EPRI NDE Issues Meeting - Amazon S3 Oxygen 70 μm 13 Contractual Efforts Structures •Advanced Scanning Systems –Increased accuracy, reliability, effectiveness •Magneto Resistive

© 2016 Electric Power Research Institute, Inc. All rights reserved.

Steve Swilley, EPRI

Director, NDE

NDE Technology Week

June 2016

Savannah

EPRI NDE

Issues Meeting

2© 2016 Electric Power Research Institute, Inc. All rights reserved.

Thank you for being here!


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


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


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


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.


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


Leo Martin

NDE APC Chair

Duke Energy

Opening Remarks


Thinking Ahead


Let’s talk

about where

we’ve been …

… and where

we need to go.

The differences always make Right Now a bit tricky.


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


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”


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


Can the future come fast enough?


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


Electrification - the Pathway to Economy-wide CO2 Reductions


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)


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


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


Old Adage


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

9

Current Branch Activities


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

16

Life Management,

POD and Reliability


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


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)


• Flip the

graph on

its side

29


• 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


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)

32

Thank you! Questions?



Ron Schoff

Senior Program Manager

Technology Innovation

NDE Technology Week

June 21, 2016

Technology InnovationFinding Needles in Haystacks


Electric Power Research Institute



Technology Innovation Program


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


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


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


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


• 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


NDE Research Technology Gaps being addressed


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


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


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.


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


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, [email protected], @ronschoff33

https://itunes.apple.com/us/podcast/epri-unplugged-podcast-series/id1102893586?mt=2

https://incubatenergy.org/

http://www.epri.com/

http://eprijournal.com/

mailto:[email protected]




Robert Bouck

Sr. Program Manger, NDE Technology

NDE Issues Meeting

Tuesday, 06/21/2016

EPRI NDE Program

Technology TransferThinking Ahead . . .


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


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


NDE Program’s Process for Planning

Technology Transfer – Thinking Ahead . . .

Project Deliverable Types /

Technology Transfer MethodLi

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Oth

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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


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


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


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)


– EPRI supported Training

4. Phased Array Technologies: Essential Variables Defined (3002008758)


5. BOP Heat Exchanger Tubing Inspection Techniques Update, Rev 4 (3002007796)


6. Nondestructive Evaluation: Reactor Pressure Vessel Threads in Flange Examination Requirements (3002007626)


7. Nondestructive Evaluation: Industry Best Practices for Performing Reliable NDE - Implementation Guide (3002007329)



Transforming Technology into Products is Hard




Mark Dennis

Program Manager – NDE Modeling & Simulation

NDE Technology Week

June 21, 2016

Procedure Demonstration

for Single-Sided Ultrasonic

Examinations for Stainless

Steel Piping


Outline

Project Overview

Results to Date

Future Work

Questions


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



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)



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)



Piping

Axial Flaws are Challenging - Detection and Coverage – We have ideas


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.



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.




Doug Kull

Sr. Technical Leader

Developing User Friendly

Versions of EPRI Phased

Array Procedures


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


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


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

http://www.epriq.com/


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


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





J. Leif Esp


06/21/2016

The EPRI NDE Workplan

and Technology Transfer

Computer Based Training for

WOL NDE


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…


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


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


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


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)



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


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


Training Preview


Training Preview


Training Preview


Training Preview


Training Preview


Training Preview


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



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




J. Leif Esp


06/21/2016

The EPRI NDE Workplan and Technology Transfer

Nondestructive Evaluation: Phased Array Technologies:

Phased Array Essential Variables Defined


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


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


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


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


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


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


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



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




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: [email protected]

mailto:[email protected]


Balance-of-Plant (BOP) Heat Exchanger Tubing Inspection


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.




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




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.



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.




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.




Patrick O’Regan

[email protected]

NDE Technology Week

June 21, 2016

Reactor Pressure Vessel

Threads in Flange


RPV – Threads in Flange

Current Requirements

Inspection Challenges

Industry Investigation

Path Forward


Current Requirements

Inspections required per ASME Section XI

Other Codes/Countries have similar requirements


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


Industry Investigations

Literature review

Survey of industry inspection results

Evaluation of Potential Degradation Mechanisms

Flaw Tolerance Evaluation

Risk Impact Assessment


Literature Review

Stud Removal Issues

Overpressure Events

Current Operating Practices


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


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


EPRI Report #3002007626


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


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




Ronnie Swain

Program Manager

Performance Demonstration

NDE Issues MeetingJune 2016

Broadening the Application of

Recommended Best Practices

Based on Industry NDE

Initiatives


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


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


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


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


