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ROAD-MAP OF INDIGENIZATION OF NDE/ISI PROGRAMME OF NPP’S IN PAKISTAN (Tahir Nazir)

Dy. Chief Engineer NCNDT, PAEC

PRESENTATION OUTLINE

Introduction of NCNDT

Nuclear Power Plants (NPP,s) in Pakistan

PSI/ISI of Nuclear Power Plants (NPP,s) in Pakistan

ISI of Industrial Plants in Pakistan

Contribution of IAEA in Development of Human Resources and Inspection Facilities of NCNDT

Future Plans and Goal

2

INTRODUCTION OF NATIONAL CENTRE FOR NON-DESTRUCTIVE

(NCNDT)

3

The NCNDT is housed in 05-storeyed building having a

covered area of about 3300 square meters with

properly designed:

Laboratories

Lecture Halls

Offices

Meeting Rooms

150-Seat Auditorium

6

INTRODUCTION TO NCNDT

LABORATORIES

7

MT / VT Lab

Concrete Testing Lab ET Lab

UT Lab

MAJOR ACTIVITIES OF NCNDT

Inspection & Testing Services to PAEC and National Industry

Training and Qualification of Inspection Personnel

Equipment Calibration Services

Third Party Inspection Services

Mechanical and Metallographic Testing Services

Failure Analysis and Condition Assessment

Research and Development

Promotion of Pakistan Society for NDT (PASNT)

8

HISTORY Year Achievements

1971-95

• NDT Group Started at PINSTECH

• Lead Trainers got certified through IAEA

• Provision of Training & Inspection Services to PAEC & National Industry

1995-2000 • Establishment of NCNDT

• Developed Training Manuals for IAEA

2000-05 Started ISI in Conventional Island of NPPs

Hold National Conferences on NDT

2005-10 • Started ISI of different Piping System Welds in Nuclear Island of NPPs

2010-16

2016-17

• Started ISI of Components Welds

• RT of SG Nozzles Dissimilar Metal Welds

• ET of Steam Generator Tubes

• PSI of C-3/C-4

CAPABILITIES (HUMAN RESOURCE)

10

Engineers and Scientists 22

• PhD 3

• MS Engineering 14

• MSc Physics 1

• BS Engineering 4

Technical Staff 95

Administrative Staff 6

Total 123

11

28

40

27

8

13

5 5

8

15

20

14

11

16

8 8

5 4 3 3 2 2

0

5

10

15

20

25

30

35

40

45

RT UT PT MT ET VT LT

Level-1 Level-2 Level-3

126 92 27

* Some Persons have certificates in more than one NDT method

CAPABILITIES (HUMAN RESOURCE) Certified NDT Personnel at NCNDT

CAPABILITIES (EQUIPMENT) Ultrasonic Testing

– Ultrasonic Flaw Detectors (digital) › USM 36 SX › USM 35 SX › USM 58L › USM GO

– Ultrasonic Thickness Meters › Pocket Mike › DMS-2 › DM 4DL › WM2 › MMX-6L › TI-MVX

– Time of Flight Diffraction (TOFD)

– Phased Array Ultrasonic Testing (PAUT)

– Motorized WeldRover Scanner/Semi Automatic and Hand Scanners 12

CAPABILITIES (EQUIPMENT)

13

Analog Flaw Detectors Digital Flaw Detectors

OmniScan with Motorized WeldRover Scanner

Phased Array Equipment

CAPABILITIES (EQUIPMENT)

Radiographic Testing – X-Ray Machines

› Andrex Smart 225 kV › Andrex 300KV › YXLON International Andrex Smart 200 and 300 kV › Isovolt Titan-E GE Inspection Technologies 225 kV

– Gamma Ray Sources › Iridium-192 (Many sources)

› Cobalt-60

– Film Viewers

– Densitometers

14

CAPABILITIES (EQUIPMENT)

Radiographic Testing – Manual Film Processor

– Automatic Film Processor

– Film Dryer

– Reference Radiographs (ASTM and IIW)

– Equipment for Digital Industrial Radiography (DIR)

› X-Ray Film Digitizer

› Computed Radiography System (Durr CR-35)

› Fluoroscopic System Developed at NCNDT

15

CAPABILITIES (EQUIPMENT)

16

X-Ray Machine Ir-192 Source

Interpretation Room Exposure Room

CAPABILITIES (EQUIPMENT)

17

Film Digitizer Digital Fluoroscopy system

Imaging Plate Scanner Durr CR-35

CAPABILITIES (EQUIPMENT) Magnetic Particle Test Equipment

– Portable Magnetizing Units (Prod, Coil, Center Conductor)

– AC/DC Yokes & Permanent Magnets

– Magnetization Coil

– Residual Field Strength Meter

– UV Lights

– Demagnetizers

18

CAPABILITIES (EQUIPMENT)

Liquid Penetrant Testing – Penetrant Test Materials (Visible and Fluorescent)

– UV Lights

– Ultrasonic Cleaner

– UV light meters

– Thermometer (Digital/distance)

– Visible Light/Lux Meter

– Comparator blocks

19

CAPABILITIES (EQUIPMENT)

Visual Testing – Videoscope

(7.5m, 6mm dia, Stereo Measurement)

– Magnifiers/Mirrors

– Hand-held Microscope (100 X)

– Boroscope

20

CAPABILITIES (EQUIPMENT)

Eddy Current Testing – Eddy Current Flaw Detectors

› MS 5800 Multiscan, › MAD 8D, › Phasec 2D › Phasec 3D › EEC-39 RFT › ECT48 › EM-3300

– Eddy Current Conductivity Meter

– Coating thickness gauge

– Depth Gauge

21

CAPABILITIES (EQUIPMENT)

22

Calibration Tubes

EM 3300 MS 5800 Multi Scan and EFC 39 RFT

ECT 48 LB

CAPABILITIES (EQUIPMENT)

23

Infra-Red Thermographic Camera Wire Rope Testing Equipment

Strain Gauging System

INTERNATIONAL COLLABORATION

24

Collaboration between Pakistan and Sri Lanka in the field of NDT

MoU has been signed for exchanging know-how including NDT.

Chairman AEC Sri Lanka visited NCNDT in Nov. 2012

TRAINING MATERIAL DEVELOPED BY NCNDT AND REVIEWED AND FINALIZED BY IAEA

25

IAEA Document No. Title

TCS No. 03, 1992

TCS No. 09, 1999

TCS No. 10, 1999

TCS No. 11, 2000

Industrial Radiography

Industrial Management and

Quality Control Personnel

Ultrasonic Testing of Materials

Liquid Penetrant and

Magnetic Particle Testing

TRAINING MATERIAL DEVELOPED BY NCNDT AND REVIEWED AND FINALIZED BY IAEA

26

27

STATUS OF NUCLEAR POWER PLANTS (NPP’s) IN PAKISTAN

NUCLEAR POWER PLANTS (NPP’s) IN PAKISTAN

28

NUCLEAR POWER PLANTS (NPP’s) IN PAKISTAN Operating Reactors in Pakistan

Reactor Province Type MWe gross MWe net Construction start

Commercial operation

Karachi 1 Sindh PHWR 137 90 1966 December 1972

Chashma 1 Punjab PWR 325 300 1993 June 2000

Chashma 2 Punjab PWR 325 300 2005 May 2011

Chashma 3 Punjab PWR 340 330 May 2011 December 2016

Total (4) 1127 operating

29

NUCLEAR POWER PLANTS (NPP’s) IN PAKISTAN Nuclear Power Reactors Under Construction

Reactor Province Type MWe gross MWe net Construction start

Planned Commercial operation

Chashma 4 Punjab PWR 340 330 Dec 2011 May 2017

Kanupp- 2 Sindh PWR 1100 1100 Aug 2015 late 2021

Kanupp-3 Sindh PWR 1100 1100 May 2016 late 2022

Total (3) 2540

30

NUCLEAR POWER PLANTS (NPP’s) IN PAKISTAN Nuclear Power Reactors Planned for Construction in near Future

Reactor Province Type MWe gross.

Chashma 5 Punjab PWR 1000

Muzaffargarh-1 Punjab PWR 1000

Muzaffargarh-2 Punjab PWR 1000

Total (3)

3000

Government has set a target of 8,000 MWe. Electricity from Nuclear Power Plants by 2030.

31

32

IN-SERVICES INSPECTION (ISI) OF NUCLEAR POWER PLANTS

(NPP’s) IN PAKISTAN

ISI OF NUCLEAR POWER PLANTS

33

Activity Nuclear Power Plant

In-Service Inspection (ISI)

Chashma Nuclear Power Plant UNIT # 1 (C-1)

Chashma Nuclear Power Plant UNIT # 2 (C-2)

Karachi Nuclear Power Plant (KANUPP)

CHASHMA NUCLEAR POWER PLANTS UNIT-1 (C-1), UNIT-2 (C-2)

34

ISI OF C-1 AND C-2 Reference Codes

35

Nuclear Power Plant Reference Code Chashma Nuclear Power Plant UNIT # 1

ASME Section XI (Rules for In-service Inspection of Nuclear Power Plant Components 2007 (1989)

Chashma Nuclear Power Plant UNIT # 2

ASME Section XI (Rules for In-service Inspection of Nuclear Power Plant Components 2001

ISI OF C-1 AND C-2

Inspection Program

NOTE:

(1) If the first period completion percentage for any examination category exceed 34%, at least 16 % of the required examination shall be performed in the second period.

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Inspection interval

Inspection period, calendar Years of

Plant Service Within the Interval

Minimum Examinations Competed, %

Maximum Examinations Credited, %

All 3 7

10

16 50 (1)

100

50 75

100

ISI OF C-1 AND C-2

The Regulatory Body:

In Pakistan, The Pakistan Nuclear Regulatory Authority (PNRA) is responsible for Licensing and Supervision, and Regulates the Safety and Security of all Civil Nuclear Materials and Facilities.

They also undertakes Audits and Periodic Reviews

NCNDT is the only Inspection Organization in Pakistan, authorized by PNRA to perform PSI/ISI of NPP,s.

37

38

ISI OF C-1 AND C-2

ISI OF C-1 AND C-2

Inspection Personnel's Qualification Documents

As an inspection organization, NCNDT performs the examination with qualified NDE system

(Equipment, Procedures and Personnel's)

The inspection personnel's qualified in accordance with SNT-TC-1A / CP-189 documents.

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ISI OF C-1 AND C-2

ISI of C-1 was performed during Re-Fueling Outage (RFO-1) to RFO-10

ISI of C-2 during RFO-1 to RFO-4

RFO-11 of C-1 is in progress from 03 April, 2017.

Domains of ISI Activities:

ISI in Conventional Island (CI)

ISI in Nuclear Island (NI)

40

ISI OF C-1 AND C-2

Inspection Methods:

Visual Examination (VT-1, VT-2, VT-3).

Surface Examination (MT, PT)

Volumetric Examination (RT, UT, ET)

41

ISI OF C-1 AND C-2 ISI of Conventional Island

42

NDT METHOD COMPONENTS INSPECTED Visual Testing Ultrasonic Testing Ultrasonic Thickness Measurements

Emergency Diesel Generator’s Cylinders, Turbine

& Generator Parts

Piping System Welds, Turbine & Generator Parts

Piping System Welds

ISI OF C-1 AND C-2

ISI of Conventional Island

43

NDT METHOD COMPONENTS INSPECTED Penetrant Testing Radiographic Testing Magnetic Particle Testing Eddy Current Testing

Piping System Welds, Turbine & Generator Parts Piping System Welds Dearator Tank, Turbine & Generator Parts Low and High Pressure Heaters, Main Condensers, SCW Heat Exchangers, Lube Oil Coolers and Non-Essential Chillers

ISI OF C-1 AND C-2 ISI of Nuclear Island

44

NDT METHOD COMPONENTS INSPECTED Ultrasonic Testing

Piping System Welds of Residual Heat Removal System (SRH), Safety Injection System (SIS), Main Feed Water System (SMF), Chemical & Volume Control System (SCV) and Reactor Coolant System (SRC) Components Welds of Steam Generator and Pressurizer welds and Regenerative Heat Exchanger, Reactor Coolant Pump (RCP)

ISI OF C-1 AND C-2 ISI of Nuclear Island

45

NDT METHOD COMPONENTS INSPECTED Radiographic Testing

Piping System Welds of Residual Heat Removal System (SRH), Safety Injection System (SIS), Main Feed Water System (SMF), Chemical & Volume Control System (SCV) and Reactor Coolant System (SRC). Components Welds of Steam Generator Inlet Nozzle Dissimilar Metal Weld.

ISI OF C-1 AND C-2 ISI of Nuclear Island

46

NDT METHOD COMPONENTS INSPECTED Penetrant Testing

Piping System Welds of Residual Heat Removal System (SRH), Safety Injection System (SIS), Main Feed Water System (SMF), Chemical & Volume Control System (SCV) and Reactor Coolant System (SRC) Components Welds of Steam Generator and Pressurizer welds and Regenerative Heat Exchanger, Reactor Coolant Pump (RCP)

ISI OF C-1 AND C-2

ISI of Nuclear Island

47

NDT METHOD COMPONENTS INSPECTED Eddy Current Testing Hardness Testing Material Analysis Visual Testing

Steam Generators Tubes Turbine & Generator Parts High Pressure Turbine Steam Piping Closure nuts , impeller of RCP, Diffusion Assembly

PT of Diffuser Assembly of RCP of C-1 UT of Studs of RCP

Ultrasonic Weld Inspection and Thickness Measurement in Conventional Island

48

ISI OF C-1 AND C-2

ISI OF C-1 AND C-2

49

Ultrasonic Weld Inspection of Safety Injection System of CNPGS Unit # 1

50

ISI OF C-1 AND C-2

RT of Cross-Over Piping

51

Metallography during RFO-2

ISI OF C-1 AND C-2

ET of LP Heater RT during RFO-3

ISI OF TURBINE PARTS C-2

52

53

Positioning Tool Developed for Radiographic Testing of Steam Generator Nozzle Dissimilar Metal Weld

ISI OF C-1 AND C-2

ISI OF KANUPP

54

ISI OF KANUPP ISI of Nuclear Island

55

NDT METHOD COMPONENTS INSPECTED Ultrasonic Testing Ultrasonic Thickness Measurements Radiographic Testing

Piping System and Components Welds, Snout Jaws Intrados of Elbows of Feeder Piping System Redundant Emergency Injection Water System (RIJW) and Forced Emergency Injection Water System (FIJW) Piping Systems Welds, Snout Jaws

ISI OF KANUPP

ISI of Nuclear Island

56

NDT METHOD COMPONENTS INSPECTED

Eddy Current Penetrant Testing Hardness Testing

Tubes of Steam Turbine Condenser RIJW and FIJW Piping Systems Snout Jaws

57

PRE-SERVICES INSPECTION (PSI) OF NUCLEAR POWER PLANTS

(NPP,S) IN PAKISTAN

CHASHMA NUCLEAR POWER PLANTS UNIT-3 (C-3) AND UNIT 4 (C-4)

58

PSI OF C-3/C-4

NCNDT carried out first PSI of Safety Class 2 & 3 Piping System Welds/Supports of Chashma Nuclear Power Plant Unit # 3 in 2016. NCNDT performed this activity as sub-contractor of China Nuclear Power Operation Technology Corporation Limited (CNPO). After Through evaluation, CNPO has accepted NCNDT as potential supplier of non-destructive testing services for nuclear power plant.

59

PSI OF C-3/C-4

After successful completion of PSI of C-3, NCNDT carried out PSI of Safety Class 2 & 3 Piping System Welds/Supports of Chashma Nuclear Power Plant Unit # 4 in 2017.

60

PSI OF C-3/C-4 Reference Codes

61

Nuclear Power Plant Reference Code Chashma Nuclear Power Plant UNIT # 3

ASME Section XI (Rules for In-service Inspection of Nuclear Power Plant Components 2001

Chashma Nuclear Power Plant UNIT # 4

ASME Section XI (Rules for In-service Inspection of Nuclear Power Plant Components 2001

PSI OF C-3/C-4 PSI of Nuclear Island

62

NDT METHOD COMPONENTS INSPECTED Ultrasonic Testing Radiographic Testing

Piping System Welds of Residual Heat Removal System (SRH), Safety Injection System (SIS), Main Feed Water System (SMF) and Main Steam System (SMS). Piping System Welds of Residual Heat Removal System (SRH), Safety Injection System (SIS)

PSI OF C-3/C-4

PSI of Nuclear Island

63

NDT METHOD COMPONENTS INSPECTED Penetrant Testing Visual Testing

Piping System Welds of Residual Heat Removal System (SRH), Safety Injection System (SIS), Containment Spray System (SCS), Main Feed Water System (SMF) and Main Steam System (SMS). Piping Supportsof Residual Heat Removal System (SRH), Safety Injection System (SIS), Containment Spray System (SCS), Main Feed Water System (SMF) and Main Steam System (SMS).

64

Ultrasonic Testing of Piping Weld of Residual Heat Removal System (SRH) performed by NCNDT

PSI OF C-3/C-4

Liquid Penetrant Testing of Piping Weld of Main Steam System (SMS)

PSI OF K-2/K-3

Work on two Karachi Nuclear Power Projects Unit-2 (K-2) and Unit-3 (K-3) with capacity of 2200 megawatts of electricity is in progress. In near future, NCNDT will perform PSI and ISI of these plants. The inspection code for K2 / K3 is RSE-M

65

CONTROL POINT WITNESS OF C-1,C-2, C-3/C-4, K-2/K-3 DURING MANUFACTURING OF REACTOR

PRESSURE VESSEL, STEAM GENERATOR, PRESSURIZER

66

CONTROL POINT WITNESS OF C-1, C-2, C-3/C-4, K-2/K-3 COMPONENTS

NCNDT Engineers remained fully involved in Control Point Witness of C-1,C-2, C-3/C-4, K-2/K-3 during manufacturing of Reactor Pressure Vessel, Steam Generator, Pressurizer.

67

CONTROL POINT WITNESS OF C-1, C-2, C-3/C-4, K-2/K-3 COMPONENTS

Ultrasonic Testing witness on a Steam Generator Weld of K-2/K-3

68

CONTROL POINT WITNESS OF C-1, C-2, C-3/C-4, K-2/K-3 COMPONENTS

Magnetic Particle Testing witness on a Steam Generator Weld of K-2/K-3

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IN-SERVICES INSPECTION (ISI) OF CONVENTIONAL INDUSTRIAL

PLANTS IN PAKISTAN

71

National Power Industry

WAPDA (Water and Power Development Authority)

• Tarbela Power Station

• Mangla Power Station

• Warsak Power Station

• Jabban Hydel Power Plant, Dargai

UCH Power Plants

ROUSCH Power Plant, Khanewal

Korangi Thermal Power Station, Karachi

Kot Addu Power Company (KAPCO)

INSPECTION SERVICES

National Process Industry Oil and Gas Plants

Refineries

Fertilizers

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Served more than 100 organizations nation-wide …

INSPECTION SERVICES

CONTRIBUTION OF IAEA

IN DEVELOPMENT OF HUMAN RESOURCES AND INSPECTION

FACILITIES OF NCNDT

73

COLLABORATION WITH IAEA

NCNDT has been receiving extensive support from IAEA through Technical Co-operation (TC) Projects, Regional Cooperative Agreement (RCA) Projects and Coordinated Research (CR) Projects :

74

Workshop on “Structural Integrity of RPV”

at NCNDT under IAEA, 27-30 May 2014

Workshop on “ISI of NPPs” at NCNDT under IAEA,

18-20 May 2016

IAEA TECHNICAL CO-OPERATION (TC) PROJECTS For Cycle 2016-17 (In progress)

“Development of Capabilities for PSI and ISI of RPV and Other Vital Components of NPPs”

Contribution through Fellowship, Scientific Visits, Expert Mission

Organized Workshop at NCNDT under IAEA, 18-20 May 2016

For the Cycle 2014-2015 –“Ensuring Integrity of System Structure and Components in

Nuclear Power Plants for Safe and Reliable Operation” .

Organized Workshop at NCNDT under IAEA, 27-30 May 2014

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IAEA TECHNICAL CO-OPERATION (TC) PROJECTS

1. Development of Capabilities for Automated Ultrasonic Testing and Corrosion Monitoring for Integrity Assessment (PAK/4/046)

2. Development of In-Service Inspection (ISI) Facilities for Nuclear Power Plants (PAK/8/015)

3. Non-Destructive Evaluation of Pressurized Components and Concrete Structures (PAK/8/013)

4. NDT Equipment Calibration and Concrete Testing (PAK/8/011)

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– Capacity Building in Applications of Advanced NDE Technologies for Enhancing Industrial Productivity – (in progress) (RAS/1/020)

– Supporting Advanced Non-Destructive Examination for Enhanced Industrial Safety, Product Quality and Productivity (RAS/1/013)

– Application of Digital Industrial Radiography (DIR) and Computer Tomography (CT) in Industry and Civil Structures (RAS/8/110)

– Development and Application of Advanced Industrial Radiography and Tomography Techniques (RAS/8/105)

– Non-Destructive Testing and Evaluation (RAS/8/085)

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IAEA REGIONAL CO-OPERATIVE AGREEMENT (RCA) PROJECTS

Optimization of Digital Industrial Radiographic (DIR) Techniques for Special Applications and Development of Procedures and Protocols (2007-2010)

– Developed Low Cost Digital Fluoroscope at NCNDT

Corrosion and Deposit Determination in Large Diameter Pipes, with and without Insulation by Radiography Testing (2002-2005)

– Standard Protocols of Test: NDT Radiographic Examination For Determination of Corrosion and Deposits in Pipe Having Diameter Larger Than 150 mm

In Situ Applications of X-ray Fluorescence Techniques (2000-2003)

– Standardization of Non-destructive X-ray Fluorescence (XRF) Alloy Analyzer for In-service Inspection

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IAEA COORDINATED RESEARCH (CR) PROJECTS

COLLABORATION WITH IAEA - SUMMARY Publications for IAEA (Training Course Guidelines) = 04

Expert Missions

NCNDT to IAEA = 17

IAEA to NCNDT = 19

IAEA Regional Courses held at NCNDT = 05

IAEA Scientific Visitors to NCNDT = 04

IAEA Trainees to NCNDT = 04

IAEA TC Projects = 06

IAEA RCA Projects = 05

IAEA CR Projects = 03

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FUTURE PLANS AND GOAL OF NCNDT

PRESENT CAPABILITIES At present, NCNDT is carrying out mostly manual inspection services in;

– Conventional Island (since 2000)

– Piping and Components Welds in Nuclear Island (since 2006)

Not yet performed mechanized inspection of Reactor Pressure Vessel (RPV) of NPPs

81

FUTURE PLAN

82

NDT METHOD COMPONENTS TO BE INSPECTED

Ultrasonic Testing

Inspection of Reactor Pressure Vessel (RPV), (Shell Welds, Head Welds, Shell to Flange Weld, Head to Flange Weld, Nozzle to Vessel Weld, Nozzle Inside Radius Section, Nozzle to Safe End Butt Weld, Closure Studs),

FUTURE PLAN

83

NDT METHOD COMPONENTS TO BE INSPECTED

Visual Testing Surface Methods

Inspection of Reactor Pressure Vessel (RPV), Head to Flange weld, Nozzle to Safe End Socket Weld, Closure Studs, Closure Washers, Vessel Interior, Interior attachments within beltline region, Core Support Structure, Bolts, Studs, Nuts Inspection of Reactor Pressure Vessel (RPV), Head to Flange Weld, Nozzle to Safe End Socket Weld, Welded Attachments.

FUTURE PLANS

Training of Manpower for Mechanized Inspection Systems for Reactor Pressure Vessel (RPV)

Procurement of Mechanized Inspection Systems for Reactor Pressure Vessel (RPV)

Fabrication of Mock ups

FUTURE PLANS

Local Fabrication of UT and ET Probes

Development of Qualification and Evaluation Facility:

ASME/PDI

ENIQ

FUTURE GOAL

Development of Capabilities for Indigenization of Pre-Service and In-Service Inspection of Reactor Pressure Vessel and other Vital Components of Nuclear Power Plants

Enhance International Cooperation including IAEA

CONCLUSION

› NCNDT is capable of performing manual inspection of Piping and Components Welds in Nuclear Island.

› NCNDT, PAEC allocated budget for Procurement of Mechanized Inspection System for RPV of NPPs.

› Training of Manpower to perform Mechanized Inspection System is in progress.

› Hopefully, NCNDT, PAEC will achieve these targets shortly.

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THANK YOU