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. Jrg Barei, 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 bilingual
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VGB Workshop Material and Quality Assurance May 13-15, 2009 in Copenhagen

Structure
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Abbreviations Terminology Field of application Basis of the material acceptance Requirements on the material manufacturers or suppliers Requirements on the materials for pressure equipment Further processing within the component manufacturer Test activities within the material inspection Occurrences, deviations Order placed with the material manufacturers or suppliers Additional regulations Castings List of material data sheet 13.1 til 13.12 separately shown materials Requirements on filler material

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

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

Topics
Description 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 pieces
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VGB Workshop Material and Quality Assurance May 13-15, 2009 in Copenhagen

Example X10CrWMoVNb9-2
General 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 certificates
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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 aufgefhrt ist, nur dann eingesetzt werden, wenn vor dessen Einsatz in Anlagen eine Begutachtung nach der Druckgerterichtlinie 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 drfen nur berprfte Erschmelzungsverfahren (Elektro-Lichtbogenverfahren mit Vakuum-Entgasung oder geeigneter Nachbehandlung) angewandt werden. Diese sind im Zeugnis aufzufhren. 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 aufzufhren. - nahtlose Rohre nach DIN EN 10216-2 - Schmiedestcke in Anlehnung an DIN EN 10216-2 Der Analysengehalt fr Cu ist auf max. 0,3 % begrenzt und in der Prfbescheinigung auszuweisen.
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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 10216-2 The analysis content of Cu is limited to max. 0.3 % and must be shown on the test certificate.

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

Beispiel / Example X10CrWMoVNb9-2

- Stckanalyse / parts analysis 4. Die Stckanalyse erfolgt bei Rohren und Schmiedestcke ber 142 mm Auendurchmesser an einem Teil je Schmelze. Fr die Abweichungen von der Stckanalyse ist die Tabelle 5 der DIN EN 10216-2 heranzuziehen. For the deviation from the parts analysis refer to Table 5 of DIN EN 10216-2. 4. The parts analysis is performed for one part per heat on tubes and forged pieces exceeding an outside diameter of 142 mm.

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

Beispiel / Example X10CrWMoVNb9-2

- Vergtungsbehandlung / quenching and tempering treatment 5. Die Vergtungsbehandlung ist in Bezug auf die Temperaturhhe, Haltezeit und das Abkhlmedium nach dem Normalisieren sowie in Bezug auf die Anlasstemperatur im Zeugnis anzugeben. Die Normalisierungstemperatur fr Rohre und Schmiedestcke 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. Fr die mechanisch-technologischen Eigenschaften gelten die Anforderungen der DIN EN 10216-2. Abweichend von der Liefernorm wird eine Kerbschlagarbeit von mindestens 41/68 J (Probenrichtung quer/lngs) gefordert. Fr Bauteile, welche im Zeitstandbereich eingesetzt werden, ist je Schmelze und Abmessung die Ersatzstreckgrenze Rp0,2 bei 600 C zu bestimmen. Die Prfung erfolgt an Querproben. Rundproben haben den Vorzug vor Flachproben. 6. The requirements of DIN 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

- Gefgenachweis / microstructure verification 7. Je Abmessung, Schmelze und Wrmebehandlungslos ist durch einen Mikroschliff (200:1 und 500:1) zu dokumentieren, dass kein nichtangelassener Martensit vorhanden ist. Bei der Dokumentation ist mindestens eine Bildgre des Originalphotos von 10,5 cm Breite und 7 cm Hhe bzw. bei digitaler Fotographie eine Mindestbildgre von 10 cm Breite und 8 cm Hhe (Mindestauflsung der Mikroskopkamera 600 x 480 Bildpunkte) einzuhalten. Der Mastab muss im Bild enthalten sein. 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.
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7.

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

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

Beispiel / Example X10CrWMoVNb9-2

- Hrteprfung / hardness testing 8. An den metallographischen Schliffen wird eine Hrteprfung HV10 ber den Wanddickenverlauf erstellt. Folgende Hrtewerte sind einzuhalten: - min. 190 HV10 - max. 260 HV10 8. On the metallographic crosssections 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

- Oberflchenprfungen / surface examinations 9. Die Oberflchenprfung auf Lngs- und Querfehler erfolgt nach den halbzeug-abhngigen DIN EN Prfnormen. - Rohre nach DIN EN 10246-12 - Schmiedestcke nach DIN EN 10228-1 Der Punkt 11 (a) unter Zustzliche 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 10228-1 Here, item 11 (a) must be observed specification.
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Bestimmungen dieser Spezifikation under "Additional provisions" of this

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

Beispiel / Example X10CrWMoVNb9-2

- Oberflchenprfungen / surface examinations an Bden im Bord- und Krempen-bereich At the bottom within flange and rim area Schmiedestcke Forged pieces D > 142 mm Rohre fr Sammler Tubes for collectors Rohre fr warmverformte Biegungen, warmverformte Biegungen und Formstcke Rohre Tubes D > 142 mm

100 %

Tubes for hot formed bendings, hot formed bendings and casts 100 % 100 % 100 % 100 % Qualittsklasse / Zulssigkeitsklasse (M) Quality grade / eligibility class (M) Freiformschmiede-st M1 M1 cke Klasse 3 Open-die forgings class 3 Gesenkschmiede-st cke Klasse 2 Closed-die drop forgings class 2
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M1

M2

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

Beispiel / Example X10CrWMoVNb9-2

- Oberflchenprfungen / surface examinations -

10. ber alle Prfungen ist ein Abnahmeprfzeugnis nach DIN EN 10204, 3.2 auszustellen.

10. For all tests an acceptance test certificate must be issued according 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

- Zustzliche 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 (li 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 test
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VGB Workshop Material and Quality Assurance May 13-15, 2009 in Copenhagen

Beispiel / Example X10CrWMoVNb9-2

- Zustzliche 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 application
Below 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 of DIN 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 acceptance

Below 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 guideline VGB-R 109 under item 4.2: The inner profile of pipes with a T/D ratio of 0.18 must 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 14.2 14.3 14.4 Requirement on the manufacturer of filler materials Requirements on filler material Type of certificate regarding the delivery 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!

To place an order: http://www.vgb.org/shop/product_info.php/products_id/500 Contact: olaf.baumann@vgb.org

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