EPRI NDE Issues Meeting - Amazon S3 Oxygen 70 μm 13 Contractual Efforts Structures •Advanced Scanning Systems –Increased accuracy, reliability, effectiveness •Magneto Resistive
Post on 09-Jun-2018
218 Views
Preview:
Transcript
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Steve Swilley, EPRI
Director, NDE
NDE Technology Week
June 2016
Savannah
EPRI NDE
Issues Meeting
3© 2016 Electric Power Research Institute, Inc. All rights reserved.
Safety Emergency exit
Standard in-room hazards
– Wires, luggage, other trip hazards
– Hot coffee
Resources
– Closest hospitalMemorial Health Savannah Hospital912-350-8000
– Closest pharmacyCVS on Bull Street912-238-1494
– Closest Urgent CareApple Care Savannah912-200-3219
4© 2016 Electric Power Research Institute, Inc. All rights reserved.
Nuclear Safety Culture NUCLEAR IS DIFFERENT
“The core values and behaviors resulting from
a collective commitment by leaders and individuals
to emphasize safety over competing goals
to ensure protection of people and the environment.”
-- USNRC Safety Culture Policy Statement
For the Commercial
Nuclear Power Industry,
nuclear safety remains the
overriding priority
Personal Accountability
Questioning Attitude
Effective Safety Communication
Leadership Safety Values and Actions
Decision-Making
Respectful Work Environment
Continuous Learning
Problem Identification and Resolution
Environment for Raising Concerns
Work Processes
5© 2016 Electric Power Research Institute, Inc. All rights reserved.
Agenda - TodayTime Topic Speaker
8:00 WELCOME STEVE SWILLEY, EPRI
08:10
KEYNOTE PRESENTATIONS
THE EPRI NDE PROGRAM: THINKING AHEAD
NDE, MATERIALS STATE AWARENESS AND RELIABILITY WITHIN THE
US AIR FORCE
VC SUMMER UNITS 2 AND 3: STATUS, CHALLENGES, AND FUTURE DIRECTION
STEVE SWILLEY, EPRI
RYAN MOOERS, AIRFORCE RESEARCH
LABORATORY
ANDREA STERDIS, SCANA
9:30 EPRI TECHNOLOGY INNOVATION: FINDING NEEDLES IN HAYSTACKSRON SCHOFF, EPRI
10:00 BREAK
10:15EPRI NDE PROGRAM TECHNOLOGY TRANSFER
THE 2016 NDE DELIVERABLES MADE AVAILABLE TO ALL STAKEHOLDERSBOB BOUCK AND EPRI STAFF
12:00 LUNCH
1:15 PERSPECTIVES ON NDE RELIABILITY GREG SELBY, EPRI
1:45 US NUCLEAR REGULATORY COMMISSION / NUCLEAR REGULATORY RESEARCH PERSPECTIVES STEPHEN CUMBLIDGE /
CAROL NOVE, NRC
2:15 NDE AND THE NUCLEAR PROMISE: CAN IT DELIVER? MARK RICHTER, NEI
2:45 INDUSTRY OPERATIONAL EXPERIENCE TO BE ANNOUNCED
3:30 NDE TECHNOLOGY SHOWCASE
7:30 ADJOURN
6© 2016 Electric Power Research Institute, Inc. All rights reserved.
2016 Technology Showcase Exhibitors Today at 3:30
Advanced OEM Solutions (AOS)
Applied Technical Services, Inc.
Applus RTD
AREVA, Inc.
Core VIS, Inc.
Curtiss-Wright Nuclear
Eddyfi
FlawTech
General Electric Co.
IHI Southwest Technologies, Inc.
Jamko Technical Solutions
Mirion Technologies (Imaging) LLC.
MISTRAS Group, Inc.
SciAps, Inc.
Sonaspection International, Ltd.
Sonic Systems International, Inc.
Structural Integrity Associates, Inc.
System One
WesDyne International
Westinghouse Electric Company LLC
ZETEC, Inc.
7© 2016 Electric Power Research Institute, Inc. All rights reserved.
Agenda - Wednesday
Time Topic Speaker
8:00 THINKING AHEAD - RECAP STEVE SWILLEY, EPRI
8:15 BREAKOUT GROUPS
KEN RUSSELL / BECKY SCOTT, R SCOTT CONSULTING
SCOTT CARLBERG /
RENITA CRAWFORD, EPRI
10:45 BREAK
11:00
NDE IN THE EPRI NUCLEAR SECTOR
CONCRETE
FUELS AND DRY STORAGE
UNDERGROUND PIPING AND TANKS
BOB BOUCK , EPRI
SAL VILLALOBOS, EPRI
JEREMY RENSHAW, EPRI
STEVE KENEFICK, EPRI
11:45 THINKING AHEAD - MEETING SUMMARY STEVE SWILLEY
12:00 LUNCH
1:15
EPRI NDE PROGRAM - TECHNICAL ADVISORY COMMITTEE (TAC) [OPEN MEETINGS]
RELIABILITY TAC
TECHNOLOGY TAC
PHIL ASHWIN
NATHAN MUTHU
5:00 ADJOURN
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Leo Martin
NDE APC Chair
Duke Energy
Opening Remarks
10© 2016 Electric Power Research Institute, Inc. All rights reserved.
Let’s talk
about where
we’ve been …
… and where
we need to go.
The differences always make Right Now a bit tricky.
11© 2016 Electric Power Research Institute, Inc. All rights reserved.
NDE Issues Meeting
We started having the Issues Meeting over 20 years ago
– Our business model had changed
– The Issues Meeting was established as a means to collect input from industry stakeholders, to help ensure that our program content was relevant
It helped, and we’ve kept doing it
12© 2016 Electric Power Research Institute, Inc. All rights reserved.
NDE Issues Meeting
Lately we’ve used themes
– 2010 – “NDE: Going Underground”
underground piping
– 2011 – “Bridging the Gaps”
strategic thinking
– 2013 – “Driving NDE Reliability”
after missing flaws in the field
– 2014 – “Technology Transfer –
Moving The Dial”
getting technology products out there
– 2015 – “Global Cooperation”
thinking as a global fleet
This year, it’s
“Thinking Ahead”
13© 2016 Electric Power Research Institute, Inc. All rights reserved.
Thinking ahead
It gets harder and harder to find the correct balance of
research content; there’s a fundamental conflict between
imperatives
– Keep the current fleet safe, reliable, economic and operating
– Prepare for future needs as the global nuclear fleet’s technology
and purposes evolve
For the next few minutes,
let’s look far ahead
14© 2016 Electric Power Research Institute, Inc. All rights reserved.
Can the future come fast enough?
15© 2016 Electric Power Research Institute, Inc. All rights reserved.
Clean Electric Sector Enables Economy-wide Emission Reduction
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
2015 2020 2025 2030 2035 2040 2045 2050
U.S. Economy-wide Emissions
Bill
ion
s T
on
s C
O2
eq.
Source: US-REGEN data; Energy Modeling Forum 24
CH4, N2O, and F-gases
Non-Electric Sector CO2
Electric Sector CO2
60%
70%
80%
Economy-
wide
Emission
Reduction
16© 2016 Electric Power Research Institute, Inc. All rights reserved.
Electrification - the Pathway to Economy-wide CO2 Reductions
17© 2016 Electric Power Research Institute, Inc. All rights reserved.
Pathway to 2050
Coal and Gas Carbon
Capture and Sequestration
Source: Carbon Capture Image – htcco2systems.com; Gen IV Image – KAERI
Generation IV Nuclear(co-production – electricity, hydrogen steam)
High-Altitude WindGen III Photovoltaic (PV)
(e.g., High power density PV cells)
Large-Scale Storage(e.g., Regenesys Flow Battery)
18© 2016 Electric Power Research Institute, Inc. All rights reserved.
Globally we have a fleet of over 400 commercial reactors
– Some are facing the end of life
– But most are challenged to achieve long-term operational,
economic and regulatory viability
– And many new plants and new plant designs are becoming reality
Now let’s look at today,
and at the nearer future
There are new challenges and opportunities for NDE
19© 2016 Electric Power Research Institute, Inc. All rights reserved.
In this session
One of these challenges is continued aging;
what NDE is needed to look even deeper into the
structure of materials?
– In this session Ryan Mooers of the US Air Force
Research Laboratory will discuss another industry’s
approach to similar challenges
Another challenge is construction of new reactor
units, often in a regulatory and industrial
infrastructure context that is unready for it
– In this session Andrea Sterdis of SCANA will discuss
the construction of new AP-1000 units at the VC
Summer site in South Carolina
Integrity Service Excellence
21© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
1
Integrity Service Excellence
NDE, Materials State
Awareness, and
Reliability Within the
US Air Force
22 June 2016
Ryan Mooers
Associate Materials Research Engineer
Materials State Awareness Branch (RXCA)
Structural Materials Division
Materials and Manufacturing Directorate
Air Force Research Laboratory
2
Disclaimer
• The views expressed in this presentation are
those of the author and do not reflect the
official policy or position of the United States
Air Force, Department of Defense, or the
United States Government
3
Outline
• Introduction
– Vision/ Motivation
– Who, What, How, and Where’s
• Current Branch Efforts
– In-House Research
– Contracted Efforts
• POD and Reliability
– Connection with ASIP
– Doing a POD study
Photo Courtesy of Dr. Eric Lindgren
4
USAF NDE Vision
Digitally-enabled Reliable
Nondestructive Quantitative
Materials / Damage Characterization
Regardless of Scale
5
Motivation / Objectives
Improve NDE Capability / Reliability / Efficiency to
• Provide decision quality information to
determine asset integrity (Safety FIRST!)
Maintain user confidence in asset safety
• Minimize disassembly and related maintenance
induced damage (save time and money)
Minimize false calls
• Optimize materials design and production
For Our Airmen
6
Where We Came From
• Initially for Quality Control
– 1919 Materials Section mission included “make
routine inspection tests for Procurement Section”*
– Initial applications in radiography and magnetic
particle inspections
• Evolved to include parts in use
• US Air Force established in 1947
• Formalized NDT Section in 1952
• NDE Branch stood up in 1974
• Materials State Awareness Branch:
– Result of Reorganization in 2012Lt. H.H. Arnold,
Military Aviator Number 1, 1911
General of the Air
Force
*Slipstream, 1919 McCook Field Newsletter
“The next Air Force is going to be built around
scientists – around mechanically minded fellows.”
Gen H.H. Arnold
7
Where We Fit & What We Do
Air Force
Research Laboratory
RXSAAdvanced
Engineering,
Rapid Response
RXCAResearch,
Development,
Transition
AF
Life Cycle
Management Center
AF
Sustainment
Center
AFSC NDI Program ManagerComplex NDI Managers
Depot/Field/SPO Support
AF NDI Office
Maintain NDI operational
infrastructure
NDI Executive
Working Group
8
How We Do It
Augmented Materials Design, Processing, and Performance
Efficient and Effective ASIP/PSIP/MX Actions
Model-driven Quantitative Representation of Material/Damage State with Statistical Metrics
3D Representation and Validation
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.20
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
crack length (in)
PO
D
MAPOD
exp.
Signal Analysis and Uncertainty Quantification
NDE Damage / Materials
Characterization
10
In House Research Efforts
Modeling and Simulation
• Eddy Current
– Complex/ Commercial
Probes
– Angular/ Dimension
Variation
– True Impedance
Comparison
• Ultrasound
– Realistic microstructure
– Anisotropy
– Characterization based
on received signal
11
In-House Research Efforts
Composites
• Impact Damage
Characterization
– Area and depth
5 MHz Beam Model
shear longitudinal
10 MHz Beam Model
shear longitudinal
12
In-House Research
Material Characterization
• Micro texture Regions
– Produce false indication
– Potential to affect
material properties
• Single Crystal Elastic
Constant Measurement
– Crystal plasticity models
– Need accurate values
• CMC Degradation
– FTIR Inspection
– Chemical changes due
to heating
SiC fiber
BN
matrix
SiO2
Oxygen
70 μm
13
Contractual Efforts
Structures
• Advanced Scanning
Systems
– Increased accuracy,
reliability, effectiveness
• Magneto Resistive
Sensing
– Low frequency, multi-
layer inspection
• Remote Access NDE
– Hard to reach areas
– Minimize disassembly
14
Contractual Efforts
Propulsion
• Sonic IR for Turbine
Blades
– Whole field inspection
– Reduction operator time
– Reduced false call and
hazardous waste
– Transitioning to Tinker
AFB
– Next step: Disks
• Crack sizing in disk
– Model assisted inversion
routine
scan,x (mils)
index,y
(m
ils)
T D40 20 x 10.matb
-50 0 50
-80
-60
-40
-20
0
20
40
60
80 -60
-40
-20
0
20
40
60
scan,x (mils)
index,y
(m
ils)
T D40 20 x 10.matb
-50 0 50
-80
-60
-40
-20
0
20
40
60
80 -400
-300
-200
-100
0
100
200
300
400
scan,x (mils)
index,y
(m
ils)
VIC-3D: 20x10x1.2 mil
-50 0 50
-80
-60
-40
-20
0
20
40
60
80-50
0
50
scan,x (mils)
index,y
(m
ils)
VIC-3D: 20x10x1.2 mil
-50 0 50
-80
-60
-40
-20
0
20
40
60
80-400
-300
-200
-100
0
100
200
300
400
Simulation
Experimental.
Vhoriz Vvert
x
y
Model-assisted
analysis of EC
impedance plane
EC Probe
15
Longer Term Initiatives
• ASK (Advance Sustainment Knowledge) NDE
– Capture / exploit all NDE related data
• Assure inspections performed and performed as intended
• Increase effectiveness/efficiency of inspection processes
• Integrate into characterization efforts
• Damage State Awareness (DSA)
– Quantify size of damage detected
• Significant leveraging of modeling and simulation
• Data driven and Bayesian inversion routines
• Data Registration
– Register inspection data to specific location
• Use for potential inversion
• Tie to location and into Digital Thread/ Digital Twin
17
Link to USAF Integrity Programs
Structures
Aircraft Structural Integrity Program (ASIP)
• Established in 1958 after five destroyed
B-47 aircraft in March – April 1958*– Four losses attributed to fatigue
• Uses probabilistic approach to establish
aircraft service life capability: “Safe-Life”
*ASC-TR-2010-5002, Threats to Aircraft Structural Safety, Incl. a Compendium of Selected Structural Accidents/Incidents, March 2010.
• Loss of F-111 (Dec, 1969)* and F-5 (April,
1970)* far short of qualified “Safe-Life”– Designs intolerant of manufacturing and/or
service-induced defects
• Leads to Damage Tolerance Approach– Tolerate defects for some inspection-free period
of service usage
– Formally integrated into ASIP in 1975
18
Link to USAF Integrity Programs
Propulsion
Propulsion Structural Integrity Program (PSIP)
• Introduced in 1978 as Engine Structural
Integrity Program (ENSIP)
• ENSIP MIL-STD 1783, published 1984
– Becomes MIL-HDBK-1783 in 1997, now Rev B
• PSIP MIL-STD 3024, published 2008
– Applicable to gas turbine engines
– Essentially a safe life approach
… but crack growth criteria also enforced
– Components retired with remaining serviceable life
• Damage Tolerance Methods to extend service
life are being pursued
*http://www.f-16.net/f-16-news-article3930.html. **http://www.geaviation.com/military/engines/f110/
P&W F-100*
GE F-110**
19
Overview of ASIP
Aircraft Structural Integrity Program (ASIP)
• Governed by MIL-STD-1530C
• Establishes required safety metrics for structures
• Fracture mechanics enables predictive management
of fatigue– Periodic inspection before crack reaches critical size
USAF is meeting required safety metrics for structures,
but at a high cost
• Composites are approaching DTA capability– Predictive damage evolution is maturing towards realization
• Corrosion managed by time-based assessments– Prediction of corrosion evolution not available
– Primary hurdle is predicting breakdown of coatings and/or
inhibitors in primers/sealants
20
NDE in ASIP: Representative
DTA Risk Assessment
Initial Crack
Size
Distribution
Max Stress
per Flight
Crack
Growth
CurveStress
Intensity
Factor
Fracture
Toughness
Single Flight
Probability of
Failure
Probability of
Failure
between
Inspections
Cumulative
Expected
Failures
Integration/
Calculation
Repair
Crack Size
Distribution
Inspection
Capability
(POD)
21
NDE in ASIP: Representative
DTA Risk Assessment
Initial Crack
Size
Distribution
Max Stress
per Flight
Crack
Growth
CurveStress
Intensity
Factor
Fracture
Toughness
Single Flight
Probability of
Failure
Probability of
Failure
between
Inspections
Cumulative
Expected
Failures
Integration/
Calculation
Repair
Crack Size
Distribution
Inspection
Capability
(POD)
NDE/SHM POD:
a primary input
into risk
assessment
22
DTA Crack Growth
Crack Size, 𝑙
Flight
Hours
Initial Flaw Size
Estimate
Critical Length
Time to Critical
Length𝐼1 𝐼2
23
DTA Crack Growth Cont.
Crack Size, 𝑙
Flight
Hours
𝐼1
We didn’t find
anything
We get to use new
initial crack length
based on NDE
capability
24
DTA Crack Growth Cont.
Crack Size, 𝑙
Flight
Hours
𝐼1
We get to use new
initial crack length
based on NDE
capability
We didn’t find
anything
How Do We
Determine our
NDE Capability
25
Probability of Detection
• Probability that, for a
crack of certain length:
– The signal will be at a
detectable level during a
given inspection
scenario &…
– The inspector will call
out a flaw
• Sources of uncertainty:
– Probe characteristics
– Operator
– Calibration procedure
– Electrical noise in
systems
– Crack features
– And many more…
26
Major Parts to a POD Study
• Capture variability in parameter space
– Some are known to be unimportant others are too
difficult to vary over
• Develop a test matrix to capture data from all
variations
– Determine min and max values of parameters or guess
at distributions (Full or Sparse)
– Document why other parameters weren’t considered
• Gather Experimental Data
– Many inspection opportunities – representative parts
– With and without flaws
27
Building a POD Curve
0 2 4 6 8 100
0.05
0.1
0.15
0.2
0.25
0.3
0.35
Flaw Size, 𝑎(mm)
Sig
nal S
trength
, 𝑎
(V)
𝑎 = 𝛽0 + 𝛽1𝑎 + 𝜀
𝜀~𝑁[0, 𝜎2]
28
0 2 4 6 8 100
0.05
0.1
0.15
0.2
0.25
0.3
0.35
Flaw Size, 𝑎(mm)
Sig
nal S
trength
, 𝑎
(V)
0
2
4
6
8
10
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0
2
4
6
8
10
0
0.0
5
0.1
0.1
5
0.2
0.2
5
0.3
0.3
5
02
46
81
00
0.0
5
0.1
0.1
5
0.2
0.2
5
0.3
0.3
5
Fla
w S
ize, 𝑎
(mm
)
Signal Strength, 𝑎 (V)
Building a POD Curve
• Flip the
graph on
its side
29
Building a POD Curve
• Set threshold
value
• Fix value of a
• Identify region of
response curve
above threshold
• Integrate this area
for all values of aF
law
Siz
e, 𝑎
(mm
)
Signal Strength, 𝑎 (V)
𝑎𝑡ℎ
Fixed 𝑎 value
30
POD Curve
• This is where we
get the NDE limit
– Which Point
• Input to DTA
– Curve or just a few
points
• Largest flaw we
will miss
0 1 2 3 4 5
x 10-3
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
Pro
bab
ilit
y o
f D
etect
ion,
PO
D(a
)
Flaw Size, a
𝑎90 𝑎90/95
𝑎20
31
NDE in ASIP: Representative
DTA Risk Assessment
Initial Crack
Size
Distribution
Max Stress
per Flight
Crack
Growth
CurveStress
Intensity
Factor
Fracture
Toughness
Single Flight
Probability of
Failure
Probability of
Failure
between
Inspections
Cumulative
Expected
Failures
Integration/
Calculation
Repair
Crack Size
Distribution
Inspection
Capability
(POD)
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Ron Schoff
Senior Program Manager
Technology Innovation
NDE Technology Week
June 21, 2016
Technology InnovationFinding Needles in Haystacks
2© 2016 Electric Power Research Institute, Inc. All rights reserved.
Electric Power Research Institute
5© 2016 Electric Power Research Institute, Inc. All rights reserved.
Research
& Discovery
(TRL 1-2)
Innovation
& Development
(TRL 3-4)
Pilots &
Demonstration
(TRL 5-6)
Commercialization
& Diffusion
(TRL 7-9)
Technology Maturity in Terms of Technology Readiness Level (TRL)
Lawrence Livermore,
Harvard University
and the University of
Illinois at Urbana-
Champaign, have
developed a new type
of carbon capture
media composed of
core-shell
microcapsules that
reacts with and
absorbs carbon
dioxide (CO2).
TerraPower is
developing a 600
megawatt-electric
prototype Traveling
Wave Reactor TWR-P.
intended to have start-
up around 2022. This
is the next step in the
journey to full
commercialization and
deployment of the 4th
generation reactor with
closed cycle fuel.
NET Power, CB&I,
Exelon, Toshiba and
8 Rivers Capital
are developing a
50MWth natural gas
demonstration plant
that will validate a new
high efficiency power
cycle using CO2 as the
working fluid.
In September 2014,
Southern California
Edison unveiled the
Tehachapi Energy
Storage Project, the
largest battery energy
storage system
(BESS) in North
America The 32-MWh
(8 MW x 4 hours)
using lithium-ion
batteries.
TI is Focused on Scouting Pre-Commercial Tech and Incubating Promising TRL 1-6 Options
6© 2016 Electric Power Research Institute, Inc. All rights reserved.
Global Points of ViewCommon Characteristics for Future Scenarios
Energy and Emissions
Reducing emissions will remain a long-
term global issue
Global energy demand will remain flat in
OECD; grow in non-OECD
Efficiency and Renewables
Energy efficiency gains will be made across
the energy value chain
The cost of wind and solar energy will
decrease; global deployment to increase
Customer Expectations
Primary drivers: choice, control, comfort, & convenience
IoT will digitally connect every customer to every thing
Increased dependence on electricity requires higher reliability
and power quality
Increased resiliency to physical/cyber/weather events
Water
Increasingly water-constrained future
over the long term
Water-energy interfaces continue to
expand
7© 2016 Electric Power Research Institute, Inc. All rights reserved.
Future Vision: Integrated Energy Network
Integrated Energy
Network
A Network of Infrastructures that
connects customers with clean
energy production and use
Using Cleaner
Energy and
Electrification
Producing
Cleaner
Energy
Integrating
Energy
Resources
8© 2016 Electric Power Research Institute, Inc. All rights reserved.
Facilitating the Power System of the FutureSharp Focus on Relevant, Advanced R&D
Advanced Fossil &
Nuclear Generation
Next-Gen Renewable
Energy & Integration
Bulk/Grid-Scale Energy
Storage
Integration of Customer
Resources
Next-Gen Electric
Technologies
Distributed Energy
Storage
Grid Modernization
Integrated, Secure Grid
Architecture
Integrated Modeling &
Planning Framework
Producing
Cleaner Energy
Using
Cleaner Energy
Integrating
Energy Resources
Materials
NDE
Robotics/UAS
Sensors
Big Data
Water
Cross-Cutting
R&D
9© 2016 Electric Power Research Institute, Inc. All rights reserved.
• Focus on research needs of an Integrated Energy Network
• Form and Engage Innovation Networks
• Identify emerging science, technology, regs and models
• Evaluate opportunities via structured due diligence method
• Collaborate with Universities, Developers, Governments, and other
industry stakeholders where appropriate
EPRI Innovation Scouting
Innovation
Networks
Scout for
Opportunities
360° EvaluationPerformance/Economic/Policy
Collaborate to Support
Industry Adoption
10© 2016 Electric Power Research Institute, Inc. All rights reserved.
NDE Research Technology Gaps being addressed
11© 2016 Electric Power Research Institute, Inc. All rights reserved.
Key Results – NDE Modeling and Simulation
Continue development of NDE modeling and simulation tools to facilitate more efficient and cost effective design and implementation of NDE technology; to address NDE for materials degradation issues in all sectors
– Delivered a technical update (2015) that includes a benchmarking assessment of various NDE modeling and simulation packages:
Semi-analytical CIVA, 2D finite difference Wave2000 Plus, and 3D finite difference Wave3000 Plus software
This research transitions to NDE program in 2017
Value – Adds NDE modeling and simulation capability to program for members; addresses an NDE technology gap, enhances NDE development and implementation process, reduces costs associated with mock-up fabrication, and provides state-of-art NDE training tools via use of simulation processes.
CIVA Simulation
Experiment
Flaw simulation vs. actual data
Shows good correlation
12© 2016 Electric Power Research Institute, Inc. All rights reserved.
Key Results - GelSight Imaging
GelSight Imaging was evaluated to address a technology gap to improve remote visual examination flaw detection and characterization capability.
– It is a proprietary elastomeric retrographic sensor material for collecting 3D surface measurement data.
– It is capable of fast, reliable acquisition, and recording of multiple 3-D images of flaws and anomalies of surfaces. Algorithms permit surface condition imaging and measurement of micron scale surface features, providing a true representation of a material surface.
GelSight laboratory gantry measurement system was installed in the EPRI metallurgy lab in late 2014.
– Successfully demonstrated and verified GelSight capabilities for surface material condition and flaw characterization; collecting and analyzing flaw length, width (20 micron threshold), and depth approximation measurements. Data collection still in process.
GelSight is commercially available, and may be adaptable for various measurement applications.
20 micron laser etched flaw
Base GelSight Image
of laser flaw
3-D GelSight (Measurement) Image
of laser flaw
Value – GelSight technology addresses a gap to improve
and provide alternatives to remote visual examination
flaw detection & characterization capability
13© 2016 Electric Power Research Institute, Inc. All rights reserved.
Key Results – Sol-Gel Spray-on Sensor Technology
Develop and validate Sol-Gel piezoelectric sensor
technology for deployment on power plant components for
degradation detection and characterization; potential uses
include: complex configurations, inaccessible components.
R&D focused on addressing implementation challenges:
Sensor resilience and longevity
Mounting, cables, and connectors
Signal noise level
Successful prototype
Phased Array
Current development toward FAC Applications
Conceptual use in field for FAC
-- as an example application where permanent
placement could be a significant advantage
Early lab prototype phased array wiring
Value – Addresses a gap to develop online monitoring
as a more effective and efficient method for detecting
and characterizing various active degradation
mechanisms.
14© 2016 Electric Power Research Institute, Inc. All rights reserved.
Key Results – Vibrothermography and Thermography
• Developing rapid screening inspection methods for
metallic and nonmetallic materials, using
vibrothermography and other thermal imaging methods
• Currently evaluating/comparing new low-cost vs. high-
performance thermal cameras; recently performed IR
inspections on 3 AEP dams; technical white paper
summarizing comparison results is in process.
• Vibrothermography equipment is being fabricated.
• Potential Use – Flaw detection in large structures,
components
Value - Addresses a technology gap to develop and
implement rapid screening inspection methods to
address industry degradation issues
Area is vibrated, flaw
generates heat, detected with
IR thermography
15© 2016 Electric Power Research Institute, Inc. All rights reserved.
Continue the Discussion
Subscribe to our Podcast on iTunes
Visit our incubatenergy.org and follow
the conversation on Twitter & LinkedIn
EPRI website: www.epri.com
EPRI Journal: eprijournal.com
Twitter: @EPRINews
Contact me with any questions: Ron Schoff, rschoff@epri.com, @ronschoff33
16© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Robert Bouck
Sr. Program Manger, NDE Technology
NDE Issues Meeting
Tuesday, 06/21/2016
EPRI NDE Program
Technology TransferThinking Ahead . . .
2© 2016 Electric Power Research Institute, Inc. All rights reserved.
Technology Transfer Topics
Technology Readiness Levels
Technology transfer planning
– Types of Projects/Products the NDE Program produces
Technology transfer challenges
Technology transfer enablers
Example projects ready for implementation
3© 2016 Electric Power Research Institute, Inc. All rights reserved.
Technology Readiness Levels
Research & Discovery Innovation & Development DemonstrationCommercialization & Diffusion
Stage 1 Stage 2 Stage 3 Stage 4Gate Gate
Commer-
cialization
Early
Commercial
Deployment
Demon-
stration
Early
Demon-
stration
System
Validated
Subsystem
Validation
Proof of
Concept
Validated
Concepts
Formulated
Exploratory
Research
TRL 9TRL 8TRL 7TRL 6TRL 5TRL 4TRL 3TRL 2TRL 1
Commer-
cialization
Early
Commercial
Deployment
Demon-
stration
Early
Demon-
stration
System
Validated
Subsystem
Validation
Proof of
Concept
Validated
Concepts
Formulated
Exploratory
Research
TRL 9TRL 8TRL 7TRL 6TRL 5TRL 4TRL 3TRL 2TRL 1
Gate Gate
4© 2016 Electric Power Research Institute, Inc. All rights reserved.
NDE Program’s Process for Planning
Technology Transfer – Thinking Ahead . . .
Project Deliverable Types /
Technology Transfer MethodLi
cens
ing /
Roy
altie
s
NDE A
lert
New
slette
r
IR R
epor
t
TU /
TR R
epor
t
TU /
TR w
ith E
mbe
dded
Vid
eo
Video
(e.g
. PP
T "Mix",
EPRI
Youtu
be, .
. . )
Distri
bute
d as
an
Issu
e Pro
gram
White
Pap
er
Cock
pit
Poste
d on
EPR
IQ.com
Execu
tabl
e / W
ebsite
/ App
licat
ion
CBT /
Mul
timed
ia
Wor
ksho
p / C
onfe
renc
e
Form
al T
rainin
g / C
ertif
icat
ion
Proce
dura
lized
Dem
onstra
tion
Use
r/Wor
king
Gro
up
Vendo
r col
labo
ratio
n
Cust
omer
Ass
ista
nce
/ Site
visit
ASM
E C
ode
Regu
lato
ry B
ody End
orse
men
t
Availa
bility
of H
ardw
are
Oth
er
Raw / Preliminary Research
Technology to be developed and commercialized
Technology Improvements
Technology assessments
Leveraging Existing Technologies into derivative product 5 5 5 5 5 5 5
Technology / Technique targeting NDE Efficiencies ($$$) 6 6 6 6 6 6 6 6
Technique development
Technique Improvements 1, 2 1, 2 1, 2 1, 2 1, 2
Leveraging Existing Techniques into derivative product
Capability Studies / Assessments / Demonstrations
Technical Basis Development (PD, Relief Request, . . .) 4 4 4 4 4 4 4 4
NDE Industry Guidelines
Round Robin Studies
Reference Material
Training Materials 3 3 3 3 3 3 3 3
Service
Human Performance Improvement 7 7 7 7 7 7 7 7 7
Hardware
Assembled Package
5© 2016 Electric Power Research Institute, Inc. All rights reserved.
Technology Transfer Challenges
At what levels in any organization are technologies;– Evaluated
– Recognized and embraced
– Funded by capital or other budgets
– Implemented
Resistance to change– “It’s good enough”
The “Technology Supplier” didn’t receive the technology
“I don’t want to be first”– Lack of Pilots/Prototypes/Demonstrations
Legal implications– Licensing etc.
Technology supplier sees the technology as not theirs and available to all suppliers– The “Not Invented Here” syndrome
Your thoughts?– Opportunity to discuss tomorrow in TAC meetings
6© 2016 Electric Power Research Institute, Inc. All rights reserved.
Technology Transfer Enablers
Members engaging vendors (and vice versa)
The “right” pieces of research made publically available– Ease of access
Engage project sponsors
Heightened EPRI reach out to Members/Vendors
Vendor participation in TAC meetings
Workshops/Conferences
Language translation
Your thoughts?– Opportunity to discuss tomorrow in TAC meetings
7© 2016 Electric Power Research Institute, Inc. All rights reserved.
Example projects ready for implementation
1. Procedure for Single-Side Ultrasonic Examination for Stainless Steel Piping: Encoded Ultrasonics (3002007780)
– Accessed through EPRI.com by Members in support of Vendors
2. Procedure for Manual Phased Array UT Testing of Weld Overlays Procedure: EPRI-WOL-PA-1, Revision 4 (3002008330)
– Publically available through EPRI.com
3. Computer Based Training for Weld Overlay NDE Final Version (3002006657)
– Accessed through EPRI.com by Members in support of Vendors
– EPRI supported Training
4. Phased Array Technologies: Essential Variables Defined (3002008758)
– Publically available through EPRI.com
5. BOP Heat Exchanger Tubing Inspection Techniques Update, Rev 4 (3002007796)
– Accessed through EPRI.com by Members in support of Vendors
6. Nondestructive Evaluation: Reactor Pressure Vessel Threads in Flange Examination Requirements (3002007626)
– Publically available through EPRI.com
7. Nondestructive Evaluation: Industry Best Practices for Performing Reliable NDE - Implementation Guide (3002007329)
– Publically available through EPRI.com
8© 2016 Electric Power Research Institute, Inc. All rights reserved.
Transforming Technology into Products is Hard
9© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Mark Dennis
Program Manager – NDE Modeling & Simulation
NDE Technology Week
June 21, 2016
Procedure Demonstration
for Single-Sided Ultrasonic
Examinations for Stainless
Steel Piping
11© 2016 Electric Power Research Institute, Inc. All rights reserved.
Outline
Project Overview
Results to Date
Future Work
Questions
12© 2016 Electric Power Research Institute, Inc. All rights reserved.
Procedure Demonstration for Single-Sided Ultrasonic Examinations for Stainless Steel
Piping
There is currently no qualified UT procedure for when
access is limited (for example, far side) for austenitic
stainless steel piping welds.
This project builds upon recent activities to develop such
a procedure.
The previous study was successful in detecting
circumferentially oriented non-IGSCC defects. The
activities of this currently project include the following:
– Evaluation of manual ultrasonic techniques (including
ultrasonic phased array technology)
– Procedure qualification for non-IGSCC piping
applications with favorable inside-surface geometries
– Improved far-side flaw detection for IGSCC-
susceptible piping
– Far-side flaw detection for axially oriented defects
13© 2016 Electric Power Research Institute, Inc. All rights reserved.
Procedure Demonstration for Single-Sided Ultrasonic Examinations for Stainless Steel
Piping
Summary from previous Work – Encoded Techniques
– Testing was performed on several piping specimens in the as-welded condition.
IGSCC and non-IGSCC from 4.0 in. to 36.0 in. diameter and 0.237–2.625 in. thickness.
– Ultrasonic phased array technology showed promise for circumferential flaws.
100% detection for the Non-IGSCC and 83% for the field removed IGSCC test samples.
– IGSCC not detected from the far side was likely due to the component inside-surface
geometry, which prohibits direct line of sight for any UT approach.
Nondestructive Evaluation: Ultrasonic Methods for Single-Side Examination of Austenitic Stainless Steel Piping Welds (1025234)
14© 2016 Electric Power Research Institute, Inc. All rights reserved.
Procedure Demonstration for Single-Sided Ultrasonic Examinations for Stainless Steel
Piping
Summary from previous Work – Manual Techniques
– Testing was performed on several piping specimens in the as-welded condition.
IGSCC and non-IGSCC from 12.0 in. to 36.0 in. diameter and 0.688–2.625 in. thickness.
– Manual ultrasonic phased array technology results for circumferential flaws (One candidate).
94% detection for the Non-IGSCC and 86% for the field removed IGSCC test samples.
Unacceptable number of false calls
Procedure Demonstration for Single-Side Ultrasonic Examinations for Stainless Steel Piping: Manual Phased Array Ultrasonics (3002005443)
15© 2016 Electric Power Research Institute, Inc. All rights reserved.
Procedure Demonstration for Single-Sided Ultrasonic Examinations for Stainless Steel
Piping
Axial Flaws are Challenging - Detection and Coverage – We have ideas
16© 2016 Electric Power Research Institute, Inc. All rights reserved.
ASME Code Case N711 “Alternative Examination Coverage Requirements for Examination Category B-
F, B-J, C-F-1, and C-F-2, and R-A Piping Welds"
Used to evaluate the necessary volume of material within the weld material and on the far side of the weld required to be examined based on Risk Informed Methodology.– Configuration (Pipe-Pipe, Pipe-Valve, Pipe-Pump, etc.)
– Degradation Mechanism (Thermal Fatigue, IGSCC, etc.)
– Primary volume of interest may be reduced or increased
Not presently approved for use in accordance with U.S. Nuclear Regulatory Commission (NRC) Regulatory Guide 1.147.
No real technical changes between N711 and N711-1 (out for letter ballot – ASME Section XI standards committee) but developed additional technical bases and supporting references to specifically address NRC input.
Pat O’Regan has proposed a new 2017 project to develop examples of how to determine the primary volume of interest.
17© 2016 Electric Power Research Institute, Inc. All rights reserved.
Procedure Demonstration for Single-Sided Ultrasonic Examinations for Stainless Steel
Piping
Future Work
– Revisit manual phased array approach to reduce false calls.
– Improve techniques for axial flaws.
– Demonstration on PDI blind specimens.
– Monitor ASME Code Case N711 progress.
– December 2016 publish 3002007780 report documenting the
results to date.
18© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Doug Kull
Sr. Technical Leader
Developing User Friendly
Versions of EPRI Phased
Array Procedures
20© 2016 Electric Power Research Institute, Inc. All rights reserved.
Scope
Review and revise the currently qualified EPRI non-encoded manual phased array procedures (PA)– Improve the ease of use
– Make easier to integrate into member ISI programs
Assemble a focus group comprised of industry leaders – Review the procedure modifications
– Provide feedback on how the procedures could be better utilized
Once Weld Overlay (WOL) procedure has been completed the same format will be applied to all remaining EPRI manual non-encoded PA procedures
Procedure Report Number Est Completion Date
EPRI-WOL-PA-1 1015134 6/10/2016
EPRI-DMW-PA-1 1016645 9/10/2016
EPRI-PIPE-MPA-1 1016650 12/23/2016
EPRI-PIPE-TWS-MPA-1 1016650 12/23/2016
EPRI_RPV_PA_1 1015430 TBD
PDI_UT_12 1015149 TBD
PDI_UT_13 1021166 TBD
21© 2016 Electric Power Research Institute, Inc. All rights reserved.
Technology Transfer & Deliverables
Notable Member Engagement – Industry Focus Group
S.Hamel, K.Hacker, N.Finney, D.Brown, & A.Zipper
– Numerous calls, several procedure revisions, & countless emails
Technology Transfer Method Technical Basis Document – Members only
Procedure – Free Release Assembled Package (PDF & MS Word)
Ancillary Documents – EPRIQ.com members
– Table 1, Table 2, & Supporting Procedures (e.g., Thickness and Contour (T&C) and Receipt Inspection Procedure (RIP))
Target Applications– Manual PA Practitioners and Inservice Inspection (ISI) Planners
22© 2016 Electric Power Research Institute, Inc. All rights reserved.
Notable Highlights
First procedure (EPRI-WOL-PA-1) was published on 6/10
Streamlined the WOL Procedure– Reduced the page count by more than 50% (106 to 52)
– Generated two new procedures (T&C and RIP)
– Aligned the procedure with current industry terminology
– Applied lessons learned from recent operating experience (OE) and other procedure modifications
Eliminated the need to continuously revise the EPRI document based on simple equipment changes
Improved the distribution process– Access to MS Word version will be easier to incorporate into ISI Programs
– Procedure documents available to everyone
– If validation or verification is needed, the official Quality Assurance (QA) document (.pdf) is available at www.EPRIQ.com
23© 2016 Electric Power Research Institute, Inc. All rights reserved.
Other Items of Interest
Weld Overlay– Technical Basis Document
Nondestructive Evaluation: Procedure for Manual Phased Array UT of Weld Overlays: Technical Basis Document
EPRI Product ID# 3002008323
– Procedure
Nondestructive Evaluation: Procedure for Manual Phased Array UT of Weld Overlays: Procedure – EPRI-WOL-PA-1 Revision 4
EPRI Product ID# 3002008330
Dissimilar Metal Welds– Revision of this procedure (EPRI-DMW-PA-1) is in progress
– Deliverable Due Date: 9/10/2016
Cross Sector Applications– NDE is looking at possible applications of the process within the EPRI Fossil Group
24© 2016 Electric Power Research Institute, Inc. All rights reserved.
Accessing the Procedures
Step #1 – Download and Open the
Appropriate Report from www.epri.com
– WOL – 3002008330 – Available Now
– DMW – 3002008333 – 9/10/2016
– PIPE – 3002008334 – 12/18/2016
– PIPE-TWS – 3002008335 – 12/18/2016
Step #2 – Click the Attachment Tab in
your PDF viewer (Icon: Paperclip)
Step #3 – Double click the PDF or MS
Word version of the procedure
25© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
J. Leif Esp
Sr. Technical Leader
06/21/2016
The EPRI NDE Workplan
and Technology Transfer
Computer Based Training for
WOL NDE
27© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Drivers
Due to lack of recent power plant construction many examiners have limited, if any, experience in construction related NDE– Weld overlays may be the only component regularly examined where
examiners are expected to identify and ultrasonically characterize new fabrication related flaws
– Current examinations procedures address contamination cracks, lack of bond (LOB), and lack of fusion (LOF) flaws but do not specifically address other fabrication flaws that may be found during examinations of Alloy 52/52M material
Ductility dip cracking (DDC)
Hot cracking
Etc…
28© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Drivers (Continued)
– A need for enhanced and updated training has been identified as a causal factor during past operating experience (OE)
– This new training should cover –
Welding processes
Potential fabrication defects
–Types of defects
–Where they are likely to exist
Comparison of detected flaws to acceptance standards
Recent OE
–The ability to providing this training on site – immediately prior to examinations could reduce the potential for human performance errors
29© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Drivers / History
Much of the material for training is already in place –
however it is spread amongst various older training material,
many technical reports, various other industry support
documents, along with captured operating experience from
the industry
In 2014 this project was initiated to gather all of this material
and provide an updated training course that would be
available via a computer based training (CBT) course
30© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2014 / 2015 / 2016
Key Tasks– Bring all available material together to create an updated and enhanced CBT
course. Examples of this type of material is as follows:
EPRI 912 course – UT Operator Training for Weld Overlay Examination 1989
Overlay Handbook: Part 1 – Welding Procedures; Part 2 – NDE. EPRI, Palo Alto, CA: 2010.1021075.
Nondestructive Evaluation: Proposed Code Case Criteria for Technical Basis of Weld Overlay Indication Evaluation and Disposition Based on Advanced Technology Assessments. EPRI, Palo Alto, CA:2009. 1019118.
NP-4720-LD Examination of Weld-Overlaid Pipe Joints, October 1986.
PDI-UT-8
Code Case N-504-4
Code Case N-740
ASME Section XI, Appendix Q
31© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2014 / 2015 / 2016 (Continued)
CBT Creation
– Using all available material creation of the CBT course was started in
2014
– A draft course outline was created to form a baseline for what the
course would accomplish
– Main course objectives were to provide training for
First time NDE examiners of weld overlays (Modules 1 through 3)
Refresher training for experienced examiners of weld overlays –
including updated OE (Modules 2 and 3)
Brief training for site personnel that are new to weld overlays
(management or other staff) (Module 3)
33© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2014 / 2015 / 2016 (Continued)
During 2014 and 2015 CBT creation was carried out– Created story boards for each module specified in the outline
– Created training interactions to demonstrate principles discussed in the modules
– Storyboards were transferred to outside contractor and placed into the CBT format
– First draft of the CBT was created with suggestions for additional interactions and activities
Internal review for consistency and usability was performed in the fall of 2015
Comments provided to CBT vendor to be incorporated into training
34© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2016 Wrap Up
CBT creation has been completed and interactions have been
completed
– Intentionally left some interactions out – member input on these
interactions is needed
Code Case N-740 evaluation examples (acceptable and rejectable)
Appendix Q evaluation examples (acceptable and rejectable)
Examples of useful formulas
EPRI Software QA (SQA) performing a review of the CBT course and
ensuring compliance across multiple software platforms / web
browsers
After completion of SQA initial validation Beta Version will be released
41© 2016 Electric Power Research Institute, Inc. All rights reserved.
What is the Path to Technology Transfer?
Summer of 2016 – Beta Version will be released for testing, validation, and comments– Mr. Donahue at Duke Energy volunteered in 2014 to have Duke
participate in the beta testing phase
– Mr. Lofthus at Southern Company has also volunteered his staff to take part in the beta testing phase
– The Beta Version will be released for testing in early July
– The testing window will be 2 – 3 weeks in duration and all comments from the testing will be addressed prior to release of the Final Version.
We do ask if anyone has any additional interactions they please provide them during the beta phase
– Specifically we are looking for real world evaluations (both acceptable and rejectable) for Code Case N-740 and Appendix Q
42© 2016 Electric Power Research Institute, Inc. All rights reserved.
What is the Path to Technology Transfer?
October 2016 – Final Version will be released for use– Currently planning for stand alone CBT product available for download from
EPRI.com
– Current path also includes a Nantel compliant version of training
This delivery path is currently under evaluation
Member Engagement– Beta Version is a designated point for member engagement
Member feedback must be addressed prior to release of Final Version
Target Applications– Just in time training for;
New examiners with little or no weld overlay examination experience
Experienced examiner that needs a refresher and exposure to past OE
Utility management staff that need a brief explanation of the weld overlay process
43© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
J. Leif Esp
Sr. Technical Leader
06/21/2016
The EPRI NDE Workplan and Technology Transfer
Nondestructive Evaluation: Phased Array Technologies:
Phased Array Essential Variables Defined
45© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Drivers
Advances in technology has lead to the use of phased array
ultrasonics on a much broader scale and the use of phased
array technology continues to rise every year
– Phased array techniques can provide viable solutions on complex
and limited configurations
– Phased array techniques can enhance examinations by generating
multiple angles from a single search unit
46© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Drivers (Continued)
Many essential variables that pertain to conventional UT also apply to phased array UT, however there are more variables to consider when using phased array technology
These additional variables are not currently addressed by ASME Section XI, Appendix VIII
This project focused on;– Determining which variables were considered essential with various
PA instruments
– Developing a technical basis to support revisions to ASME Section XI, Appendix VIII or other Codes and standards
– Evaluating processes that could be used to control these parameters in an efficient manor
47© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Drivers / History
Phased array has been in used to perform ASME Section XI
examinations for over a decade – so what has the US
industry addressed this up to now?
– Procedure owners and Performance Demonstration Administrators
(PDA) have identified the essential variables in the course of the
procedure qualification and these variables were clearly defined in
the qualified procedures
While the process was effective is was clear that these
variables needed to be codified
48© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2013 / 2014
Key Tasks– Review of all PA essential variables currently identified in the
Section V of the ASME Code and other international standards
– Review all currently Appendix VIII qualified phased array procedures in an effort to produce a combined list of essential variables
– Survey Industry
Hardware / software manufacturers were asked to provide all variables within their systems that they deemed essential
Probe / wedge manufacturers were asked to provide all essential parameters involved in the manufacturing and use of probes / wedges
49© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2013 / 2014 (Continued)
Testing
– Using the information obtained from the surveys and literature
searches, a series of tests were performed to determine if the
variables were actually essential
Tests included;
– Manufacturing of various probes and wedges to compare
different variables
– Collection and evaluation of data using various parameters
– Confirmatory computer modeling
50© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2013 / 2014 (Continued)
At the end of 2014 a technical update report was issued
documenting research results obtained to date
– Additional studies were recommended prior to starting the
codification process so the project was extended
51© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2015 / 2016
New phase of the project allowed for the completion of the
following activities;
– Testing of specialized probes provided by manufacturer to validate
proprietary variables related to composite materials used to
fabricate various PA search units
– Solicitation of feedback from members prior to publishing of final
report
52© 2016 Electric Power Research Institute, Inc. All rights reserved.
What is the Path to Technology Transfer?
2016 publicly available report has been released– Report 3002008768, Nondestructive Evaluation: Phased Array Technologies:
Essential Variables Defined is publicly available for download from EPRI.com
Member Engagement– Feedback from the members has been vital in ensuring that the project staff
understood the needs of the industry and provided a product that would meet those expectations
Target Applications– Research provided in the report will be able to be utilized by the members to form the
Technical Basis for including phased array essential variables in ASME Section XI, Appendix VIII or other Codes and standards
EPRI’s role in the continuation of the Technology Transfer– Through this project EPRI will continue to guide and provide support to members
attempting to the include phased array essential variables into various Codes and standards
– In subsequent years the ASME Section XI Development Support Project will support the needed modifications to ASME Section XI, Appendix VIII by using or referencing the findings of this project
53© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Balance-of-Plant
(BOP) Heat Exchanger
Tubing Inspection
Techniques Update, Rev 4
Nathan Muthu
Program Manager
EPRI
NDE Technology Development
Tel: 704.595.2546
Email: nmuthu@epri.com
55© 2016 Electric Power Research Institute, Inc. All rights reserved.
Balance-of-Plant (BOP) Heat Exchanger Tubing Inspection
Techniques Update, Rev 4
Purpose:
Heat exchanger and condenser tube leaks can interrupt normal plant operations or lead to
unscheduled plant shutdown for repair or replacement.
Using proven inspection techniques can assist in identifying issues early in the game and allow
preventative measures to be taken to preclude tube leaks or extend deterioration of the damage
Data trending may be optimized when proven inspection parameters are used. Informed decisions may
be made to efficiently manage and operate the heat exchanger program - leading to extended use of the
component - optimizing assets and providing early information for repair and replacement planning.
Globally, nuclear power plants operators are encouraged to use and maintain common inspection
practices. Lessons learned and best practices used can be shared through this guide - single resource
document
• Maintain common data analysis skills across the world – sharing of resources – workforce issues
are addressed
• To support early career system engineers. Provide them with immediate tools that they can use to
initiate and support inspections and learn the eddy current process.
56© 2016 Electric Power Research Institute, Inc. All rights reserved.
Balance-of-Plant (BOP) Heat Exchanger Tubing Inspection
Techniques Update, Rev 4
EPRI members and inspection service providers may use the information
from this guide to reliably assess balance-of-plant (BOP) heat exchanger
tubing conditions. Included in this guide are:
• Suitable electromagnetic inspection techniques for detecting and sizing both corrosion
and mechanical damage forms in balance-of-plant (BOP) heat exchanger tubing.
• Round robin eddy current inspection and results on retired heat exchanger tube bundles
and how they were evaluated and compared against destructive analysis to determine
statistical values for establishing acceptable flaw depth sizing procedures for non-
ferromagnetic and ferromagnetic tubing. Criterion used:
• Flaw Detection – Percent of flaws detected
• Flaw Sizing - determined by calculating three linear regression analysis components:
regression line slope, correlation coefficient, and Root Mean Square Error (RMSE)
• Review of electromagnetics specifically for balance-of-plant (BOP) tubing inspection
applications
57© 2016 Electric Power Research Institute, Inc. All rights reserved.
Balance-of-Plant (BOP) Heat Exchanger Tubing Inspection
Techniques Update, Rev 4
How will the information be used from this guide
Each section is unique to a specific type of damage mechanism
Complete description about the heat exchanger and its tube bundle including its
operating characteristics are provided
Where available, destructive test results on pulled tube specimens are provided
• Eddy current results are verified and compared with destructive test results in order
to optimize the inspection techniques and results.
Regression plots showing flaw sizing capability for all techniques used informs the
robustness of the technique
Step-by-step instructions on calibration set-ups and reporting can be used immediately
with slight modifications made.
Inspection parameters such as frequencies, probe information, calibration standard(s)
information, channels, probe pull speeds, and sampling rates are provided.
58© 2016 Electric Power Research Institute, Inc. All rights reserved.
Balance-of-Plant (BOP) Heat Exchanger Tubing Inspection
Techniques Update, Rev 490-10 COPPER-NICKEL PRIME SURFACE
TUBING
Data Anlaysis Technique
Sheet
Page 1 of 2Tube Material: 90-10 copper-nickel OD: 0.625"
(15.87mm)
Wall: 0.049"(1.24mm)
Acquisition Technique: conventional eddy current ID: 0.527" (13.38mm)
Examination Scope
Small-volume flaws, i.e., pits and cracks in free-span regions
Data Acquisition
Instrument Probe
Manufacturer: Zetec Manufacturer: Zetec
Model: MIZ-18 Diameter: 0.500" (1.27cm)
Analog Probe Extension Probe Type: LF-CBS
Length: N/A Probe Cable Length: 83' (25m)
Probe Speed: 12" (30.5cm)/sec. Sample Rate: 400 samples/sec.
Frequency Frequency Frequency Frequency
Differential 80 kHz 40 kHz 20 kHz 10 kHz
Absolute N/A N/A N/A N/A
Data Analysis Technique
10 kHz diff - Primary detection and sizing channel for ID pitting in midspan regions
40/10 kHz diff - Primary detection and sizing channel for ID pitting at tube support plate locations
80 kHz diff - Primary detection and sizing channel for OD flaws in midspan regions
40 kHz diff - Confirmation channel for OD flaws
20 kHz diff - Confirmation channel for ID pitting
Analysis Setup
Diff. Channels 80 kHz-diff. 40 kHz-diff. 20 kHz-diff. 10 kHz-diff.
Calibration Std. ASME std. ASME std. 1/8" (3.18mm) ID pit 1/8" (3.18mm) ID pit
Cal. Curve Type phase-to-depth phase-to-depth volts-to-depth volts-to-depth
OD Cal. Pts (%) 100,80,60,40,20 100,80,60,40,20 - -
ID Cal. Pts (%) - - 0,25,50,75,100 0,25,50,75,100
Cal. Setup ASME TWH~40°
6 volts (P-P)
ASME TWH~40°
6 volts (P-P)
100% pit @ 40°
10 volts (V-Max)
100% pit @ 40°
10 volts (V-Max)
Abs. Channels N/A N/A N/A N/A
Calibration Std.
Cal. Curve Type
OD Cal. Pts (%)
ID Cal. Pts (%)
Cal. Setup
Mix. Channels 40/10 kHz-diff. N/A N/A N/A
Type of Mix TSP
Calibration Std. 1/8" (3.18mm) ID pit
Cal. Curve Type volts-to-depth
OD Cal. Pts (%) -
ID Cal. Pts (%) 0,25,50,75,100
Cal. Setup 100% pit @ 40°
10 volts (V-Max)
Regression Analysis Results
Criteria Flaws Detected Slope Correlation Coefficient RMS Error
Preferred 80% 0.7-1.3 70% 20%
Actual 97% 0.98 94% 4%
90-10 COPPER-NICKEL PRIME SURFACE TUBING
Data Analysis Technique Sheet
Page 2 of 2 Description of Calibration Standards
ASME Standard 100, 80, 60, 40, and 20% TW flat-bottom holes 10% TW OD groove and 20% TW ID groove
ID Pit Standard four 1/8" (3.18mm) diameter round-bottom pits 100, 75, 50, and 25% TW
Detailed Analysis Setup
10 kHz diff - Primary detection and sizing channel for ID pitting in midspan regions Calibration requires a 1/8" (3.18mm) diameter round-bottom ID pit standard. Set 100% TW pit signal at 40° starting down and to the right. Set the vertical amplitude of the 100% TW pit signal to 10 volts. Establish vertical amplitude vs. percent TW calibration curve for ID flaws. ID calibration points 0,25,50,75, and 100% TW.
40/10 kHz diff - Primary detection and sizing channel for ID pitting at TSP locations Create a 40/10 kHz differential tube support plate mix. Calibration requires a 1/8" (3.18mm) diameter round-bottom ID pit standard. Set 100% TW pit signal at 40° starting down and to the right. Set the vertical amplitude of the 100% TW pit signal to 10 volts. Establish vertical amplitude vs. percent TW calibration curve for ID flaws. ID calibration points 0,25,50,75, and 100% TW.
80 kHz diff - Primary detection and sizing channel for OD flaws in midspan regions Setup requires ASME standard. Set lift-off horizontal, ASME TW hole starting down and to the right. ASME TW hole should fall at roughly 40° from horizontal. Set amplitude of the ASME TW hole signal at 6 volts peak-to-peak. Establish phase angle vs. percent TW calibration curve for OD flaws. OD calibration points 20,40,60,80, and 100% TW.
40 kHz diff - Confirmation channel for OD flaws Setup requires ASME standard. Set lift-off horizontal, ASME TW hole starting down and to the right. ASME TW hole should fall at roughly 40° from horizontal. Set amplitude of the ASME TW hole signal at 6 volts peak-to-peak. Establish phase angle vs. percent TW calibration curve for OD flaws. OD calibration points 20,40,60,80, and 100% TW.
20 kHz diff - Confirmation channel for ID pitting Calibration requires a 1/8" (3.18mm) diameter round-bottom ID pit standard. Set 100% TW pit signal at 40° starting down and to the right. Set the vertical amplitude of the 100% TW pit signal to 10 volts. Establish vertical amplitude vs. percent TW calibration curve for ID flaws. ID calibration points 0,25,50,75, and 100% TW.
59© 2016 Electric Power Research Institute, Inc. All rights reserved.
Balance-of-Plant (BOP) Heat Exchanger Tubing Inspection
Techniques Update, Rev 4
How will the information be used from this guide
Vendors need to engage with EPRI members to access this product
Product will be available to all members on-line on December 18, 2016
Rev 4 will supersede Rev 3
It is encouraged not to use the techniques verbatim when doing inspections
• Techniques provided is good starting point. Slight tweaks may be required to
optimize the technique
This is a living document. Provide updates to EPRI
If something worked better than what was documented and used, then let the
technique(s) be superseded with the improved technique. Inform the industry so that
they can start using it
This is a continuous collaborative effort between members, vendors and EPRI.
60© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Patrick O’Regan
poregan@epri.com
NDE Technology Week
June 21, 2016
Reactor Pressure Vessel
Threads in Flange
62© 2016 Electric Power Research Institute, Inc. All rights reserved.
RPV – Threads in Flange
Current Requirements
Inspection Challenges
Industry Investigation
Path Forward
63© 2016 Electric Power Research Institute, Inc. All rights reserved.
Current Requirements
Inspections required per ASME Section XI
Other Codes/Countries have similar requirements
64© 2016 Electric Power Research Institute, Inc. All rights reserved.
Inspection Challenges
1 – 8 hours critical path time
0.1 to 1.2 R of dose
FME into the vessel from the UT transducer or tool
Suspended load poses personnel safety concern
65© 2016 Electric Power Research Institute, Inc. All rights reserved.
Industry Investigations
Literature review
Survey of industry inspection results
Evaluation of Potential Degradation Mechanisms
Flaw Tolerance Evaluation
Risk Impact Assessment
66© 2016 Electric Power Research Institute, Inc. All rights reserved.
Literature Review
Stud Removal Issues
Overpressure Events
Current Operating Practices
67© 2016 Electric Power Research Institute, Inc. All rights reserved.
Industry Survey
Survey of RPV Threads in Flange inspections
US and non-US operators
– US operators (94 units)
More than 10,600 examinations
Zero reportable indications
68© 2016 Electric Power Research Institute, Inc. All rights reserved.
Industry Survey
Survey of RPV Threads in Flange inspections
US and non-US operators
– Non-US operators
76 units replied
Some indications identified on a few plants
• Obtained additional information to assess applicability
• Non relevant and not service induced
70© 2016 Electric Power Research Institute, Inc. All rights reserved.
Path Forward
ASME Code Case passed by
WG-ISC and SG-WCS
Will be brought to SXI
Standards Committee at August,
2016 meeting
Several Licensees have relief
requests under development
and should submit in 2016
71© 2016 Electric Power Research Institute, Inc. All rights reserved.
Summary
Exceptional performance history of RPV Thread Ligaments
Operating experience has not identified any service induce
degradation
Existing requirements adversely impact critical path time,
worker exposure, and personnel safety concern
EPRI report documents technical basis
ASME and Licensee activities underway to eliminate
requirement
72© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Ronnie Swain
Program Manager
Performance Demonstration
NDE Issues MeetingJune 2016
Broadening the Application of
Recommended Best Practices
Based on Industry NDE
Initiatives
74© 2016 Electric Power Research Institute, Inc. All rights reserved.
What the Project Did
In the spirit of the industry process improvements made for DM weld inspections, this project compiled industry best practices into a document intended to assist plant NDE personnel in planning and execution of reliable NDE
Phase 1 (2015) – Worked with industry experts to identify and compile all reference materials and pertinent information needed for inclusion the guideline document
– Focus Group: Kevin Hacker – Dominion; Jason Coulas – Ontario Power Generation;
Kenneth Panther – Entergy; Scott Hamel – NextEra Energy; Ned Finney – Duke Energy; Jay Miller – Exelon; Dave Anthony – Exelon; Damon Priestley – TVA; Gary Lofthus – Southern Nuclear;Dave Gonzales – Pacific Gas & Electric; Wade Miller – Sonic Systems;Joel Harrison – System One; Jeremy Timm – Curtiss-Wright;Michael Lashley – Structural Integrity Assoc.; Joe Persinger – AREVA;Steve Sabo – Wesdyne; John Abbott – EPRI; Bret Flesner – EPRI; Jeff Landrum – EPRI; Steve Swilley – EPRI; Carl Latiolais – EPRI; Ronnie Swain – EPRI
75© 2016 Electric Power Research Institute, Inc. All rights reserved.
What the Project Did (continued)
Phase 2 (2016) – Used information gathered in Phase 1 to develop a high-level guide
covering all aspects of planning and performing NDE in a nuclear power plant
Section Titles:
– Pre-Examination Preparation
– Scheduling Examinations
– NDE Staffing
– NDE Staff Indoctrination
– Examiner Preparation, Training, and Practice
– Pre-Job Briefing
– Use of Team Scanning
– Oversight
– Post-Job Debriefing
– NDE Data Review
– Examination / Outage Close-Out
– References
76© 2016 Electric Power Research Institute, Inc. All rights reserved.
Technical Basis
Recent NDE OE has included cases of poor planning, execution, or data review practices that resulted in issues with the NDE reliability or efficiency
As a result of OE pertaining specifically to DM weld examinations, the NDE Improvement Focus Group (NIFG) was chartered in 2012 to review industry practices and develop guidelines and recommendations intended to improve ultrasonic (UT) examination of DM welds
Based on the strength of the NIFG products, the NDE Action Plan Committee requested that additional NDE guidance be developed to assist station NDE personnel with planning and executing all NDE with the same high standards of reliability
77© 2016 Electric Power Research Institute, Inc. All rights reserved.
How Can It Be Accessed and Used Accessing the product
– Much like the NIFG products, this report has been made available for free to the public
Go to www.epri.com
Put the title or report number (above) in the search bar
Click the download button
– Title of Report: Nondestructive Evaluation: Industry Best Practices to Performing Reliable NDE
Implementation Guide
3002007329
How to use the product
– The report has been formatted as a quick reference guide
For seasoned plant NDE personnel, it can be referenced similar to a checklist to ensure that all the right bases are covered
For new or less-experienced plant NDE personnel, or for vendor personnel assisting a plant with completion of NDE activities, this product can be a used as a “how-to” guide for approaching any NDE challenge
Can be used in conjunction with other helpful EPRI ISI products, such as the NDE Guide for Compliance with Class 1 Inservice Inspection Requirements (Product Number 3002005425)
– Provides high-level best practices and key aspects involved in proper planning and execution of NDE in the plant
– In cases where a greater level of detail on a specific topic may be helpful to the end user, references to other EPRI or industry documents are provided in the report
– The document is intended to be implemented in accordance with the Station’s plans and procedures
top related