachten.

9. The surface examination for longitudinal and cross defects is performed according to the semi-finished product related DIN EN test standards.- tubes according to

DIN EN 10246-12- forged pieces according to

DIN EN 10228-1Here, item 11 (a) must be observed under "Additional provisions" of this specification. 18

VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Beispiel / Example – X10CrWMoVNb9-2- Oberflächenprüfungen / surface examinations -

an Böden im Bord- und Krempen-bereich

At the bottom within flange and rim area

Schmiedestücke

Forged pieces

D > 142 mm

Rohre für Sammler

Tubes for collectors

Rohre für warmverformte

Biegungen, warmverformteBiegungen und

Formstücke

Tubes for hot formed bendings,

hot formed bendings and casts

Rohre

Tubes

D > 142 mm

100 % 100 % 100 % 100 % 100 %Qualitätsklasse / Zulässigkeitsklasse (M)

Quality grade / eligibility class (M)M1 Freiformschmiede-stü

cke Klasse 3

Open-die forgingsclass 3

M1 M1 M2

Gesenkschmiede-stücke Klasse 2

Closed-die drop forgings class 2 19

VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Beispiel / Example – X10CrWMoVNb9-2- Oberflächenprüfungen / surface examinations -

10. Über alle Prüfungen ist ein Abnahmeprüfzeugnis nachDIN EN 10204, 3.2auszustellen.

10. For all tests an acceptance test certificate must be issuedaccording to DIN EN 10204,3.2.

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Beispiel / Example – X10CrWMoVNb9-2- Zusätzliche Anforderungen / additional requirements -

Additional requirements for tubes and tube bends

Compliance of the specification due to the harmonized product standards

respectively to the guideline VGB-R 508 L

Ordered according to the inside diameter (liØ ≥ 200 mm)

UT test for longitudinal defects

UT test for cross defects and lamination (D > 142 mm)

Wall thickness measurement using UT (D > 142 mm) for the application

within the creeping range

Tightness test21

VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Beispiel / Example – X10CrWMoVNb9-2- Zusätzliche Anforderungen / additional requirements -

Additional requirements for forged pieces

Material expert opinion

Compliance of the specification due to the harmonized product standards

respectively to the guideline VGB-R 508 L

UT test in a low contour

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Current revision

The revision of the guideline VGB-R 109 (2nd edition 2008) comprised:

Checking of new published standards and their matters

Detailed definition - field of application in this guideline

Body structure specification for the inner profile of pipes

Image size definition and quality for micrograph respectively documentation

Requirements definition for the manufacturer of filler materials and also for

filler materials

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Field of applicationBelow item 3 a new paragraph is expressed:

„The field of application includes types of products within the high-pressure range (≥ 40 bar) of the steam boiler assembly according to the definition ofDIN EN 12952-1 category III and IV of the pressure equipment directive as well as the high-pressure pipeline systems of category III of the pressure equipment directive of a power plant. In addition, the following high-pressure pipeline systems are affected:-..-.. up to the double shutoff.The application of components not listed must be agreed separately.”

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Basis of the material acceptanceBelow item 4 a new paragraph is expressed:

„The material manufacturer must guarantee the manufacturer concerning those materials listed in Sections 13.2 to 13.12 and used within the creeping range that the supplied products meet the established properties within the standard scatter range of the creep strength. For this purpose, the material manufacturer declares on the acceptance test certificate that the manufacturing processes are equivalent to those of the material for which he determined test results. The qualification verification or the equivalence of the manufacturing process must be confirmed by a specified authority on the acceptance test certificate.”

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Body structure for the inner profile of pipes

Stipulation in the guidelineVGB-R 109 under item 4.2:

„The inner profile of pipeswith a T/D ratio of ≤ 0.18must be ocularly round.“

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Requirements on filler material

Why?

Up to now requirements on semi-finished products were defined –

depending on product standards (tube, flat product, forged piece)

in general and material referred.

In harmonized product standards there are low information according to the

requirements on filler material.

Up to now the filler material is not considered!

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Requirements on filler material

Section 14 is newly worked out:

14.1 Requirement on the manufacturer of filler materials

14.2 Requirements on filler material

14.3 Type of certificate regarding the delivery

14.4 Requirements on the supplier of filler material

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Requirements on filler material

Additional requirements for:

For the application within the hot yield strength range

The requirements shall be worded according to the requirements on the

base material of the same type.

The pure weld metal must comply with the requirements on the highest

application temperature within the short-term range of the base materials to

be processed.

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Requirements on filler material

application within the creeping range

Each manufacturer must furnish verification regarding creep tests on

its own product (pure weld metal).

For this stipulations have been applied.

As a requirement on the weld metal, the creep strengths of the base

materials to be joined by welding are to be taken as a basis.

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Final view VGB-R 109 (2nd edition)

Practical oriented guideline adjusted to the current status of standards and

technical standards.

EN standards in configuration with experience of operators and plant

respectively semi-finished products producer is the basis. Now in addition with

the topic filler material.

A uniform requirements description on materials and semi-finished products are

permitted.

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VGB Workshop „Material and Quality Assurance“May 13-15, 2009 in Copenhagen

Thank you very much for your attention!

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To place an order: http://www.vgb.org/shop/product_info.php/products_id/500Contact: [email protected]