Integration of nondestructive examination reliability and fracture mechanics

A multi-year program at the Pacific Northwest Laboratory is in progress to determine the reliability of ultrasonic ISI that is performed on light-water reactor primary systems, using probabilistic fracture mechanics (FM) analysis to determine the impact of NDE unreliability on system safety, and to evaluate advanced ultrasonic techniques. This paper is a review of the last year's highlights. Emphasis is placed upon the results of a pipe inspection round robin, advanced technique evaluation, joint study with Westinghouse, qualification document, underclad crack detection sizing studies, and a FM analysis using the PRAISE code for studying inspection parameters.     

NDE reliability and SAFT-UT final development

The Evaluation and Improvement of NDE Reliability for Inservice Inspection of Light Water Reactors (NDE Reliability) program at the Pacific Northwest Laboratory (PNL) was established by the US Nuclear Regulatory Commission (NRC) to determine the reliability of current inservice inspection (ISI) techniques and to develop recommendations that will ensure a suitably high inspection reliability. This is a progress report covering the programmatic work from October 1987 through September 1988.The program for Validation and Technology Transfer for SAFT-UT is designed to accomplish the final step of moving research results into beneficial application. Accomplishments for FY88 in Synthetic Aperture Focusing of Ultrasonic Test data (SAFT-UT) under this program are discussed in this paper. The information is treated under the copies of Code Activities, Field Validation, and Seminars.     

Failure probability assessment of wall-thinned nuclear pipes using probabilistic fracture mechanics

The integrity of nuclear piping system has to be maintained during operation. In order to maintain the integrity, reliable assessment procedures including fracture mechanics analysis, etc., are required. Up to now, this has been performed using conventional deterministic approaches even though there are many uncertainties to hinder a rational evaluation. In this respect, probabilistic approaches are considered as an appropriate method for piping system evaluation. The objectives of this paper are to estimate the failure probabilities of wall-thinned pipes in nuclear secondary systems and to propose limited operating conditions under different types of loadings. To do this, a probabilistic assessment program using reliability index and simulation techniques was developed and applied to evaluate failure probabilities of wall-thinned pipes subjected to internal pressure, bending moment and combined loading of them. The sensitivity analysis results as well as prototypal integrity assessment results showed a promising applicability of the probabilistic assessment program, necessity of practical evaluation reflecting combined loading condition and operation considering limited condition.     

基于ASME和RSE-M规范的含平面缺陷奥氏体不锈钢核级管道剩余寿命预测方法的数值对比研究

核级管道在加工和安装环节可能存在不同的缺陷。此外,由于核电厂运行条件的影响,管道中可能存在少量缺陷,如裂缝。需要合理预测评估含缺陷管道的剩余寿命,以便安排更换方案,避免对核电厂的效率造成严重影响。本文根据ASME和RSE-M规范,在应力强度因子计算、裂纹扩展分析和裂纹稳定性评价等环节,通过数值对比研究了含有平面缺陷的奥氏体不锈钢核级管道的剩余寿命评估方法,为类似工作提供参考。      

Results of reliability test program on light water reactor piping

The Japan Atomic Energy Research Institute has conducted a piping reliability test program to demonstrate the safety and reliability of light water reactor primary piping. In this program, pipe fatigue test, leak-before-break (LBB) verification test and pipe rupture test were carried out to examine the integrity of piping, to verify the LBB and to demonstrate the effectiveness of protective measures against jet impingement and pipe whip loads under a pipe rupture event.In the pipe fatigue test, a procedure to predict the fatigue crack growth was developed, and the integrity of piping during the plant service life was evaluated. In the LBB verification test, the pipe fracture test and the leak rate test were performed to verify the LBB in the primary piping.In the pipe rupture test, the influence of jet impingement on the target disk and the deformation behavior of whipping pipe and restraint were investigated. Using the test results, the jet impingement behavior and the effectiveness of pipe whip restraint were demonstrated.     

Characterization of hydrogen concentration in Zircaloy claddings using a low-frequency acoustic microscope with a PVDF/LFB transducer

Hydrogen embrittlement is one of the major mechanisms responsible for the degradation of ductility of Zircaloy cladding materials. Currently the characterization of hydrogen concentration (HC) very often relies on destructive methods that are time-consuming and costly. In this research, an ultrasound-based nondestructive evaluation (NDE) technique is reported for the determination of HC in Zircaloy claddings. This ultrasound-based NDE technique employs a low frequency acoustic microscope (AM) with a PVDF/LFB transducer and a Fourier-based signal processing technique. With this AM technique, a relation between the ultrasound wavespeed and the HC of Zircaloy is established. A resolution of HC measurements with the current technique is demonstrated to be better than 200 ppm. This NDE technique has been developed with an aim to have a better resolution and also to be potentially applied to poolside inspection.     

Development of probability of detection functions for evaluating integrity of axial outside diameter stress corrosion cracks in steam generator

The reliability of an eddy current testing (ECT) inspection system depends upon the inspection technique and quality of analyst. In evaluating the integrity of a steam generator (SG) tube, degradation detection and sizing accuracy are considered performance measures of the nondestructive evaluation (NDE) system. A probability of detection (POD) model serves as a functional measure of the ability of an NDE system to detect degradation. It is one of the inputs in the operational assessment, and it is used to estimate the degradation during service via ECT of the SG tube. In this study, the POD functions of the inspection technique and analyst were obtained to quantitatively analyze the ECT bobbin probe for axial outside diameter stress corrosion cracks in SG tubes. This should serve to evaluate the integrity of the SG tubes. The depth and amplitude of defects were used as parameters of the POD model. Hit (detection) and miss (no detection) binary data obtained from destructive and nondestructive inspection of cracked tubes were also used.     

Reliability analysis for stiff versus flexible piping

The overall objective of this research project is to develop a technical basis for flexible piping designs which will improve piping reliability and minimize the use of pipe supports, snubbers, and pipe whip restraints. The current study was conducted to establish the necessary groundwork based on the piping reliability analysis.A confirmatory piping reliability assessment indicated that removing rigid supports and snubbers tends to either improve or affect very little the piping reliability. We then investigated a couple of changes to be implemented in Regulatory Guide (RG) 1.61 and RG 1.122 aimed at more flexible piping design. We concluded that these changes substantially reduce calculated piping responses and allows piping redesigns with significant reduction in number of supports and snubbers without violating ASME code requirements. Furthermore, the more flexible piping redesigns are capable of exhibiting reliability levels equal to or higher than the original stiffer design.An investigation of the malfunction of pipe whip restraints confirmed that the malfunction introduced higher thermal stresses and tended to reduce the overall piping reliability. Finally, support and component reliabilities were evaluated based on available fragility data. Our result indicated that the support reliability usually exhibits a moderate decrease as the piping flexibility increases. Most on-line pumps and valves showed an insignificant reduction in reliability for a more flexible piping design.     

在役核压力管道模糊失效概率的计算方法

含缺陷核压力管道的失效概率实质上是一个模糊随机概率.本文应用模糊随机概率理论,同时考虑压力管道评定参数的随机性和失效模式判定的模糊性影响,提出了计算含缺陷核压力管道模糊失效概率的方法.与传统的压力管道可靠性分析方法相比,本方法考虑了模糊失效区域,评定的结果更为精确.     

Development of flow-induced vibration evaluation methodology for large-diameter piping with elbow in Japan sodium-cooled fast reactor

This paper describes the current status of flow-induced vibration evaluation methodology development for the primary piping in Japan sodium-cooled fast reactor, with particularly emphasis on the development approach and research activities that investigate unsteady hydraulic characteristics in a short-elbow piping. The approach to the methodology development was defined: experiment-based methodology and simulation-based one as well as extrapolation logic to the reactor condition based on no dependency on Reynolds number in the high Reynolds number range from the experimental results. Experimental efforts have been made using 1/3-scale single-elbow test sections for the hot-leg piping as the main activity. Recent experiments using the 1/3-scale test section revealed that a swirl flow at the inlet of the hot-leg piping hardly influenced pressure fluctuations onto the pipe though a slight deformation of flow separation was observed. Numerical results under different Reynolds number conditions appear in this paper using the unsteady Reynolds Averaged Navier Stokes equation approach, indicating its applicability to the hot-leg piping experiments.     

管道系统的功能性评定准则研究

管道系统的功能性是不同于管道系统压力边界完整性的一项要求，美国核管理委员会（NRC）提出了管道系统功能性的2种评定准则。为了探讨功能性评定准则的来源以及应用，通过研究经典文献中有关功能性评定准则的内容，阐述了2种评定准则的来历和依据，分析了2种功能性评定准则的特点，指出了使用功能性评定准则的注意事项。通过一个管道系统功能性评定的实例，提出2种功能性评定准则在不同的核电厂设计阶段的应用策略。对于新建的核电厂，尽量使用C级限值来保证管道系统的功能性，如果是已建造的核电厂，则可以用D级限值附加5个条件来保证管道系统的功能性。      

Overview of NRC funded NDE research at US Pacific Northwest laboratory

There are currently several major nondestructive examination (NDE) related programs in progress at PNL which are supported by the US Nuclear Regulatory Commission. Three of these programs are Integration of NDE and Fracture Mechanics, Development of Real-Time SAFT-UT System for the Inservice Inspection of LWRs, and Acoustic Emission-Flaw Relationships for Inservice Monitoring of Nuclear Reactor Pressure Boundaries. This paper presents an overview of each program and highlights significant accomplishments.     

Extended applications of LBB piping evaluation diagrams for a new plant design

Plant specific data, such as pipe geometry, material properties and pipe loads, are required to apply leak-before-break (LBB) to a piping system. Thus, LBB evaluation cannot be done until piping design and routing are completed. A simple method for evaluating LBB for piping systems during design process considering the effects of nozzle and the change in local and global compliance in cracked piping system is developed in this paper. This method produces piping evaluation diagrams for intermediate pipe locations and pipe-nozzle interface locations which defines the LBB requirements to the piping designer for use during the design process and is independent of pipe routing. Piping evaluation diagrams can be used for the LBB evaluation for a new plant design.     

Screening method for piping wall loss by flow accelerated corrosion

Flow accelerated corrosion (FAC) phenomenon has persisted its impact on plant reliability and personnel safety. Unless we change the operation condition drastically, most parameters affecting FAC will not be effectively controlled. In order to help expand piping inspection coverage, we have developed a screening approach to monitor the wall thinning by direct current potential drop (DCPD) technique. To improve the applicability to the complex piping network such as the secondary cooling water system in PWR's, we devised the equipotential control method that can eliminate undesired leakage currents outside a measurement section. In this paper, we present Wide Range Monitoring (WiRM) and Narrow Range Monitoring (NaRM) with Equipotential Switching Direct Current Potential Drop (ES-DCPD) method to rapidly monitor the thinning of piping. Based on the WiRM results, susceptible locations can be identified for further inspection by ultrasound technique (UT). On-line monitoring of a thinned location can be made by NaRM. Finite element analysis results and a closed-form resistance model are developed for the comparison with measured wall thinning by the developed DCPD technique. Verification experiments were conducted using UT as the reference. The result shows that model predictions and the experimental results agree well to confirm that both WiRM and NaRM based on ES-DCPD can be applicable to FAC management efforts.     

Steam generator small bore piping socket weld inspection using the phased array ultrasonic technique

As nuclear power plants age, the likelihood of failures in the small bore piping used in those plants caused by exposure to mechanical vibrations during plant operations increases. While small bore piping failures rarely cause plant shutdown, the management of small piping has been a keen area of interest since their repair or maintenance requires a reactor trip. Steam generator (SG) drain pipe socket welds are small diameter piping connections (nominal pipe schedule 3–4 inches) susceptible to mechanical vibration. SG drain pipe socket weld failures have caused coolant leakage. Therefore, more reliable inspection technologies for small bore piping need to be developed to detect problems at an early stage and prevent pipe failures. This research aims to improve the reliability and accuracy of small bore piping inspections through the design, manufacture and application of a new phased array ultrasonic testing technique and inspection system for SG drain line socket welds.     

Manufacture of first wall mock-ups with calibrated defects for fabrication control methods: Development of UT detectable defects

A Research and Development program for the ITER Blanket-First Wall has been implemented in Europe to provide input data for the manufacture of the full-scale production components. In this frame, FW mock-ups have been fabricated according to ITER FW design requirements.In order to define acceptance criteria for non-destructive examination (NDE) for the series production, FW mock-ups (FWMU) representative of ITER FW are manufactured with calibrated defects to be validated by heat flux tests to assess the critical defect dimensions able to degrade fatigue performance and lifetime, when located at Be/CuCrZr joint corners and beryllium tile edges, and at the CuCrZr/CuCrZr and CuCrZr/316L SS joints.In order to create the defects of given dimensions, two techniques were studied: alumina and zirconia coating using a PVD technique in one hand; and on the another hand alumina and quartz thicker inserts.The paper describes the different approaches used to manufacture test samples with calibrated defects, before applying on FW mock-ups, and related non-destructive examination (NDE) by ultrasonic examination (UT). High heat flux (HHF) testing is not part of this work.     

Effect of through-wall stress gradients on piping failure probabilities

An approach has been developed that predicts leak and rupture probabilities of reactor piping in a structured parametric format. This approach applies the probabilistic fracture mechanics code pc-PRAISE (Piping Reliability Analysis Including Seismic Events) to address the mechanical and thermal fatigue life of piping. The probabilistic fracture mechanics model is applied to predict the relative effects of uniform stresses and through-thickness stress gradients on the reliability of stainless steel piping welds. Results generated using the numerical technique revealed that the calculated leak probabilities can be sensitive to the different types of stress gradients and to local stress concentrations.     

Development of expert system for nuclear piping integrity

The objective of this paper is to develop a nuclear piping integrity expert system (NPIES) for nuclear piping integrity. This paper describes the structure and the development strategy of the NPIES system. The NPIES system consists of five parts; user interface, database, knowledge base, expert and integrity evaluation parts. The user interface part is developed to connect the user and the NPIES system effectively. In the database part, nuclear piping material properties are stored; the unknown material properties are stored in the knowledge base part. Various rules for inferring material properties are stored in the knowledge base part. The most appropriate evaluation method for a given input condition is recommended in the expert part. Finally, the integrity evaluation part is developed for the evaluation of piping integrity effectively.     

Reliability analysis of nuclear piping system using semi-Markov process model

The paper presents a general model for evaluating the rupture frequencies and reliability of the piping system in nuclear power plant based on the theory of semi-Markov process. The proposed model is able to incorporate the effect of aging related degradation of pipes. Time dependent rupture frequencies are computed and compared against those obtained from the homogeneous Markov process model. The influence of flaw and leak inspection intervals on the piping rupture probability is investigated.     

Development of FBR piping bellows joints in Japan

For the practical use of fast breeder reactors (FBRs) reduction of construction costs is one of the most important factors. If the long and winding route of piping systems (needed to absorb the thermal expansion) can be shortened and simplified, sharp reductions in related apparatus, equipment and reactor building etc. can be expected (especially in the case of loop type FBRs). The use of bellows joints, which possess good ability to absorb thermal expansion, is one of the best means of shortening the piping system. From 1983 to 1988, the Power Reactor and Nuclear Fuel Development Corporation promoted extensive research and development on FBR piping bellows joints, which covered areas such as strength evaluation methods, manufacturing and inspection techniques, maintenance and repair techniques, investigation of safety logic etc. The purpose of that work was to ensure that the application of bellows joints to FBR main piping systems was a technical and practical possibility. The conclusion was that the use of FBR piping bellows joints was feasible. Consequently, both draft structural design rules and draft manufacturing and maintenance rules were formulated based on the results. This paper presents a summary of the program and the results of the research and development.