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S+C Competence

Services for Direct Reduction

OD Measurement Device

Tube Growth Monitoring

Recently, Schmidt + Clemens has developed and built a new device capable of measuring the outer diameter every 10mm of the length of the entire tube assembly with an accuracy in the hundredths of mm. These values can be used to verify the quality of the Schmidt + Clemens manufacturing process, but also as a zero baseline reference for future outer diameter readings during an inspection of the furnace, and therefore to provide a detailed value of the creep expansion evolution over the tube life.

ODB – Outside Diameter Baseline equipment at work

Most failures of direct reduction reformer tubes are caused by creep expansion of the upper part of the tube. Creep damage can be monitored by means of an accurate graph that shows the evolution of the outer diameter and the elongation.

When considering the creep deformation curve with the three creep stages (primary, secondary and tertiary stage) the best moment to replace a tube is right before the tertiary stage of creep. Every tube has its own creep evolution graph, by means of which the creep failure can be prevented.

ODB – actual result of outside diameter measurement for a reformer tube assembly

As tube manufacturers, the best information we can be provide to our customers is an accurate outer diameter baseline. Other techniques such as the magnetic baseline cannot be considered relevant, because the amount of chromium in the material produces a nonmagnetic response in the as-cast condition. Due to this effect, magnetic baselining of tubes do not provide further information than a nonmagnetic response. For this reason the best information is found in the dimensional baseline, as it offers far more opportunities to properly assess creep in a later inspection.

Even more, as it is well known in the industry, dimensional control is a repetitive, stable and objective technique. Due to the previous characteristics, a measure like the dimensional measurement is preferable to other techniques with higher result variability and requiring the interpretation of an inspector.

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