epri nde program technology transfer accessing …...... b-j, c-f-1, and c-f-2, and r-a piping...
TRANSCRIPT
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Robert Bouck
Sr. Program Manger, NDE Technology
NDE Issues Meeting
Tuesday, 06/21/2016
EPRI NDE Program
Technology TransferThinking Ahead . . .
2© 2016 Electric Power Research Institute, Inc. All rights reserved.
Technology Transfer Topics
Technology Readiness Levels
Technology transfer planning
– Types of Projects/Products the NDE Program produces
Technology transfer challenges
Technology transfer enablers
Example projects ready for implementation
3© 2016 Electric Power Research Institute, Inc. All rights reserved.
Technology Readiness Levels
Research & Discovery Innovation & Development DemonstrationCommercialization & Diffusion
Stage 1 Stage 2 Stage 3 Stage 4Gate Gate
Commer-
cialization
Early
Commercial
Deployment
Demon-
stration
Early
Demon-
stration
System
Validated
Subsystem
Validation
Proof of
Concept
Validated
Concepts
Formulated
Exploratory
Research
TRL 9TRL 8TRL 7TRL 6TRL 5TRL 4TRL 3TRL 2TRL 1
Commer-
cialization
Early
Commercial
Deployment
Demon-
stration
Early
Demon-
stration
System
Validated
Subsystem
Validation
Proof of
Concept
Validated
Concepts
Formulated
Exploratory
Research
TRL 9TRL 8TRL 7TRL 6TRL 5TRL 4TRL 3TRL 2TRL 1
Gate Gate
4© 2016 Electric Power Research Institute, Inc. All rights reserved.
NDE Program’s Process for Planning
Technology Transfer – Thinking Ahead . . .
Project Deliverable Types /
Technology Transfer MethodLi
cens
ing /
Roy
altie
s
NDE A
lert
New
slette
r
IR R
epor
t
TU /
TR R
epor
t
TU /
TR w
ith E
mbe
dded
Vid
eo
Video
(e.g
. PP
T "Mix",
EPRI
Youtu
be, .
. . )
Distri
bute
d as
an
Issu
e Pro
gram
White
Pap
er
Cock
pit
Poste
d on
EPR
IQ.com
Execu
tabl
e / W
ebsite
/ App
licat
ion
CBT /
Mul
timed
ia
Wor
ksho
p / C
onfe
renc
e
Form
al T
rainin
g / C
ertif
icat
ion
Proce
dura
lized
Dem
onstra
tion
Use
r/Wor
king
Gro
up
Vendo
r col
labo
ratio
n
Cust
omer
Ass
ista
nce
/ Site
visit
ASM
E C
ode
Regu
lato
ry B
ody End
orse
men
t
Availa
bility
of H
ardw
are
Oth
er
Raw / Preliminary Research
Technology to be developed and commercialized
Technology Improvements
Technology assessments
Leveraging Existing Technologies into derivative product 5 5 5 5 5 5 5
Technology / Technique targeting NDE Efficiencies ($$$) 6 6 6 6 6 6 6 6
Technique development
Technique Improvements 1, 2 1, 2 1, 2 1, 2 1, 2
Leveraging Existing Techniques into derivative product
Capability Studies / Assessments / Demonstrations
Technical Basis Development (PD, Relief Request, . . .) 4 4 4 4 4 4 4 4
NDE Industry Guidelines
Round Robin Studies
Reference Material
Training Materials 3 3 3 3 3 3 3 3
Service
Human Performance Improvement 7 7 7 7 7 7 7 7 7
Hardware
Assembled Package
5© 2016 Electric Power Research Institute, Inc. All rights reserved.
Technology Transfer Challenges
At what levels in any organization are technologies;– Evaluated
– Recognized and embraced
– Funded by capital or other budgets
– Implemented
Resistance to change– “It’s good enough”
The “Technology Supplier” didn’t receive the technology
“I don’t want to be first”– Lack of Pilots/Prototypes/Demonstrations
Legal implications– Licensing etc.
Technology supplier sees the technology as not theirs and available to all suppliers– The “Not Invented Here” syndrome
Your thoughts?– Opportunity to discuss tomorrow in TAC meetings
6© 2016 Electric Power Research Institute, Inc. All rights reserved.
Technology Transfer Enablers
Members engaging vendors (and vice versa)
The “right” pieces of research made publically available– Ease of access
Engage project sponsors
Heightened EPRI reach out to Members/Vendors
Vendor participation in TAC meetings
Workshops/Conferences
Language translation
Your thoughts?– Opportunity to discuss tomorrow in TAC meetings
7© 2016 Electric Power Research Institute, Inc. All rights reserved.
Example projects ready for implementation
1. Procedure for Single-Side Ultrasonic Examination for Stainless Steel Piping: Encoded Ultrasonics (3002007780)
– Accessed through EPRI.com by Members in support of Vendors
2. Procedure for Manual Phased Array UT Testing of Weld Overlays Procedure: EPRI-WOL-PA-1, Revision 4 (3002008330)
– Publically available through EPRI.com
3. Computer Based Training for Weld Overlay NDE Final Version (3002006657)
– Accessed through EPRI.com by Members in support of Vendors
– EPRI supported Training
4. Phased Array Technologies: Essential Variables Defined (3002008758)
– Publically available through EPRI.com
5. BOP Heat Exchanger Tubing Inspection Techniques Update, Rev 4 (3002007796)
– Accessed through EPRI.com by Members in support of Vendors
6. Nondestructive Evaluation: Reactor Pressure Vessel Threads in Flange Examination Requirements (3002007626)
– Publically available through EPRI.com
7. Nondestructive Evaluation: Industry Best Practices for Performing Reliable NDE - Implementation Guide (3002007329)
– Publically available through EPRI.com
8© 2016 Electric Power Research Institute, Inc. All rights reserved.
Transforming Technology into Products is Hard
9© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Mark Dennis
Program Manager – NDE Modeling & Simulation
NDE Technology Week
June 21, 2016
Procedure Demonstration
for Single-Sided Ultrasonic
Examinations for Stainless
Steel Piping
11© 2016 Electric Power Research Institute, Inc. All rights reserved.
Outline
Project Overview
Results to Date
Future Work
Questions
12© 2016 Electric Power Research Institute, Inc. All rights reserved.
Procedure Demonstration for Single-Sided Ultrasonic Examinations for Stainless Steel
Piping
There is currently no qualified UT procedure for when
access is limited (for example, far side) for austenitic
stainless steel piping welds.
This project builds upon recent activities to develop such
a procedure.
The previous study was successful in detecting
circumferentially oriented non-IGSCC defects. The
activities of this currently project include the following:
– Evaluation of manual ultrasonic techniques (including
ultrasonic phased array technology)
– Procedure qualification for non-IGSCC piping
applications with favorable inside-surface geometries
– Improved far-side flaw detection for IGSCC-
susceptible piping
– Far-side flaw detection for axially oriented defects
13© 2016 Electric Power Research Institute, Inc. All rights reserved.
Procedure Demonstration for Single-Sided Ultrasonic Examinations for Stainless Steel
Piping
Summary from previous Work – Encoded Techniques
– Testing was performed on several piping specimens in the as-welded condition.
IGSCC and non-IGSCC from 4.0 in. to 36.0 in. diameter and 0.237–2.625 in. thickness.
– Ultrasonic phased array technology showed promise for circumferential flaws.
100% detection for the Non-IGSCC and 83% for the field removed IGSCC test samples.
– IGSCC not detected from the far side was likely due to the component inside-surface
geometry, which prohibits direct line of sight for any UT approach.
Nondestructive Evaluation: Ultrasonic Methods for Single-Side Examination of Austenitic Stainless Steel Piping Welds (1025234)
14© 2016 Electric Power Research Institute, Inc. All rights reserved.
Procedure Demonstration for Single-Sided Ultrasonic Examinations for Stainless Steel
Piping
Summary from previous Work – Manual Techniques
– Testing was performed on several piping specimens in the as-welded condition.
IGSCC and non-IGSCC from 12.0 in. to 36.0 in. diameter and 0.688–2.625 in. thickness.
– Manual ultrasonic phased array technology results for circumferential flaws (One candidate).
94% detection for the Non-IGSCC and 86% for the field removed IGSCC test samples.
Unacceptable number of false calls
Procedure Demonstration for Single-Side Ultrasonic Examinations for Stainless Steel Piping: Manual Phased Array Ultrasonics (3002005443)
15© 2016 Electric Power Research Institute, Inc. All rights reserved.
Procedure Demonstration for Single-Sided Ultrasonic Examinations for Stainless Steel
Piping
Axial Flaws are Challenging - Detection and Coverage – We have ideas
16© 2016 Electric Power Research Institute, Inc. All rights reserved.
ASME Code Case N711 “Alternative Examination Coverage Requirements for Examination Category B-
F, B-J, C-F-1, and C-F-2, and R-A Piping Welds"
Used to evaluate the necessary volume of material within the weld material and on the far side of the weld required to be examined based on Risk Informed Methodology.– Configuration (Pipe-Pipe, Pipe-Valve, Pipe-Pump, etc.)
– Degradation Mechanism (Thermal Fatigue, IGSCC, etc.)
– Primary volume of interest may be reduced or increased
Not presently approved for use in accordance with U.S. Nuclear Regulatory Commission (NRC) Regulatory Guide 1.147.
No real technical changes between N711 and N711-1 (out for letter ballot – ASME Section XI standards committee) but developed additional technical bases and supporting references to specifically address NRC input.
Pat O’Regan has proposed a new 2017 project to develop examples of how to determine the primary volume of interest.
17© 2016 Electric Power Research Institute, Inc. All rights reserved.
Procedure Demonstration for Single-Sided Ultrasonic Examinations for Stainless Steel
Piping
Future Work
– Revisit manual phased array approach to reduce false calls.
– Improve techniques for axial flaws.
– Demonstration on PDI blind specimens.
– Monitor ASME Code Case N711 progress.
– December 2016 publish 3002007780 report documenting the
results to date.
18© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Doug Kull
Sr. Technical Leader
Developing User Friendly
Versions of EPRI Phased
Array Procedures
20© 2016 Electric Power Research Institute, Inc. All rights reserved.
Scope
Review and revise the currently qualified EPRI non-encoded manual phased array procedures (PA)– Improve the ease of use
– Make easier to integrate into member ISI programs
Assemble a focus group comprised of industry leaders – Review the procedure modifications
– Provide feedback on how the procedures could be better utilized
Once Weld Overlay (WOL) procedure has been completed the same format will be applied to all remaining EPRI manual non-encoded PA procedures
Procedure Report Number Est Completion Date
EPRI-WOL-PA-1 1015134 6/10/2016
EPRI-DMW-PA-1 1016645 9/10/2016
EPRI-PIPE-MPA-1 1016650 12/23/2016
EPRI-PIPE-TWS-MPA-1 1016650 12/23/2016
EPRI_RPV_PA_1 1015430 TBD
PDI_UT_12 1015149 TBD
PDI_UT_13 1021166 TBD
21© 2016 Electric Power Research Institute, Inc. All rights reserved.
Technology Transfer & Deliverables
Notable Member Engagement – Industry Focus Group
S.Hamel, K.Hacker, N.Finney, D.Brown, & A.Zipper
– Numerous calls, several procedure revisions, & countless emails
Technology Transfer Method Technical Basis Document – Members only
Procedure – Free Release Assembled Package (PDF & MS Word)
Ancillary Documents – EPRIQ.com members
– Table 1, Table 2, & Supporting Procedures (e.g., Thickness and Contour (T&C) and Receipt Inspection Procedure (RIP))
Target Applications– Manual PA Practitioners and Inservice Inspection (ISI) Planners
22© 2016 Electric Power Research Institute, Inc. All rights reserved.
Notable Highlights
First procedure (EPRI-WOL-PA-1) was published on 6/10
Streamlined the WOL Procedure– Reduced the page count by more than 50% (106 to 52)
– Generated two new procedures (T&C and RIP)
– Aligned the procedure with current industry terminology
– Applied lessons learned from recent operating experience (OE) and other procedure modifications
Eliminated the need to continuously revise the EPRI document based on simple equipment changes
Improved the distribution process– Access to MS Word version will be easier to incorporate into ISI Programs
– Procedure documents available to everyone
– If validation or verification is needed, the official Quality Assurance (QA) document (.pdf) is available at www.EPRIQ.com
23© 2016 Electric Power Research Institute, Inc. All rights reserved.
Other Items of Interest
Weld Overlay– Technical Basis Document
Nondestructive Evaluation: Procedure for Manual Phased Array UT of Weld Overlays: Technical Basis Document
EPRI Product ID# 3002008323
– Procedure
Nondestructive Evaluation: Procedure for Manual Phased Array UT of Weld Overlays: Procedure – EPRI-WOL-PA-1 Revision 4
EPRI Product ID# 3002008330
Dissimilar Metal Welds– Revision of this procedure (EPRI-DMW-PA-1) is in progress
– Deliverable Due Date: 9/10/2016
Cross Sector Applications– NDE is looking at possible applications of the process within the EPRI Fossil Group
24© 2016 Electric Power Research Institute, Inc. All rights reserved.
Accessing the Procedures
Step #1 – Download and Open the
Appropriate Report from www.epri.com
– WOL – 3002008330 – Available Now
– DMW – 3002008333 – 9/10/2016
– PIPE – 3002008334 – 12/18/2016
– PIPE-TWS – 3002008335 – 12/18/2016
Step #2 – Click the Attachment Tab in
your PDF viewer (Icon: Paperclip)
Step #3 – Double click the PDF or MS
Word version of the procedure
25© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
J. Leif Esp
Sr. Technical Leader
06/21/2016
The EPRI NDE Workplan
and Technology Transfer
Computer Based Training for
WOL NDE
27© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Drivers
Due to lack of recent power plant construction many examiners have limited, if any, experience in construction related NDE– Weld overlays may be the only component regularly examined where
examiners are expected to identify and ultrasonically characterize new fabrication related flaws
– Current examinations procedures address contamination cracks, lack of bond (LOB), and lack of fusion (LOF) flaws but do not specifically address other fabrication flaws that may be found during examinations of Alloy 52/52M material
Ductility dip cracking (DDC)
Hot cracking
Etc…
28© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Drivers (Continued)
– A need for enhanced and updated training has been identified as a causal factor during past operating experience (OE)
– This new training should cover –
Welding processes
Potential fabrication defects
–Types of defects
–Where they are likely to exist
Comparison of detected flaws to acceptance standards
Recent OE
–The ability to providing this training on site – immediately prior to examinations could reduce the potential for human performance errors
29© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Drivers / History
Much of the material for training is already in place –
however it is spread amongst various older training material,
many technical reports, various other industry support
documents, along with captured operating experience from
the industry
In 2014 this project was initiated to gather all of this material
and provide an updated training course that would be
available via a computer based training (CBT) course
30© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2014 / 2015 / 2016
Key Tasks– Bring all available material together to create an updated and enhanced CBT
course. Examples of this type of material is as follows:
EPRI 912 course – UT Operator Training for Weld Overlay Examination 1989
Overlay Handbook: Part 1 – Welding Procedures; Part 2 – NDE. EPRI, Palo Alto, CA: 2010.1021075.
Nondestructive Evaluation: Proposed Code Case Criteria for Technical Basis of Weld Overlay Indication Evaluation and Disposition Based on Advanced Technology Assessments. EPRI, Palo Alto, CA:2009. 1019118.
NP-4720-LD Examination of Weld-Overlaid Pipe Joints, October 1986.
PDI-UT-8
Code Case N-504-4
Code Case N-740
ASME Section XI, Appendix Q
31© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2014 / 2015 / 2016 (Continued)
CBT Creation
– Using all available material creation of the CBT course was started in
2014
– A draft course outline was created to form a baseline for what the
course would accomplish
– Main course objectives were to provide training for
First time NDE examiners of weld overlays (Modules 1 through 3)
Refresher training for experienced examiners of weld overlays –
including updated OE (Modules 2 and 3)
Brief training for site personnel that are new to weld overlays
(management or other staff) (Module 3)
32© 2016 Electric Power Research Institute, Inc. All rights reserved.
33© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2014 / 2015 / 2016 (Continued)
During 2014 and 2015 CBT creation was carried out– Created story boards for each module specified in the outline
– Created training interactions to demonstrate principles discussed in the modules
– Storyboards were transferred to outside contractor and placed into the CBT format
– First draft of the CBT was created with suggestions for additional interactions and activities
Internal review for consistency and usability was performed in the fall of 2015
Comments provided to CBT vendor to be incorporated into training
34© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2016 Wrap Up
CBT creation has been completed and interactions have been
completed
– Intentionally left some interactions out – member input on these
interactions is needed
Code Case N-740 evaluation examples (acceptable and rejectable)
Appendix Q evaluation examples (acceptable and rejectable)
Examples of useful formulas
EPRI Software QA (SQA) performing a review of the CBT course and
ensuring compliance across multiple software platforms / web
browsers
After completion of SQA initial validation Beta Version will be released
35© 2016 Electric Power Research Institute, Inc. All rights reserved.
Training Preview
36© 2016 Electric Power Research Institute, Inc. All rights reserved.
Training Preview
37© 2016 Electric Power Research Institute, Inc. All rights reserved.
Training Preview
38© 2016 Electric Power Research Institute, Inc. All rights reserved.
Training Preview
39© 2016 Electric Power Research Institute, Inc. All rights reserved.
Training Preview
40© 2016 Electric Power Research Institute, Inc. All rights reserved.
Training Preview
41© 2016 Electric Power Research Institute, Inc. All rights reserved.
What is the Path to Technology Transfer?
Summer of 2016 – Beta Version will be released for testing, validation, and comments– Mr. Donahue at Duke Energy volunteered in 2014 to have Duke
participate in the beta testing phase
– Mr. Lofthus at Southern Company has also volunteered his staff to take part in the beta testing phase
– The Beta Version will be released for testing in early July
– The testing window will be 2 – 3 weeks in duration and all comments from the testing will be addressed prior to release of the Final Version.
We do ask if anyone has any additional interactions they please provide them during the beta phase
– Specifically we are looking for real world evaluations (both acceptable and rejectable) for Code Case N-740 and Appendix Q
42© 2016 Electric Power Research Institute, Inc. All rights reserved.
What is the Path to Technology Transfer?
October 2016 – Final Version will be released for use– Currently planning for stand alone CBT product available for download from
EPRI.com
– Current path also includes a Nantel compliant version of training
This delivery path is currently under evaluation
Member Engagement– Beta Version is a designated point for member engagement
Member feedback must be addressed prior to release of Final Version
Target Applications– Just in time training for;
New examiners with little or no weld overlay examination experience
Experienced examiner that needs a refresher and exposure to past OE
Utility management staff that need a brief explanation of the weld overlay process
43© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
J. Leif Esp
Sr. Technical Leader
06/21/2016
The EPRI NDE Workplan and Technology Transfer
Nondestructive Evaluation: Phased Array Technologies:
Phased Array Essential Variables Defined
45© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Drivers
Advances in technology has lead to the use of phased array
ultrasonics on a much broader scale and the use of phased
array technology continues to rise every year
– Phased array techniques can provide viable solutions on complex
and limited configurations
– Phased array techniques can enhance examinations by generating
multiple angles from a single search unit
46© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Drivers (Continued)
Many essential variables that pertain to conventional UT also apply to phased array UT, however there are more variables to consider when using phased array technology
These additional variables are not currently addressed by ASME Section XI, Appendix VIII
This project focused on;– Determining which variables were considered essential with various
PA instruments
– Developing a technical basis to support revisions to ASME Section XI, Appendix VIII or other Codes and standards
– Evaluating processes that could be used to control these parameters in an efficient manor
47© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Drivers / History
Phased array has been in used to perform ASME Section XI
examinations for over a decade – so what has the US
industry addressed this up to now?
– Procedure owners and Performance Demonstration Administrators
(PDA) have identified the essential variables in the course of the
procedure qualification and these variables were clearly defined in
the qualified procedures
While the process was effective is was clear that these
variables needed to be codified
48© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2013 / 2014
Key Tasks– Review of all PA essential variables currently identified in the
Section V of the ASME Code and other international standards
– Review all currently Appendix VIII qualified phased array procedures in an effort to produce a combined list of essential variables
– Survey Industry
Hardware / software manufacturers were asked to provide all variables within their systems that they deemed essential
Probe / wedge manufacturers were asked to provide all essential parameters involved in the manufacturing and use of probes / wedges
49© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2013 / 2014 (Continued)
Testing
– Using the information obtained from the surveys and literature
searches, a series of tests were performed to determine if the
variables were actually essential
Tests included;
– Manufacturing of various probes and wedges to compare
different variables
– Collection and evaluation of data using various parameters
– Confirmatory computer modeling
50© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2013 / 2014 (Continued)
At the end of 2014 a technical update report was issued
documenting research results obtained to date
– Additional studies were recommended prior to starting the
codification process so the project was extended
51© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Review 2015 / 2016
New phase of the project allowed for the completion of the
following activities;
– Testing of specialized probes provided by manufacturer to validate
proprietary variables related to composite materials used to
fabricate various PA search units
– Solicitation of feedback from members prior to publishing of final
report
52© 2016 Electric Power Research Institute, Inc. All rights reserved.
What is the Path to Technology Transfer?
2016 publicly available report has been released– Report 3002008768, Nondestructive Evaluation: Phased Array Technologies:
Essential Variables Defined is publicly available for download from EPRI.com
Member Engagement– Feedback from the members has been vital in ensuring that the project staff
understood the needs of the industry and provided a product that would meet those expectations
Target Applications– Research provided in the report will be able to be utilized by the members to form the
Technical Basis for including phased array essential variables in ASME Section XI, Appendix VIII or other Codes and standards
EPRI’s role in the continuation of the Technology Transfer– Through this project EPRI will continue to guide and provide support to members
attempting to the include phased array essential variables into various Codes and standards
– In subsequent years the ASME Section XI Development Support Project will support the needed modifications to ASME Section XI, Appendix VIII by using or referencing the findings of this project
53© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Balance-of-Plant
(BOP) Heat Exchanger
Tubing Inspection
Techniques Update, Rev 4
Nathan Muthu
Program Manager
EPRI
NDE Technology Development
Tel: 704.595.2546
Email: [email protected]
55© 2016 Electric Power Research Institute, Inc. All rights reserved.
Balance-of-Plant (BOP) Heat Exchanger Tubing Inspection
Techniques Update, Rev 4
Purpose:
Heat exchanger and condenser tube leaks can interrupt normal plant operations or lead to
unscheduled plant shutdown for repair or replacement.
Using proven inspection techniques can assist in identifying issues early in the game and allow
preventative measures to be taken to preclude tube leaks or extend deterioration of the damage
Data trending may be optimized when proven inspection parameters are used. Informed decisions may
be made to efficiently manage and operate the heat exchanger program - leading to extended use of the
component - optimizing assets and providing early information for repair and replacement planning.
Globally, nuclear power plants operators are encouraged to use and maintain common inspection
practices. Lessons learned and best practices used can be shared through this guide - single resource
document
• Maintain common data analysis skills across the world – sharing of resources – workforce issues
are addressed
• To support early career system engineers. Provide them with immediate tools that they can use to
initiate and support inspections and learn the eddy current process.
56© 2016 Electric Power Research Institute, Inc. All rights reserved.
Balance-of-Plant (BOP) Heat Exchanger Tubing Inspection
Techniques Update, Rev 4
EPRI members and inspection service providers may use the information
from this guide to reliably assess balance-of-plant (BOP) heat exchanger
tubing conditions. Included in this guide are:
• Suitable electromagnetic inspection techniques for detecting and sizing both corrosion
and mechanical damage forms in balance-of-plant (BOP) heat exchanger tubing.
• Round robin eddy current inspection and results on retired heat exchanger tube bundles
and how they were evaluated and compared against destructive analysis to determine
statistical values for establishing acceptable flaw depth sizing procedures for non-
ferromagnetic and ferromagnetic tubing. Criterion used:
• Flaw Detection – Percent of flaws detected
• Flaw Sizing - determined by calculating three linear regression analysis components:
regression line slope, correlation coefficient, and Root Mean Square Error (RMSE)
• Review of electromagnetics specifically for balance-of-plant (BOP) tubing inspection
applications
57© 2016 Electric Power Research Institute, Inc. All rights reserved.
Balance-of-Plant (BOP) Heat Exchanger Tubing Inspection
Techniques Update, Rev 4
How will the information be used from this guide
Each section is unique to a specific type of damage mechanism
Complete description about the heat exchanger and its tube bundle including its
operating characteristics are provided
Where available, destructive test results on pulled tube specimens are provided
• Eddy current results are verified and compared with destructive test results in order
to optimize the inspection techniques and results.
Regression plots showing flaw sizing capability for all techniques used informs the
robustness of the technique
Step-by-step instructions on calibration set-ups and reporting can be used immediately
with slight modifications made.
Inspection parameters such as frequencies, probe information, calibration standard(s)
information, channels, probe pull speeds, and sampling rates are provided.
58© 2016 Electric Power Research Institute, Inc. All rights reserved.
Balance-of-Plant (BOP) Heat Exchanger Tubing Inspection
Techniques Update, Rev 490-10 COPPER-NICKEL PRIME SURFACE
TUBING
Data Anlaysis Technique
Sheet
Page 1 of 2Tube Material: 90-10 copper-nickel OD: 0.625"
(15.87mm)
Wall: 0.049"(1.24mm)
Acquisition Technique: conventional eddy current ID: 0.527" (13.38mm)
Examination Scope
Small-volume flaws, i.e., pits and cracks in free-span regions
Data Acquisition
Instrument Probe
Manufacturer: Zetec Manufacturer: Zetec
Model: MIZ-18 Diameter: 0.500" (1.27cm)
Analog Probe Extension Probe Type: LF-CBS
Length: N/A Probe Cable Length: 83' (25m)
Probe Speed: 12" (30.5cm)/sec. Sample Rate: 400 samples/sec.
Frequency Frequency Frequency Frequency
Differential 80 kHz 40 kHz 20 kHz 10 kHz
Absolute N/A N/A N/A N/A
Data Analysis Technique
10 kHz diff - Primary detection and sizing channel for ID pitting in midspan regions
40/10 kHz diff - Primary detection and sizing channel for ID pitting at tube support plate locations
80 kHz diff - Primary detection and sizing channel for OD flaws in midspan regions
40 kHz diff - Confirmation channel for OD flaws
20 kHz diff - Confirmation channel for ID pitting
Analysis Setup
Diff. Channels 80 kHz-diff. 40 kHz-diff. 20 kHz-diff. 10 kHz-diff.
Calibration Std. ASME std. ASME std. 1/8" (3.18mm) ID pit 1/8" (3.18mm) ID pit
Cal. Curve Type phase-to-depth phase-to-depth volts-to-depth volts-to-depth
OD Cal. Pts (%) 100,80,60,40,20 100,80,60,40,20 - -
ID Cal. Pts (%) - - 0,25,50,75,100 0,25,50,75,100
Cal. Setup ASME TWH~40°
6 volts (P-P)
ASME TWH~40°
6 volts (P-P)
100% pit @ 40°
10 volts (V-Max)
100% pit @ 40°
10 volts (V-Max)
Abs. Channels N/A N/A N/A N/A
Calibration Std.
Cal. Curve Type
OD Cal. Pts (%)
ID Cal. Pts (%)
Cal. Setup
Mix. Channels 40/10 kHz-diff. N/A N/A N/A
Type of Mix TSP
Calibration Std. 1/8" (3.18mm) ID pit
Cal. Curve Type volts-to-depth
OD Cal. Pts (%) -
ID Cal. Pts (%) 0,25,50,75,100
Cal. Setup 100% pit @ 40°
10 volts (V-Max)
Regression Analysis Results
Criteria Flaws Detected Slope Correlation Coefficient RMS Error
Preferred 80% 0.7-1.3 70% 20%
Actual 97% 0.98 94% 4%
90-10 COPPER-NICKEL PRIME SURFACE TUBING
Data Analysis Technique Sheet
Page 2 of 2 Description of Calibration Standards
ASME Standard 100, 80, 60, 40, and 20% TW flat-bottom holes 10% TW OD groove and 20% TW ID groove
ID Pit Standard four 1/8" (3.18mm) diameter round-bottom pits 100, 75, 50, and 25% TW
Detailed Analysis Setup
10 kHz diff - Primary detection and sizing channel for ID pitting in midspan regions Calibration requires a 1/8" (3.18mm) diameter round-bottom ID pit standard. Set 100% TW pit signal at 40° starting down and to the right. Set the vertical amplitude of the 100% TW pit signal to 10 volts. Establish vertical amplitude vs. percent TW calibration curve for ID flaws. ID calibration points 0,25,50,75, and 100% TW.
40/10 kHz diff - Primary detection and sizing channel for ID pitting at TSP locations Create a 40/10 kHz differential tube support plate mix. Calibration requires a 1/8" (3.18mm) diameter round-bottom ID pit standard. Set 100% TW pit signal at 40° starting down and to the right. Set the vertical amplitude of the 100% TW pit signal to 10 volts. Establish vertical amplitude vs. percent TW calibration curve for ID flaws. ID calibration points 0,25,50,75, and 100% TW.
80 kHz diff - Primary detection and sizing channel for OD flaws in midspan regions Setup requires ASME standard. Set lift-off horizontal, ASME TW hole starting down and to the right. ASME TW hole should fall at roughly 40° from horizontal. Set amplitude of the ASME TW hole signal at 6 volts peak-to-peak. Establish phase angle vs. percent TW calibration curve for OD flaws. OD calibration points 20,40,60,80, and 100% TW.
40 kHz diff - Confirmation channel for OD flaws Setup requires ASME standard. Set lift-off horizontal, ASME TW hole starting down and to the right. ASME TW hole should fall at roughly 40° from horizontal. Set amplitude of the ASME TW hole signal at 6 volts peak-to-peak. Establish phase angle vs. percent TW calibration curve for OD flaws. OD calibration points 20,40,60,80, and 100% TW.
20 kHz diff - Confirmation channel for ID pitting Calibration requires a 1/8" (3.18mm) diameter round-bottom ID pit standard. Set 100% TW pit signal at 40° starting down and to the right. Set the vertical amplitude of the 100% TW pit signal to 10 volts. Establish vertical amplitude vs. percent TW calibration curve for ID flaws. ID calibration points 0,25,50,75, and 100% TW.
59© 2016 Electric Power Research Institute, Inc. All rights reserved.
Balance-of-Plant (BOP) Heat Exchanger Tubing Inspection
Techniques Update, Rev 4
How will the information be used from this guide
Vendors need to engage with EPRI members to access this product
Product will be available to all members on-line on December 18, 2016
Rev 4 will supersede Rev 3
It is encouraged not to use the techniques verbatim when doing inspections
• Techniques provided is good starting point. Slight tweaks may be required to
optimize the technique
This is a living document. Provide updates to EPRI
If something worked better than what was documented and used, then let the
technique(s) be superseded with the improved technique. Inform the industry so that
they can start using it
This is a continuous collaborative effort between members, vendors and EPRI.
60© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Patrick O’Regan
NDE Technology Week
June 21, 2016
Reactor Pressure Vessel
Threads in Flange
62© 2016 Electric Power Research Institute, Inc. All rights reserved.
RPV – Threads in Flange
Current Requirements
Inspection Challenges
Industry Investigation
Path Forward
63© 2016 Electric Power Research Institute, Inc. All rights reserved.
Current Requirements
Inspections required per ASME Section XI
Other Codes/Countries have similar requirements
64© 2016 Electric Power Research Institute, Inc. All rights reserved.
Inspection Challenges
1 – 8 hours critical path time
0.1 to 1.2 R of dose
FME into the vessel from the UT transducer or tool
Suspended load poses personnel safety concern
65© 2016 Electric Power Research Institute, Inc. All rights reserved.
Industry Investigations
Literature review
Survey of industry inspection results
Evaluation of Potential Degradation Mechanisms
Flaw Tolerance Evaluation
Risk Impact Assessment
66© 2016 Electric Power Research Institute, Inc. All rights reserved.
Literature Review
Stud Removal Issues
Overpressure Events
Current Operating Practices
67© 2016 Electric Power Research Institute, Inc. All rights reserved.
Industry Survey
Survey of RPV Threads in Flange inspections
US and non-US operators
– US operators (94 units)
More than 10,600 examinations
Zero reportable indications
68© 2016 Electric Power Research Institute, Inc. All rights reserved.
Industry Survey
Survey of RPV Threads in Flange inspections
US and non-US operators
– Non-US operators
76 units replied
Some indications identified on a few plants
• Obtained additional information to assess applicability
• Non relevant and not service induced
69© 2016 Electric Power Research Institute, Inc. All rights reserved.
EPRI Report #3002007626
70© 2016 Electric Power Research Institute, Inc. All rights reserved.
Path Forward
ASME Code Case passed by
WG-ISC and SG-WCS
Will be brought to SXI
Standards Committee at August,
2016 meeting
Several Licensees have relief
requests under development
and should submit in 2016
71© 2016 Electric Power Research Institute, Inc. All rights reserved.
Summary
Exceptional performance history of RPV Thread Ligaments
Operating experience has not identified any service induce
degradation
Existing requirements adversely impact critical path time,
worker exposure, and personnel safety concern
EPRI report documents technical basis
ASME and Licensee activities underway to eliminate
requirement
72© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Ronnie Swain
Program Manager
Performance Demonstration
NDE Issues MeetingJune 2016
Broadening the Application of
Recommended Best Practices
Based on Industry NDE
Initiatives
74© 2016 Electric Power Research Institute, Inc. All rights reserved.
What the Project Did
In the spirit of the industry process improvements made for DM weld inspections, this project compiled industry best practices into a document intended to assist plant NDE personnel in planning and execution of reliable NDE
Phase 1 (2015) – Worked with industry experts to identify and compile all reference materials and pertinent information needed for inclusion the guideline document
– Focus Group: Kevin Hacker – Dominion; Jason Coulas – Ontario Power Generation;
Kenneth Panther – Entergy; Scott Hamel – NextEra Energy; Ned Finney – Duke Energy; Jay Miller – Exelon; Dave Anthony – Exelon; Damon Priestley – TVA; Gary Lofthus – Southern Nuclear;Dave Gonzales – Pacific Gas & Electric; Wade Miller – Sonic Systems;Joel Harrison – System One; Jeremy Timm – Curtiss-Wright;Michael Lashley – Structural Integrity Assoc.; Joe Persinger – AREVA;Steve Sabo – Wesdyne; John Abbott – EPRI; Bret Flesner – EPRI; Jeff Landrum – EPRI; Steve Swilley – EPRI; Carl Latiolais – EPRI; Ronnie Swain – EPRI
75© 2016 Electric Power Research Institute, Inc. All rights reserved.
What the Project Did (continued)
Phase 2 (2016) – Used information gathered in Phase 1 to develop a high-level guide
covering all aspects of planning and performing NDE in a nuclear power plant
Section Titles:
– Pre-Examination Preparation
– Scheduling Examinations
– NDE Staffing
– NDE Staff Indoctrination
– Examiner Preparation, Training, and Practice
– Pre-Job Briefing
– Use of Team Scanning
– Oversight
– Post-Job Debriefing
– NDE Data Review
– Examination / Outage Close-Out
– References
76© 2016 Electric Power Research Institute, Inc. All rights reserved.
Technical Basis
Recent NDE OE has included cases of poor planning, execution, or data review practices that resulted in issues with the NDE reliability or efficiency
As a result of OE pertaining specifically to DM weld examinations, the NDE Improvement Focus Group (NIFG) was chartered in 2012 to review industry practices and develop guidelines and recommendations intended to improve ultrasonic (UT) examination of DM welds
Based on the strength of the NIFG products, the NDE Action Plan Committee requested that additional NDE guidance be developed to assist station NDE personnel with planning and executing all NDE with the same high standards of reliability
77© 2016 Electric Power Research Institute, Inc. All rights reserved.
How Can It Be Accessed and Used Accessing the product
– Much like the NIFG products, this report has been made available for free to the public
Go to www.epri.com
Put the title or report number (above) in the search bar
Click the download button
– Title of Report: Nondestructive Evaluation: Industry Best Practices to Performing Reliable NDE
Implementation Guide
3002007329
How to use the product
– The report has been formatted as a quick reference guide
For seasoned plant NDE personnel, it can be referenced similar to a checklist to ensure that all the right bases are covered
For new or less-experienced plant NDE personnel, or for vendor personnel assisting a plant with completion of NDE activities, this product can be a used as a “how-to” guide for approaching any NDE challenge
Can be used in conjunction with other helpful EPRI ISI products, such as the NDE Guide for Compliance with Class 1 Inservice Inspection Requirements (Product Number 3002005425)
– Provides high-level best practices and key aspects involved in proper planning and execution of NDE in the plant
– In cases where a greater level of detail on a specific topic may be helpful to the end user, references to other EPRI or industry documents are provided in the report
– The document is intended to be implemented in accordance with the Station’s plans and procedures
78© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity