Development of diagnosis algorithm for the check valve with spectral estimations and neural network models using acoustic signals

We have developed a method for detecting and diagnosing a disk wear failure and a foreign object failure among the various failure modes of check valves. The method is based on the acoustic emission sensors which can detect the sound wave of the leakage flow and the estimation of the power spectral densities with an auto-regressive model. For validating the method, we implemented a hydraulic test loop with an artificially failed check valve. We have found that the frequency spectrums from the acoustic signals are strongly dependent on the failure modes of the check valve and that they are nearly independent of the failure size and operating pressure through an estimation of the power spectral density with an auto-regressive signal processing model. In addition, the root mean square values of the acoustic signal and the amplitudes of the power spectral density as well as the loop pressure have a strong dependency on the failure size in each failure mode of the check valve. We developed a diagnosis algorithm by using neural network models in order to identify the type and size of the failure in the check valve. The diagnosis algorithm consists of a hierarchical model composed of three back-propagation neural networks. The results of our research and the experiments show that the diagnosis algorithm is proven to be a good solution for identifying the failures of the check valves without any disassembling work.     

Degradation mechanism of check valves in nuclear power plants

A large amount of deposit was detected at a 6-in. check valve installed in a nuclear power plant. To identify the origin of the deposit, the chemical composition of the deposit was analyzed. In this paper, in order to find out the degradation mechanism of the 6-in. check valve, vibration and temperature monitoring of the check valve are carried out during plant heat up and standby conditions. And some degradation mechanisms of the check valve are investigated. Results show that the degradation was caused by valve chattering due to the acoustic resonance.     

Evaluation of check valve monitoring methods

Check valves are used extensively in nuclear plant safety systems and balance-of-plant (BOP) systems. Their failures have resulted in significant maintenance efforts and, on occasion, have resulted in water hammer, overpressurization of low-pressure systems and damage to flow system components. Consequently, in recent years check valves have received considerable attention by the Nuclear Regulatory Commission (NRC) and the nuclear power industry. Oak Ridge National Laboratory (ORNL) is carrying out a comprehensive two phase aging assessment of check valves in support of the Nuclear Plant Aging Research (NPAR) program. As part of the second phase, ORNL is evaluating several developmental and/or commercially available check valve diagnostic monitoring methods; in particular, those based on measurements of acoustic emission, ultrasonics, and magnetic flux. These three methods were found to provide different (and complementary) diagnostic information. The combination of acoustic emission with either ultrasonic or magnetic flux monitoring yields a monitoring system that succeeds in providing sensitivity to detect all major check valve operating conditions. The three check valve monitoring methods described in this paper are still under development and are presently being tested as part of a program directed by the Nuclear Industry Check Valve Group (NIC) in conjunction with the Electric Power Research Institute (EPRI). Phase 1 of this program (water testing) is being carried out at the Utah Water Research Laboratory located on the Utah State University campus.     

An assessment of acoustic emission for nuclear pressure vessel monitoring

Recent research has greatly improved our understanding of the basic mechanisms of deformation and fracture that generate detectable acoustic emission signals in structural steels. A critical review of the application of acoustic emission (AE) to the fabrication, proof testing and in-service monitoring of nuclear pressure vessels is presented in the light of this improved understanding. The detectability of deformation and fracture processes in pressure vessel steels is discussed, and recommendations made for improving source location accuracy and the development of quantitative source assessment techniques.

Published data suggest that AE can make an important contribution to weld fabrication monitoring, and to the detection of defects in lower toughness materials during vessel proof testing. In high toughness materials, however, the signals generated during ductile crack growth may frequently be too weak for reliable detection. The feasibility of AE for continuous monitoring has not yet been adequately demonstrated because of high background noise levels and uncertainty about AE signal strengths from the defect growth processes that occur in service. In-service leak detection by AE shows considerable promise.

It is recommended that further tests are carried out with realistic defects, and under realistic conditions of loading (including thermal shock and fatigue) and of environment.     

An overview of development and application of acoustic emission methods in the United States

Beneficial uses being made of acoustic emission (AE) technology for flaw or fault detection both inside of and outside of the nuclear industry tend to be obscured by some of the earlier disappointing efforts to utilize the technology. The objective of this paper is to counter that tendency by providing an overview of a variety of AE applications being made in the United States. In addition to nuclear power applications, the paper discusses applications in other nuclear areas, fossil power plant applications, and other industrial uses including aircraft monitoring. Major AE research and development programs in progress in the United States are also summarized.     

液压下压力管线活动缺陷声发射信号研究

在液压试验装置上,对含预制裂纹的压力管开展了缺陷扩展声发射信号试验研究.全程不间断监测压力管道疲劳裂纹扩展的声发射信号,并对采集到的信号进行分析处理.结果表明:管道缺陷声发射信号的幅度和能量随加载时间逐步增大,可以用于鉴别管道是否存在活动缺陷;在缺陷贯穿前,声发射信号的幅度、能量和计数急剧增加,可以预报管道缺陷的贯穿泄漏.     

Acoustic emission for on-line reactor monitoring: Results of intermediate vessel test monitoring and reactor hot functional testing

This article discusses a program designed to develop the use of acoustic emission (AE) methods for continuous surveillance to detect and evaluate flaw growth in reactor pressure boundaries. Technology developed in the laboratory for identifying AE from crack growth and for using that AE information to estimate flaw severity is now being evaluated on an intermediate vessel test and on a reactor facility.A vessel, designated ZB-1, has been tested under fatigue loading with simulated reactor conditions at Mannheim, West Germany, in collaboration with the German Materialprüfungsanstalt (MPA), Stuttgart. Fatigue cracking from machined flaws and in a fabrication weld were both detected clearly by AE.AE data were measured on a US nuclear reactor (Watts Bar, Unit 1) during hot functional preservice testing. This demonstrated that coolant flow noise is a manageable problem and that AE can be detected under operational coolant flow and temperature conditions.     

Progress for on-line acoustic emission monitoring of cracks in reactor systems

This paper reviews accomplishments and planned tasks for the NRC-sponsored research program concerned with “Acoustic Emission/Flaw Relationships for Inservice Monitoring of Nuclear Reactor Pressure Boundaries”. The objective of the acoustic emission (AE) monitoring program is to develop and validate the use of AE methods for continuous surveillance of reactor pressure boundaries to detect flaw growth. Topics discussed include testing AE monitoring on reactors, refinement of an AE signal identification relationship, study of slow crack growth rate effects on AE generation, and activity to produce an ASTM standard for AE monitoring and to gain ASME code acceptance of AE monitoring.     

Characterisation of Al corrosion and its impact on the mechanical performance of composite cement wasteforms by the acoustic emission technique

In this study acoustic emission (AE) non-destructive method was used to evaluate the mechanical performance of cementitious wasteforms with encapsulated Al waste. AE waves generated as a result of Al corrosion in small-size blast furnace slag/ordinary Portland cement wasteforms were recorded and analysed. The basic principles of the conventional parameter-based AE approach and signal-based analysis were combined to establish a relationship between recorded AE signals and different interactions between the Al and the encapsulating cement matrix. The AE technique was shown as a potential and valuable tool for a new area of application related to monitoring and inspection of the mechanical stability of cementitious wasteforms with encapsulated metallic wastes such as Al.     

Acoustic emission monitoring of ZB-1 intermediate scale vessel test

A program to develop the use of acoustic emission (AE) flaw detection methods for continuous surveillance of reactor pressure boundaries is in process in the United States. Evaluation of laboratory developed relationships for data verification and interpretation was performed by participation in a German intermediate scale vessel (ZB-1) test. The test sequence consisted of repeated blocks of a hydrostatic test followed by two sets of cyclic loading at different R-ratios. Testing was performed in cooperation with the German Materialprüfungsanstalt at the Grosskraftwerk facility in Mannheim, West Germany. This paper discusses preliminary results obtained during the first half of the test which was performed at 70°C. The AE system detected crack growth from machined flaws and also spontaneous crack growth in a fabrication weld. AE signals from cracking were consistently high amplitude and occurred at or near peak load. Crack growth rates estimated from AE data were consistent with values derived from crackopening-displacement gauges. The test produced unique and important data needed to develop reliable application of AE methods for continuous monitoring of reactor pressure systems.     

Acoustic emission surveillance for improving availability of nuclear power plants

An experimental study of advanced acoustic emission monitoring of BWR components is being performed at Philadelphia Electric Company's Peach Bottom Atomic Power Station. The study addresses the feasibility of using continuous acoustic emission monitoring for increasing availability of LWR power units. Here we present a summary of a “Valve Surveillance” program and we describe the installation and performance of AE instrumentation for the “Pipe Surveillance” program.     

The use of acoustic emission to determine characteristic dynamic strength and toughness properties of steel

The dynamic J integral at crack initiation (J_id) and dynamic yield stress (σ_yd) are useful parameters to characterize elastic-plastic material behaviour under rapid loading rates. The critical step for evaluating J_id and σ_yd under the condition of the three point impact bending test is the detection of the crack initiation and of the yield point in the impact load–deflection curve, respectively. This paper presents an acoustic emission (AE) based method to determine the ductile crack initiation and additionally the beginning of yield. The experimental techniques used to evaluate σ_yd and J_id include both instrumented pendulum impact tests with the AE transducer within the striker (tup) and medium rate three point bend (TPB) tests with additional AE transducers on the specimen surface. Results obtained from the tests indicate that the AE method is capable of detecting general yielding and the onset of ductile crack growth (initiation). Different types of pulse shaped AE signals can be observed. They were connected with characteristic features during the loading process.     

对冲式止回阀原理及启闭特性分析

压水堆核电站主泵工况变化时,由于止回阀阻止流体逆流,回路会发生程度不同的水击现象.水击严重时不但会产生瞬时超压,危害压力边界,也可能造成止回阀失效.对冲式止回阀是一种新原理止回阀,是为解决传统止回阀关闭时产生的严重水击现象而设计的.分析和实验表明对冲式止回阀能有效地解决回路的水击问题,也能可靠地阻止流体逆流.     

核级阀门流体阻断试验技术研究

在试验装置上开展了压水堆运行参数范围内动力驱动阀门的流体阻断试验研究和止回阀的动态逆流与静态逆流试验研究。试验结果表明：开展动力驱动阀门流体阻断试验时,在设施能力不足的情况下可将阀门开启度适当减小,也能验证阀门阻断流体的能力;止回阀静态逆流试验相较于动态逆流试验能更苛刻地考验止回阀的阻断性能。本文结果可为开展同类验证试验在试验方法的选取上提供依据。     

Determination of the probability of spontaneous fracture of metal from the acoustic emission spectrum at the prefracture stage

The Weibull distribution is used to calculate the probability of failure of any type of system. In the case of the fracture of metal, the squared critical stress is taken as the random variable and the fractal dimension as the form parameter. Fluctuations of the critical stress intensity at the prefracture stage are accompanied by an acoustic response (acoustic emission). It is concluded that information about the acoustic emission intensity (amplitude criterion) is not enough to calculate the probability of spontaneous failure. It is also necessary to take account of the temperature and fractal dimension of the prefracture region. It is proved that the fractal dimension can be determined from the acoustic emission spectrum. The results of a determination of the instantaneous probability of spontaneous failure of samples of corrosion-resistance steel on the basis of acoustic emission spectroscopy are presented. __________ Translated from Atomnaya énergiya, Vol. 102, No. 6, pp. 351–358, June, 2007.     

Detection of acoustic emission events in the presence of parasitic noise

The optimum threshold for the detection of acoustic emission bursts, which are masked by parasitic noise is calculated. The theoretical results are applied to the acoustic noise generated by boiling sodium.     

Measurements of acoustic emission due to thermocycling of oxidized high temperature alloys

The ring down counts and energy of acoustic emission (AE) signals emitted during thermal cycling of oxidized IN-519, HASTELLOY X, and INCOLOY 800 H were measured. The HT alloys were oxidized in situ under a controlled oxidation potential defined by the H₂O/H₂ ratio. The hydrogen permeation was also continuously measured. A correlation between AE and changes of the hydrogen permeation which both occur during the thermal cycling procedure was observed. On the basis of the measurements some characteristic properties of the investigated oxide scales are derived.     

对冲式止回阀局部流动特性仿真模拟

当压水堆核电站主泵工况变化时,回路会发生程度不同的水击现象,严重时不仅会产生瞬时超压危害压力边界,也可能造成止回阀失效。对冲式止回阀是一种新型止回阀,其新型的导流结构设计可很好地减轻水击现象,提高核电站运行的安全性。本工作基于FLUENT流体仿真软件,利用动网格及UDF(用户自定义函数)技术,更真实地模拟了阀门关闭过程中冲压管喉部及其联接腔体内的流场与压力分布。模拟结果表明,虽然几何形状的变化会导致关闭过程中局部流速高于其他部位的,但对阀门关闭过程的稳定性影响很小。另外,通过对流场分析发现,阀门关闭过程可分为3个阶段,每一阶段均有其独立特征,为以后阀门结构的改进及可靠性分析提供了依据。     

旋启式止回阀关阀水锤优化分析

建立了双泵并联给水系统数学物理模型,针对旋启式止回阀关闭过程中形成的水锤进行编程计算,分析作用在止回阀阀板上的力矩以及阻尼扭簧力矩对关阀水锤的影响。结果表明：在双泵并联给水系统中,旋启式止回阀在关闭时会产生明显水锤,作用在阀板上的力矩对水锤的作用效果有一定影响,选择合适的止回阀阀板材料以及加装合适的弹簧可有效缓解水锤危害。