EEMUA PUB NO 218-2010 Quality requirements for the manufacture and supply of duplex stainless steels (Edition 1)《双相不锈钢生产和供应的质量要求(第1版)》.pdf

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1、 Quality requirements for the manufacture and supply of duplex stainless steels PUBLICATION 218 Edition 1 Released by IHS. NOT FOR RESALE THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION Quality requirements for the manufacture and supply of duplex stainless steels PUBLICATION 218 Edition 1

2、 Copyright 2010 The Engineering Equipment and Materials Users Association. A company limited by guarantee. Registered in England. Company number 477838. ISBN 978 0 85931 175 5 Imprint reference 03-2010 Registered and Trading Address 10-12 Lovat Lane London EC3R 8DN Telephone: +44 (0)20 7621 0011 Fax

3、: +44 (0)20 7621 0022 E-mail: saleseemua.org Website: www.eemua.org EEMUA Publication 218 - Quality requirements for duplex stainless steels EEMUA ii ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION The Engineering Equipment and Materials Users Association, more commonly known as EEMUA, is a Eu

4、ropean non-profit membership Association helping companies that own or operate industrial facilities - the users of engineering equipment and materials. EEMUA aims to improve the safety, environmental and operating performance of industrial facilities in the most cost-effective way, thereby demonstr

5、ating and pursuing leadership in asset management. EEMUA Members pursue these aims through collaboration for mutual benefit, sharing engineering experiences and expertise and by promoting their distinct interests as the users of engineering products. Specifically, the aims of EEMUA Member companies

6、are achieved by: providing the organisation within which networking, information sharing and collaboration on non-competitive technical matters can take place; influencing the way written regulations are interpreted and applied in practice; presenting and promoting Members views, and encouraging the

7、 application of good, sound engineering practices; developing user guides, specifications, training and competency schemes; facilitating Members participation in national and international standards making; influencing relevant national and European legislation and regulations. Formed in 1949 as the

8、 Engineering Equipment Users Association, and re-named in 1983 (as a result of taking over the materials association, OCMA), EEMUA has for more than fifty years given companies that own and operate process plants, power stations and other significant industrial facilities, a collaborative voice in a

9、ddressing technical and engineering related issues that impact on good integrity management and asset management practices. The Association is open to companies of all sizes that meet its engineering user criteria. Further details of current Members of EEMUA is available on the Associations website,

10、 www.eemua.org. EEMUA activities often lead to the production of publications. These are prepared for Members use and are often offered for sale as well. A list of EEMUA publications for sale is given at the end of this Publication. The full list is also on the Associations website, including detail

11、s of on-line shopping facilities. To enquire about corporate Membership, write to enquirieseemua.org or call +44 (0)20 7621 0011. EEMUA Publication 218 - Quality requirements for duplex stainless steels EEMUA iii ABOUT THIS PUBLICATION Legal Aspects All rights, title and interest in this Publication

12、 belong to EEMUA. All rights are reserved. No part of this Publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means: electronic, mechanical, photocopying, recording or other, without the express prior written agreement of the EEMUA Executive Director. I

13、nfringement of copyright is illegal and also reduces the Associations income thereby jeopardising its ability to fund the production of future publications. It has been assumed in the preparation of this Publication that: the user ensures selection of those parts of its contents appropriate to the i

14、ntended application; and that such selection and application is correctly carried out by appropriately qualified and competent persons for whose guidance this Publication has been prepared. EEMUA and the individual members of the Work Group that prepared this EEMUA publication do not, and indeed can

15、not, make any representation or give any warranty or guarantee in connection with material contained herein. EEMUA and the individual members of the Work Group that prepared this EEMUA publication expressly disclaim any liability or responsibility for damage or loss resulting from the use or relianc

16、e on this publication. Any recommendations contained herein are based on the most authoritative information available at the time of writing and on current good engineering practice, but it is essential for the user to take account of pertinent subsequent developments and/or legislation. The use of

17、standards is not a legal requirement in some countries in Europe and around the world. However, it is stressed that where a contract is placed which states that manufacture is to be in accordance with specified standards, this may be determined as a legal requirement. Manufacturers of equipment may

18、offer equipment not conforming to standards, but, in such cases, they should have to be able to prove that all legislation concerning essential safety has been complied with. This could be a time-consuming and expensive task. In this Publication, “Section“ refers to a part of this Publication. “Clau

19、se“ refers to a part of a third-party document, such as a standard. Consultation and Feedback EEMUA encourages constructive comments on this Publication from both Members of the Association and others. Comments should be sent on the standard feedback form, a copy of which is provided towards the end

20、 of this Publication. Comments are considered by the relevant EEMUA Technical Committee and may be incorporated in future editions of this Publication. New editions are publicised on the EEMUA website. Acknowledgement EEMUA acknowledges the assistance of Mr. John Marlow, of John Marlow Limited, in t

21、he production of this Publication. EEMUA Publication 218 - Quality requirements for duplex stainless steels EEMUA iv EEMUA Publication 218 - Quality requirements for duplex stainless steels EEMUA v Contents 1. Introduction . 1 2. Scope . 3 3. Definitions 5 4. Metallurgical Considerations 7 5. Manufa

22、cturer Quality Assurance Requirements 9 6. Manufacturer Quality Control . 11 7. Establishing a Purchaser Enquiry Document 13 8. Manufacturing Procedures, and Inspection and Test Plan 15 9. Manufacturing Controls 19 10. Certification . 21 11. Compliance Audit . 23 12. Materials Purchased from Stockis

23、ts 25 13. Positive Material Identification 27 14. References . 29 Tables Table 1 Commonly used standards and grades of duplex stainless steel 4 EEMUA Publication 218 - Quality requirements for duplex stainless steels EEMUA vi EEMUA Publication 218 - Quality requirements for duplex stainless steels E

24、EMUA 1 1. Introduction This EEMUA publication is aimed at manufacturers, designers, purchasers, stockists and end-users of duplex stainless steel components. It provides requirements and recommendations for the manufacture and supply of these materials in order to ensure that they meet the minimum i

25、n-service requirements of end-users in the process industries, both on- and offshore. These minimum requirements and recommendations for manufacture and supply are considered necessary for the following reasons: In the experience of EEMUA members, there has been an inconsistency in the quality of du

26、plex stainless steel components from manufacturers and stockists globally despite most end-users having detailed manufacturing specifications in place. The inconsistency in quality appears to have been largely due to variations in manufacturing process and the quality controls used by manufacturers.

27、 Until now, there has been little detailed guidance on this topic. End-users have generally not employed stringent surveillance on manufacturers and stockists to ensure that their specified requirements have been strictly adhered to. Most manufacturers have their quality systems certified to recogni

28、sed international quality standards. However, there is no guarantee that stringent manufacturing quality controls will be consistently maintained. The consequences of using duplex stainless steel components that fail to meet the purchasers specified requirements can be extremely serious. Significant

29、 project delays can be incurred as well as other consequences, leading to environmental and personnel safety issues. Failures can also be extremely costly and result in significant business losses. EEMUA Publication 218 - Quality requirements for duplex stainless steels EEMUA 2 EEMUA Publication 218

30、 - Quality requirements for duplex stainless steels EEMUA 3 2. Scope This document covers all grades of duplex stainless steel and all components for both offshore (subsea and topsides) and onshore applications in the energy, chemical and other process industries. It deals with duplex stainless stee

31、l components purchased directly from the manufacturer or from stockists. Orders for duplex stainless steel components are often placed through stockists and it is strongly recommended that stockists should adopt the requirements detailed in this EEMUA publication. There are many grades and designati

32、ons of duplex stainless steel with three generic types principally used in the aforementioned industries. These are generally distinguished by their Pitting Resistance Equivalent Number (PREN): 22% chromium duplex stainless steels with a PREN generally 35; 25% chromium duplex stainless steels with a

33、 PREN 40; and 25% chromium super duplex stainless steels with a PREN 40. In addition, there are further proprietary variations such as “lean” and “hyper” grades. Further information can be found in Table 1 (overleaf) and associated footnotes in EEMUA 1941. The more commonly used standards and grades

34、 are listed in NORSOK (Norwegian standards authority) Standard M-6302and in Table 1. The main manufacturing processes for duplex stainless steel are plate and pipe rolling, forging, casting, tube drawing, extrusion and hot isostatic pressing. All these processes are followed by solution annealing an

35、d water quenching. Typical components that are regularly manufactured in duplex stainless steel are: process vessels, pipework and pipelines (seamless and welded); flanges, hubs and fittings such as tees, elbows and bends; valve bodies and valve trim; pump casings; wellhead equipment and downhole tu

36、bing and accessories; hydraulic control and chemical injection tubing; plates and bars; bolts and fasteners; and heat exchanger tubes/tube plates. PREN = %Cr + 3.3%Mo + 16%N (several other equations exist) EEMUA Publication 218 - Quality requirements for duplex stainless steels EEMUA 4 Table 1 Commo

37、nly-used standards and grades of duplex stainless steel Generic Grade Product Type Standard Grade 22% Cr Seamless Pipe ASTM A 790 UNS S31803 UNS S32205 Welded Pipe ASTM A 928 UNS S31803 UNS S32205 Wrought Fittings ASTM A 815 UNS S31803 UNS S32205 Forgings ASTM A182 F51 F60 Plates ASTM A 240 UNS S318

38、03 UNS S32205 Castings ASTM A 995 ASTM A 890 4A (UNS J92205) Bars ASTM A 479 UNS S31803 UNS S32205 Tubes ASTM A 789 UNS S31803 UNS S32205 25% Cr Seamless Pipe ASTM A 790 UNS S32550 UNS S32750 UNS S32760 UNS S 32974 Welded Pipe ASTM A 790 UNS S32550 UNS S32750 UNS S32760 Wrought Fittings ASTM A 815 U

39、NS S32550 UNS S32750 UNS S32760 Forgings ASTM A 182 UNS S32550 UNS S32750 UNS S32760 F53 F55 F61 Plates ASTM A 240 UNS S32550 UNS S32750 UNS S32760 Castings ASTM A 995 ASTM A 890 5A (UNS J93404) 6A (UNS J93380) Bars ASTM A 479 and ASTM A276 UNS S32550 UNS S32750 UNS S32760 Tubes ASTM A 789 UNS S3255

40、0 UNS S32750 UNS S32760 UNS S32974 EEMUA Publication 218 - Quality requirements for duplex stainless steels EEMUA 5 3. Definitions Throughout this EEMUA publication, the following definitions apply. Roles recognised DesignerAn organisation that takes responsibility for equipment or system design, in

41、cluding material selection. End-userAn owner or organisation that is responsible for operation of an installation/facility. Manufacturer The company that carries out the primary steelmaking and/or further processing of the duplex stainless steel components. Purchaser The company that places the cont

42、ract or purchase order for the manufacture or supply of the duplex stainless steel components. The purchaser may be an end-user, designer or stockist. Stockist The company that acts as an intermediary supplier between the manufacturer and the purchaser but does not itself carry out manufacturing ope

43、rations. Terms used Approval A written response from the purchaser confirming agreement to a proposal by the manufacturer or stockist. May Is used to indicate that the manufacturer or stockist is permitted to do something, or that the purchaser reserves the right to do something, according to contex

44、t. Shall Is used to indicate that the manufacturer or stockist is required to take action. Should Is used to indicate that the manufacturer or stockist is recommended to take action. From DIS/ISO 21457. EEMUA Publication 218 - Quality requirements for duplex stainless steels EEMUA 6 EEMUA Publicatio

45、n 218 - Quality requirements for duplex stainless steels EEMUA 7 4. Metallurgical Considerations In order to appreciate the problems that can arise during the manufacture and processing of duplex stainless steel it is helpful to have a basic level of understanding of the associated metallurgy. Durin

46、g steelmaking and casting, duplex stainless steels cool from the liquid phase and solidify with a ferritic microstructure. On further cooling they undergo a part transformation to austenite. The structure at ambient temperature is comprised of austenite in a ferrite matrix. The ideal ratio of ferrit

47、e/austenite is widely considered to be 50/50 in order to provide an optimum combination of strength, toughness and corrosion resistance. An acceptable range is typically from 40% to 60% ferrite. Welded components usually have a quoted range in the weld and heat affected zone from 35% to 65% ferrite.

48、 In order to achieve an optimum balance of austenite and ferrite in duplex components, the correct thermal processing is required. This entails rapid cooling after casting, hot forming and solution annealing. Rapid cooling is generally done by efficient water quenching in order to extract the heat f

49、rom the components as quickly as possible. This is usually achieved by rapid transfer of the duplex components from the annealing furnace to the water quench in less than 60 s, and employing a high volume ratio of water together with extremely vigorous agitation in the water quench tank. The aim of rapid cooling from the solution annealing temperature to ambient temperature is to avoid the formation of deleterious intermetallic precipitates (also known as deleterious third phases)