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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.1

Component Asset Management with Ultra-High Pressure Cavitation Peening

Darren H. WOOD, P.E. Global Product Development Manager Lyon, France 23 October 2017



Agenda

Why UHP Cavitation Peening ?

Process Selection and Development

Tooling / Capabilities

Planning / Return on Experience

Regulatory Acceptance

Summary and Conclusions



What is Ultra High Pressure (UHP) Cavitation Peening?

Cavitation Vapor bubbles form in water

Shock Waves Occur from bubble collapse at surface generating high pressures on the material

Compressive Stresses In the surface layer of material results

High Velocity Jet Creates pressure below that of vapor pressure in water

UHP Cavitation Peening is a Well Understood, Proven Process for Surface Stress Mitigation and Improving Fatigue Life



Why discuss UHP Cavitation Peening?

PWSCC of primary components can lead to Increased inspection frequency Component repairs Component replacements

UHP Cavitation Peening is an Asset and Risk Management Tool

Greater outage scope Schedule extension Increased costs

Tensile Stress

Corrosive Environment

Susceptible Material



Agenda

Why UHP Cavitation Peening?








Surface Mitigation Process Selection

2009: 99 mitigation techniques identified 2010: 10 techniques selected based on technical / economics 2011: 3 techniques selected for additional testing Cavitation Peening Laser Shot Peening Roto Peening

2012 / 2013: Several R&D projects for: Corrosion testing on Alloy 182 samples Tooling development and qualification for UHP Cavitation Peening of BMN

nozzles (ID & OD) 2014 / 2015: UHP Cavitation Peening process and tooling development RV Head Primary Nozzle



Internal Testing Summary

UHP Cavitation Peening Prevents PWSCC

Cavitation Peening induced a compressive stress state on the surface of all samples The surface remained in compression through all corrosion testing

Cracks did not initiate on “fresh” samples treated with Cavitation Peening Shallow existing cracks on “pre-aged” samples did not propagate

after treatment with Cavitation Peening No crack initiation or growth after an additional .4% strain was applied for 1000 hours S

imila

r to

MR

P-2

67 C

orro

sion

Tes

ting



Unique Technologies Cavitation peening (Patent) Hyperbaric testing Controlled depth abrasive jet

milling High speed ceramic machining Selective coating removal Precision 5-axis machining Downhole energy tooling Nuclear cleaning &

decommissioning tooling

Customers US Navy, Air Force, Army Missile defense agency NASA National Science Foundation Pratt and Whitney Rocketdyne Rolls-Royce General Electric Energy/Aircraft Engines AREVA Lockheed Raytheon ATK Boeing Baker-Hughs Sikorsky W.L. Gore General Atomic CoorsTek

Our partner Ormond has the pedigree nuclear power requires



UHP Cavitation Peening Surface Finish

Non-peened with PT Indications

Peened No PT Indications

Before Peening

After Peening



Why AREVA Selected UHP Cavitation Peening?

Safe for both personnel and component when operated within the controlled boundaries Very robust process with a large saturation zone No risk of equipment damage or material removal No foreign material concerns Smooth transition zones with no abrupt edge between peened and unpeened regions

Compressive stress depths meet or exceed EPRI MRP requirements Very adaptable and tolerant to surface conditions and complex geometries J-grooves CRDM thermal sleeve annulus BMI nozzle inside diameter

Does not require complicated tooling compared to laser or waterjet

UHP Cavitation Peening Scored Highest with Evaluation Criteria : Safety, Results, and Ease of Implementation



UHP Cavitation Peening Qualification

The peening process effectiveness was demonstrated on full scale representative mockups at the nominal, max and min ranges of essential variables used for site implementation Full scale nozzle mockups include material and geometry constraints

X-ray diffraction was used to determine the residual stress on peened full scale representative mockups Confirm the desired peening coverage and depth

of compression has been achieved A qualification report is provided to the utility that documents how all requirements are met Topical Report / Relief Request / ASME Code

Same Essential Variable Range for Qualification Mockups and Site Implementation



Process Control and Verification

Essential variables are controlled/monitored in-process to ensure acceptable results are achieved The operator has a real-time display of all essential variables If an essential variable gets outside of the qualified limits the operator is

immediately alerted The tooling control system records the value of each essential variable The electronic data may be reviewed/verified post-process

Process Quality is Ensured and May be Verified



Agenda









Where is UHP Cavitation Peening Applicable ?

Bottom Mounted Instrumentation Nozzle

Penetrations

Safety Injection Nozzle Dissimilar Metal Weld and Safe-

End

Reactor Vessel

Alloy600 base metal

Alloy600 weld

Reactor Vessel Closure Head Penetrations

Primary RPV Nozzle Dissimilar Metal Weld and Safe-End



Bottom Mounted Instrumentation Nozzle

UHP Cavitation Peening

BMN OD Surfaces Alloy 600 (nozzle): 1 to 1.5 mm depth of compressive

stress Alloy 82/182 (j-groove weld): 1 mm depth of compressive

stress BMN ID Surfaces Alloy 600 (nozzle): 0.5 mm depth of compressive stress

Lightweight tooling easily managed from the refueling bridge



RV Closure Head UHP Cavitation Peening

CRDM OD Surfaces Alloy 600 (nozzle): from 1 mm at the minimal

parameter boundary to 1.5 mm depth of compressive stress at nominal dimensions

Alloy 82/182 (j-groove weld): 1 mm depth of compressive stress

CRDM ID Surfaces with or without Thermal Sleeve Alloy 600 (nozzle): Greater than .25 mm depth of

compressive stress on all PWSCC susceptible CRDM ID surfaces

The only process that can peen the annulus without removing or modifying the thermal sleeves

Vent Nozzle Surfaces Alloy 600 (nozzle): 0.5 mm depth of compressive stress Alloy 82/182 (j-groove weld): 1 mm depth of compressive stress

UHP Cavitation Peening is the Most Adaptive Process for these Geometries



Mega SUMO Under-Head Manipulator

NDE Synergies with Peening

Realized benefit of common manipulator Integrating and streamlining all pre-deployment

activities Delivers all peening, contingency repair, and

inspection tooling for RVCH penetrations • Simultaneous use of 2 manipulators for increased production

rates

Only one head lift necessary • Beginning of inspection • Critical path savings by installing false floor for water reclamation

before head is set, not after inspection

NDE Performance AREVA started performing Exelon head inspections

with award of peening contract Fastest full scope inspection at Braidwood: 69 hour

duration (23.2 hours ahead of schedule for 2R19)

Flexible, Robust Delivery System



Primary RPV Nozzle Dissimilar Metal Weld


Nozzle DMW ID (Weld + Heat Affected Zone) 1 mm depth of compressive stress Tool can swim NO supplemental support structures

UHP Cavitation Peening Performed from Inside the RPV, Lower Dose vs OD



Basics of the Process

Critical peening tooling (and essential variables) are the same for all applications Pumps Piping / Hoses Orifice

Observed differences are in the delivery mechanism Crawler Submarine Manually Delivered



Agenda









Peening Implementation Byron and Braidwood RVCH

78 CRDM type nozzles (5 CETs, 18 open penetrations, 55 CRDM nozzles with thermal sleeves) and 1 vent line Byron 2 – Completed May 2016 Braidwood 1 – Completed October 2016 Byron 1 – Completed March 2017 Braidwood 2 – Completed May 2017

Proven process on most challenging configuration First of a kind risks have been mitigated Extensive lessons learned to benefit next

interventions

Customer headstand modifications were implemented seamlessly and did not affect critical path UHP Cavitation Peening is a PROVEN Technology that will Maintain Your

Asset for the Life of Your Plant

<30

day

outa

ges



Site Preparation & Implementation

Equipment Setup : Two (2) UHP water jet pumps + spare and

chiller 400A @ 460VAC

Operator control station in a low dose area inside or outside containment building

Two (2) sets of each tool head



Plant Configuration and Basic Logistics for


All Work with Component on Head Stand Establish minimum

height for tooling

Experience operating two tools in parallel

Lower Internals Removed from Vessel / Flooded Cavity Workers locate equipment from refuel bridge Logically plan with a 10 year RPV ISI Plan with two tools in parallel

Hot Leg Only: Fuel Offloaded / Flooded Cavity Hot Leg + Cold Leg: Lower Internals Removed from Vessel / Flooded Cavity Workers monitor from refuel bridge Crane required to introduce tool, then released Logically plan Cold Leg mitigation with a 10 year RPV ISI Plan with two tools in parallel

RV Head BMN Primary Nozzles

Average schedule dependent on plant size / configuration and to be optimized with the operator Average dose depending on plant-specific conditions



Basic Activity Planning

Pre-Outage Tasks Establish parameters based

on as-built configuration Implementation documentation Customer-specific

qualifications and readiness demonstrations

Safety Justification Inspection Relief Request (as

applicable) must be submitted before the next required inspection and can be planned after implementation

Outage Scope (N-1 Walkdown

Recommended) Inspection Contingency Repair UHP Cavitation Peening



Agenda









ASME Code and Safety Authority Criteria

AREVA worked with EPRI, ASME, and the NRC to lead the way for Regulatory Acceptance of cavitation peening in the USA. Code Case N-770-4 is approved by ASME Provides inspection relief for primary nozzles mitigated by peening

Code Case N-729-5 is approved by ASME Provides inspection relief for RV heads mitigated by peening

MRP-335, Rev. 3 Topical Report for Primary Water Stress Corrosion Cracking Mitigation by Surface Stress Improvement: Provides technical basis for inspection relief after peening for both RV heads

and primary nozzles NRC safety evaluation released with conditions in August 2016

• RV heads with pre-existing flaws must inspect the next 2 refuel outages after peening before returning to a 10 year inspection frequency

MRP-335, Rev. 3-A : amendment to include the NRC Safety Evaluation Conditions (November 2016)

ASME Code and US Safety Authority Requirements are Established and the Benefits of Peening are Confirmed



US Precedent

UHP Cavitation Peening Was implemented in accordance with current 10 CFR 50.59 regulatory

process • The NRC review of Byron Unit 2 50.59 noted it supported the conclusions with no

concerns

Was controlled as a 10 CFR 50 Appendix B Criterion IX “special process”

Post-Peening In-service Inspection Relief Changes in the volumetric inspection frequency specified in 10 CFR

50.55(a) requires NRC approval via the relief request process • Basis provide by MRP-335, Rev. 3-A • Typically several years before the NRC will endorse the ASME Code Cases

Exelon submitted fall of 2016 for Byron 2 and received approval September 2017



Agenda









UHP Cavitation Peening Advantages

Demonstrated mitigation technology offers less complexity, more flexibility, easier and safer delivery, and higher confidence for success AREVA’s under-head experience is greatest in the industry with regard to RV head inspections and

number of nozzles repaired (predictable performance) AREVA offers both mitigation, inspection, and repair solutions from a common platform (RV head) The technology is the most adaptable process to complex geometries We are the only vendor that can peen the CRDM ID with the thermal sleeves in place, requiring no

modifications (4 loop configuration) The technology is less complex / more forgiving than laser technologies No risk of equipment damage or material removal AREVA worked closely with US NRC for peening implementation Depth of compression meets or exceeds EPRI MRP requirements

Partnering with AREVA provides access to a full scope solutions portfolio to support your unique LTO strategy NDE, engineering, contingency repair (specialized welding and machining processes), mitigation,

and even replacement components

AREVA has a proven track record in the industry of fulfilling our commitments



UHP Cavitation Peening Summary of Results

Surface Depth of Compression

AREVA EPRI / MRP CRDM Nozzle OD – Alloy 600 1 mm - 1.5 mm 1 mm

CRDM J-Groove Weld OD – Alloy 82/182 1 mm 1 mm

CRDM Nozzle ID Annulus w/ thermal sleeve – Alloy 600 .25 mm - .50 mm .25 mm

CRDM Nozzle ID (Open) – Alloy 600 .50 mm .25 mm

Vent Nozzle J-Groove Weld OD – Alloy 82/182 1 mm 1 mm

Vent Nozzle ID – Alloy 600/82/182 .50 mm .25 mm

BMN Nozzle OD – Alloy 600 1 mm - 1.5 mm 1 mm

BMN J-Groove/Repair Weld OD – Alloy 82/182 1 mm 1 mm

BMN Nozzle ID – Alloy 600 .50 mm .50 mm

Primary Nozzle DMW – Alloy 82/182 1 mm 1 mm

UHP Cavitation Peening reliably meets or exceeds EPRI MRP mitigation criteria



UHP Cavitation Peening Concluding Thoughts

Proven Technology : demonstrated in safety conscious nuclear and aerospace industries for

Asset Management : can mitigate PWSCC susceptible components, extending their useful lifetime (depending on local accounting laws, perhaps capitalize the investment)

Risk Management : planning certainty to avoid component repairs and replacements due to PWSCC which lead to increased outage cost, schedule, and dose

Schedule Optimization : reduce inspection frequency of ‘renewed’ components

Our Vision: High-performing people and technologies for safe and competitive nuclear plants worldwide



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