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BEL Valve - Cladding & Extra Tungsten Carbide Deposit issue – Case Study

BEL Valve - Cladding & Extra Tungsten Carbide Deposit issue – Case Study. Presented by R.Baskar, AMIE (Mech) ASNT NDT Level III RT,UT,PT & MT CSWIP 3.2 AWS – SCWI. BEL Valve - Cladding & Extra Tungsten Carbide Deposit issue – Case Study.

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BEL Valve - Cladding & Extra Tungsten Carbide Deposit issue – Case Study

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  1. BEL Valve - Cladding & Extra Tungsten Carbide Deposit issue – Case Study Presented by R.Baskar, AMIE (Mech) ASNT NDT Level III RT,UT,PT & MT CSWIP 3.2 AWS – SCWI

  2. BEL Valve - Cladding & Extra Tungsten Carbide Deposit issue – Case Study • Bond integrity and volumetric examination of Weld overlay (cladding) • Extra material Deposit (Tungsten Carbide)

  3. BEL Valve - Cladding & Extra Tungsten Carbide Deposit issue – Case Study Technical Justification follows

  4. BEL Valve – Cladding issue – Case Study Bond integrity and volumetric examination of Weld overlay (clading) 40 – 70 mm

  5. BEL Valve – Cladding issue – Case Study Bond integrity and volumetric examination of Weld overlay (clading) Lack of bonding at weld fusion face 40 – 70 mm

  6. BEL Valve – Cladding issue Ultrasonic Indication from overlay fusion face

  7. BEL Valve – Cladding issue Ultrasonic equipment REFERENCE LEVEL (RL) set through reference block RL Set at 90% FSH

  8. BEL Valve – Cladding issue Ultrasonic Testing - Reference block Flat bottom Drilled Hole Reference Reflector Weld Interface

  9. Bond integrity and volumetric examination of weld overlay (cladding) in accordance with API 6A

  10. BEL Valve – Cladding issue Ultrasonic Testing - Acceptance Criteria Reference : API 6A, Para. 7.4.2.3.15 - b - 2

  11. BEL Valve – Cladding issue Ultrasonic Testing - Acceptance Criteria Rejection level for multiple indication 45% FSH • RL Set at 90% FSH • Rejection level for single indication

  12. BEL Valve – Cladding issue Ultrasonic Testing - Acceptance Criteria Rejection level for Multiple indication Rejection level for Multiple indication Multiple indication from 11” ball (S.No. 48122) Multiple indication from 9” ball (S.No. 48140) No indication

  13. BEL Valve – Cladding issue Ultrasonic Testing - Acceptance Criteria based on area Reference : ASME / ASTM SA 265 Para.13.3.3 and 13.3.4

  14. BEL Valve – Extra material Deposit (Tungsten Carbide) issue – Case Study • Extra material Deposit (Tungsten Carbide) • During Tungsten carbide coating at outer surface, by process error ROBO equipment deposit some portion with Tungsten Carbide into inner surface area of bore. Deposit upto max. 3mm. Extra material Deposit (Tungsten Carbide)

  15. BEL Valve – Extra material Deposit (Tungsten Carbide) issue – Case Study • This Extra material deposit confirmed following checking: • Visual inspection, by surface color difference between Tungsten Carbide coating and cladding material deposit area • During dye penetrant testing noticed red color contrast at Tungsten Carbide area. Which is probably due to porous material observed penetrant and resulting red color contrast at that location. • Checked with PMI and noticed 80 – 84 % of Tungsten, other location 55 – 60 % Nickel • Checked hardness test and noticed 50 – 55 HRC, other cladded area 32 – 35 HRC • Checked with coating thickness gauge, it noticed 1 to 3 mm coating thickness • Inner diameter measured and noticed reduced dimension, than the nominal bore dimension. • General information, this extra material deposit is very smooth transition and stress raise free. • Based on the above check, it is clearly shows Tungsten Carbide deposit

  16. Conclusion • Based on the review of Ultrasonic indication evaluations, the indication in the cladding are well within acceptable limit and it will not affect the integrity of the valves. The valves are fit for purpose. • Leave indication in the cladding as is. Thanks

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