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.     

Products of research and development in NDT

The Nondestructive Ultrasonic Testing and Evaluation is directed to describe flaws microstructure, structure residual stress, reliability or quality insurance. An overview is given on the scientific background, interpretation capability based upon mathematic-numerical models, new design of equipments and demonstrated at components containing relevant flaws. Emphasis is laid upon SNR-improvement in the UT of austenitic weldings. Examples are shown using the backscattering technique with linear polarized shear waves. Stress measurements are performed with electromagnetic ultrasonic probes (EMAT). The surface inspection with magnetic imaging of the eddy current field or the multi-frequency eddy current methods are described. The possibilities of detection, classification and reconstruction of flaws are demonstrated in the time- and frequency domain with the satellite pulse echo technique, focal probes and the synthetic aperture methods like ALOK, Phased Array, Holography and SAFT.     

Online monitoring method using Equipotential Switching Direct Current potential drop for piping wall loss by flow accelerated corrosion

The flow accelerated corrosion (FAC) phenomenon persistently impacts plant reliability and personnel safety. We have shown that Equipotential Switching Direct Current Potential Drop (ES-DCPD) can be employed to detect piping wall loss induced by FAC. It has been demonstrated to have sufficient sensitivity to cover both long and short lengths of piping. Based on this, new FAC screening and inspection approaches have been developed. For example, resolution of ES-DCPD can be adjusted according to its monitoring purpose. The developed method shows good integrity during long test periods. It also shows good reproducibility. The Seoul National University FAC Accelerated Simulation Loop (SFASL) has been constructed for ES-DCPD demonstration purposes. During one demonstration, the piping wall was thinned by 23.7% through FAC for a 13,000 min test period. In addition to the ES-DCPD method, ultrasonic technique (UT) has been applied to SFASL for verification while water chemistry was continually monitored and controlled using electrochemical sensors. Developed electrochemical sensors showed accurate and stable water conditions in the SFASL during the test period. The ES-DCPD results were also theoretically predicted by the Sanchez-Caldera's model. The UT, however, failed to detect thinning because of its localized characteristics. Online UT that covers only local areas cannot assure the detection of wall loss.     

Experimental investigation of the stratified flow in the horizontal pipework of nuclear reactors

Laboratory tests have been performed to study the behaviour of a stratified fluid flow in horizontal piping. Concentrated calcium chloride brine and fresh water at room temperature were used to model the density difference due to thermal effects in nuclear reactors. Flow phenomena relating to the interface and mixing of the two layers were observed through the plexiglass piping by means of a flow visualization technique involving a longitudinal laser beam section through the flow.The measurements have established that, at the representative flow conditions modelled by the experiments, despite the presence of strong surface waves on the interface, little mixing occurs between the two layers. Quantitative correlations for the depth of the interface between the two layers, its surface slope and the height of surface waves have been established by the definition and use of two dimensionless Froude numbers.     

Crack detection and sizing technique by ultrasonic and electromagnetic methods

Improvements in defect detection and sizing capabilities for non-destructive inspection techniques have been required in order to ensure the reliable operation and life extension of nuclear power plants. For the volumetric inspection, the phased array UT technique has superior capabilities for beam steering and focusing to objective regions, and real-time B-scan imaging without mechanical scanning. In contrast to the conventional UT method, high-speed inspection is realized by the unique feature of the phased array technique. A 256-channel array system has developed for the inspection of weldment of BWR internal components such as core shrouds. The TOFD crack sizing technique also can be applied using this system. For the surface inspection, potential drop techniques and eddy current techniques have been improved, which combined the theoretical analysis. These techniques have the crack sizing capability for surface breaking cracks to which UT method is difficult to apply. This paper provides the recent progress of these phased array and electromagnetic inspection techniques.     

Prototype EMAT system for tube inspection with guided ultrasonic waves

A prototype system with full computer support for ultrasonic inspection of ferritic tubes using guided waves is described. The ultrasonic waves are launched and received with the aid of electromagnetic acoustic transducers which are layed out as linear phased arrays. The array structure provides a good axial directivity for the transducers so that the probe can be positioned anywhere along the tube length sequentially transmitting ultrasonic pulses in the foreward and backward directions. While the probe is fixed at one axial position during inspection the tube length is measured by the system and flaws are detected from returning ultrasonic echos. Results of the inspection of tubes with natural flaws are given and the wavelength-spectrum of the ultrasonic mode used for the inspection is discussed with respect to flaw depth sizing.     

Improvement of SH-wave EMAT phased array inspection by new eight segment probes

This paper presents a newly developed electromagnetic acoustic transducers (EMAT) probe with eight transmitter and eight receiver segments aiming to improve performance of a phased array EMAT probe with four transmitter and four receiver segments. Results of tests on artificial flaws in HAZ in a 6 inch diameter austenitic mock-up pipe were shown for characterizing its performance. The UT result with a conventional Piezo transducer was also referred for comparison.     

Ultrasonic signal characteristics by pulse-echo technique and mechanical strength of graphite materials with porous structure

Ultrasonic testing (UT) is an important non-destructive method to detect internal flaws and is widely applied to product control in industrial fields. In an investigation on ultrasonic signal characteristics in porous ceramics, the present authors developed an ultrasonic wave propagation model for the pulse-echo technique by improving an existing one for the transmission technique. A wave-pore reflection process was taken into account in the improvement. In the developed model, both diffusion and scattering losses can be treated as important factors of ultrasonic wave attenuation. The model was demonstrated by experimental data on ultrasonic signal characteristics of nuclear grade graphite. As an application of the model, the authors proposed a new approach combined UT signal with fracture mechanics to evaluate the mechanical strength of porous ceramics from UT signal. The combined approach was tried to apply to the acceptance test and the in-service inspection conditions of graphite components in the High Temperature Engineering Test Reactor (HTTR) as an example. This paper presents the developed propagation model for the pulse-echo technique as well as the combined approach. Moreover, both acceptance test and in-service inspection techniques of graphite components in high temperature gas-cooled reactors (HTGRs) using the combined approach was also proposed in this paper.     

Development of an ultra sonic phased array system for nondestructive tests of nuclear power plant components

A phased array ultrasonic inspection (PAULI) system is being developed to obtain electronically scanned ultrasonic images of the inside of nuclear power plant components for nondestructive evaluation. The development strategy of PAULI system was the modification of a medical ultrasound imaging system that had 64 individual transceiver channels. Optimization of array transducers has been also pursued based on the systematic investigation of the radiation beam field simulated by the use of the boundary diffraction wave models. 7.5 MHz phased array transducers was, then, fabricated and tested with the carbon steel specimen having side-drilled holes. For the nondestructive tests on power plant component, a sample mockup of turbine blade root with EDM notches was fabricated and the detection capability was demonstrated. The developed system can provide electronically scanned ultrasonic images in real time fashion and greatly enhance the efficiency and reliability in the flaw detection and location in comparison with the classical ultrasonic testing (UT) using A-scan signals. For the flaw classification, the analysis of the electronically scanned ultrasonic images was not sufficient at this moment but analysis of features obtained from A-scan signals of flaws at the various steering angles showed the potential capability.     

Application of advanced ultrasonic test techniques coupled with fatigue and leakage monitoring to assure integrity of BWR feedwater nozzles

As a result of feedwater nozzle cracking observed in Boiling Water Reactor (BWR) plants, several design modifications were implemented to eliminate the thermal cycling that led to crack initiation. BWR plants with these design changes have successfully operated for over ten years without any recurrence of cracking. To provide further assurance of this, the U.S. Nuclear Regulatory Commission (NRC) issued NUREG-0619, which established periodic ultrasonic testing (UT) and liquid penetration testing (PT) requirements. While these inspections are useful in confirming structural integrity, they are time consuming and can lead to significant radiation exposure to plant personnel. In particular, the PT requirement poses problems since it is difficult to perform the inspections with the feedwater sparger in place and also leads to additional personnel exposure. Clearly, an inspection and monitoring program that eliminates the PT examination and still verifies the absence of surface cracking would be extremely valuable in limiting costs as well as radiation exposure. This paper describes a program involving the application of advanced UT techniques coupled with fatigue and leakage monitoring to assure integrity of BWR feedwater nozzles. The inspection methods include: (1) scanning with optimized transducers and techniques from the outside vessel wall surface to inspect the nozzle inner radius region, and (2) scanning from the nozzle forging outside-diameter to inspect the nozzle bore region. Methods of analyzing the data using 3-D graphics displays have been developed that show crack location, size, and maximum depth of penetration into the nozzle inner surface. These techniques have been developed to the point where they are now considered a reliable alternative to the liquid penetrant requirements of NUREG-0619. An important supplement to the UT program is the use of automated fatigue, leakage and crack growth monitoring to verify the absence of cracking. This approach provides for a continuous assessment of the integrity of the nozzle structure by tracking the actual fatigue duty, measuring thermal sleeve bypass leakage and performing crack growth predictions based on actual thermal duty. Collectively, the monitoring and inspection program provides technically sound assurance of nozzle integrity and a firm basis for plant operational planning.     

Integration of nondestructive examination reliability and fracture mechanics

A multi-year program on the Integration of Nondestructive Examination and Fracture Mechanics (NDE/FM) has been funded by the U.S. Nuclear Regulatory Commission at the Pacific Northwest Laboratory. Many activities are being pursued under this program. This paper highlights some of the activities: input to the NRC Pipe Crack Task Group, an evaluation of manual ultrasonic testing of centrifugally cast stainless steel, interaction matrix, advanced UT technique evaluation, qualification document, evaluation of crack characterization techniques, international NDE reliability work, siamese imaging technique for imaging planar-type radial defects in reactor piping, fracture mechanics analysis for PTS-type flaws and piping reliability, and a position paper on piping ISI.     

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.     

On-line monitoring system development for single-phase flow accelerated corrosion

Aged nuclear piping has been reported to undergo corrosion-induced accelerated failures, often without giving signatures to current inspection campaigns. Therefore, we need diverse sensors which can cover a wide area in an on-line application. We suggest an integrated approach to monitor the flow accelerated corrosion (FAC) susceptible piping. Since FAC is a combined phenomenon, we need to monitor as many parameters as possible and that cover wide area, since we do not know where the FAC occurs. For this purpose, we introduce the wearing rate model which focuses on the electrochemical parameters. Using this model, we can predict the wearing rate and then compare testing results. Through analysis we identified feasibility and then developed electrochemical sensors for high temperature application; we also introduced a mechanical monitoring system which is still under development. To support the validation of the monitored results, we adopted high temperature ultrasonic transducer (UT), which shows good resolution in the testing environment. As such, all the monitored results can be compared in terms of thickness. Our validation tests demonstrated the feasibility of sensors. To support direct thickness measurement for a wide-area, the direct current potential drop (DCPD) method will be researched to integrate into the developed framework.     

Fracture mechanics evaluation of the structural material for fast breeder reactors

Results of fracture mechanics investigations on austenitic steels used for LMFBRs (Liquid Metal Fast Breeder Reactors) are presented. A summary of reported tests on straight piping and elbows with through wall flaws is given which agree well with predictions made by using a plastic instability model. Crack growth experiments and calculations indicate that initial flaws will not extend significantly during service. Even if considerable crack growth is postulated cracks will penetrate the piping wall with a high safety margin to unstable crack configurations. Theoretical investigations of flawed structures under high strains show that the effect of crack size can be discussed similarly to the elastic range. The information demonstrate that with respect to the design requirements and operating conditions of LMFBRs a sudden rupture of the piping can be excluded. The integrity of the coolant boundary is given also in case of initial flaws.     

Numerical weld modeling — a method for calculating weld-induced residual stresses

In the past, weld-induced residual stresses caused damage to numerous (power) plant parts, components and systems (Erve, M., Wesseling, U., Kilian, R., Hardt, R., Brümmer, G., Maier, V., Ilg, U., 1994. Cracking in Stabilized Austenitic Stainless Steel Piping of German Boiling Water Reactors — Characteristic Features and Root Causes. 20. MPA-Seminar 1994, vol. 2, paper 29, pp.29.1–29.21). In the case of BWR nuclear power plants, this damage can be caused by the mechanism of intergranular stress corrosion cracking in austenitic piping or the core shroud in the reactor pressure vessel and is triggered chiefly by weld-induced residual stresses. One solution of this problem that has been used in the past involves experimental measurements of residual stresses in conjunction with weld optimization testing. However, the experimental analysis of all relevant parameters is an extremely tedious process. Numerical simulation using the finite element method (FEM) not only supplements this method but, in view of modern computer capacities, is also an equally valid alternative in its own right. This paper will demonstrate that the technique developed for numerical simulation of the welding process has not only been properly verified and validated on austenitic pipe welds, but that it also permits making selective statements on improvements to the welding process. For instance, numerical simulation can provide information on the starting point of welding for every weld bead, the effect of interpass cooling as far as a possible sensitization of the heat affected zone (HAZ) is concerned, the effect of gap width on the resultant weld residual stresses, or the effect of the ‘last pass heat sink welding’ (welding of the final passes while simultaneously cooling the inner surface with water) producing compressive stresses in the root area of a circumferential weld in an austenitic pipe. The computer program (finite element residual stress analysis) was based on a commercially available code (Hibbitt, Karlsson, Sorensen, Inc, 1997. user's manual, version 5.6), and can be used as a 2-D or 3-D FEM analysis; depending on task definition it can provide a starting point for a fracture mechanics safety analysis with acceptable computing times.     

The evaluation of erosion/corrosion problems of carbon steel piping in Taiwan PWR nuclear power plant

Taiwan Pressurized Water Reactor (PWR), Maanshan nuclear power plant Units 1 and 2 implemented measurements of the wall thinning of the carbon steel piping under the request of regulation authority to prevent the events due to erosion/corrosion since 1989. At first, the licensee established the comprehensive inspection program by itself. Over 2000 components were inspected per unit and 300–500 pipe components were examined by ultrasonic testing per scheduled outage. The simple predictive methodology determined the operability of each individual piping component in the next fuel cycle. Based on the inspection results, the susceptible pipe components were established. Implementation of effective correction management and an improved inspection program can improve the safety, as well as the efficiency, of long-term reactor operations.     

Inspection procedure assessment using modelling capabilities

Before carrying out inspections on technical components, criteria have to be met to qualify the inspection procedure. The inspection qualification can be performed by technical justification or performance demonstration. The qualification of non-destructive testing methods can be checked on full scale mock-ups where real or realistic defects are implemented. To minimize costs it will become mandatory to model the inspection procedure. In the case of ultrasonic testing, the modelling includes the ultrasonic probe, the pulse-defect interaction and the probe geometry. The applied modelling code is the elastodynamic finite integration technique (EFIT) which includes mode conversion effects. The results of the code are either wave fields, A-scans at different probe positions or complete r.f. data fields. Examples demonstrate the efficiency in modelling angle beam probes which transmit both pressure, shear and subsurface longitudinal waves. These waves are scattered by horizontal or surface breaking cracks. The modelled r.f. data fields are used within the synthetic aperture focusing approach to predict the ultrasonic image which would be obtained in performing the experiment. In addition it will be shown that the EFIT wave fronts for anisotropic homogeneous media are explicitly related to the group velocity in these media.     

Sizing and characterization of ultrasonic indications using imaging techniques

For discontinuity analysis more and more sophisticated methods are used in the nuclear industry. The rapid development of computer technology offers the possibility to use imaging techniques. Instead of specialized focusing transducers the more flexible synthetic focusing techniques can be used. Presupposing that the material is ultrasonically isotropic and homogeneous, imaging techniques make it possible to visualize the reflectivity of the volume to be tested.Siemens developed the high speed holographic instrument Holo 3000 in cooperation with the University of Bochum. In this paper the method of Broad Band Holography is presented in the context of other imaging techniques.Different filtering methods have been investigated in order to achieve highest resolution and best signal to noise ratio with a given dataset. Different transducers respective wave modes have been applied to austenitic welds and claddings. The reconstructed image was evaluated using image processing techniques in order to investigate the possibilities to produce results easier to be quantifed than the original reconstruction.The results presented show a reliable expert tool for analysis measurements which also can be used for flaw detection.     

The newest two-phase flow control devices in LWR equipment based on ultrasonic and WAT-technology

This paper deals with new acoustic methods of two-phase flow diagnostics used to carry out research in the fields of nuclear power thermophysics and nuclear power plant (NPP) technologies equipment control. All the designs are to be used under extreme conditions, characteristic for water coolant, with temperature up to 350°C and pressure 20 MPa. All the safety and reliability requirements are met. The methods use waveguide ultrasonic transducers for longitudinal and bending waves, made according to specially designed technology (waveguide acoustic transducers — WAT technology). This paper deals with the operating principles of transducers and processing device physical models as well as some results on the practical use of this equipment. The method of acoustic impedance is based on measuring attenuation of a longitudinal or bending ultrasonic wave in a thin-walled tube diameter vapour fraction or the level of the coolant in the tank. The waveguide transducers, designed by the centre, use bending waves of a surface type. They enable us to carry out diagnostics of the liquid film on the inner surface of the tube or discover gas inclusions in the liquid flow. The paper touches upon the method of acoustic emission for measuring moisture content in a steam flow.     

SCC testing of pipe materials in BWR environment

A test loop has been installed in Ringhals 1 BWR, including facilities for Constant Elongation Rate Testing (CERT) and Electrochemical Potential (ECP) measurements in primary reactor water at reactor operation temperature. The loop is designed as to minimize transport time for reactor water from the reactor pressure vessel to the specimens being tested. Thus the testing environment is representative of the primary piping systems of BWRs, also with regard to short-lived constituents like hydrogen peroxide.The test program, which is in progress, has covered seven tests during start-up conditions or during power operation with presently current reactor water chemistry. In this presentation only CERT testing results on heavily sensitized austenitic chromium—nickel stainless steel are presented, although many other materials have been tested.Results show sensitized austenitic stainless steel is more prone to intergranular stress corrosion cracking (IGSCC) in actual than in simulated BWR environment and that start-up environment is chemically more aggressive than power operation environment. Reproducibility of the CERT technique as used is excellent.