application of nde tool for diagnostics on ageing degradation · pdf fileapplication of nde...

Pusan National University Quality Engineering & Failure Prevention Lab마스터 부제목 스타일 편집

Joon-Hyun Lee

Application of NDE tool for Diagnostics on

Ageing Degradation

Director, Basic Atomic Energy Research Institute School of Mechanical EngineeringPusan National University ,Busan 609-735, Korea

IAEA Workshop on Detection, research, management and monitoring of ageing factors,Buenos Aires, Argentina, 9-12 December 2008

Basic Atomic Energy Research Institute

Pusan National University Quality Engineering & Failure Prevention Lab

Contents

1. Current and Future Status for Inspection and

Monitoring Technologies at Nuclear Power Plants in

Korea

2. Development of Advanced Nondestructive Diagnosis

Technology for NPP Piping System


Current and Future Status for Inspection and Monitoring Technologies at Nuclear Power Plants

in Korea

Pusan National University Quality Engineering & Failure Prevention Lab4

Introduction1

2 Performance Demonstration Initiative(PDI) in Korea3 Present NDE Techniques for Nuclear Power Plants

FAC (Flow Accelerated Corrosion)Application of NDE in Nuclear Power Plants

Condition Monitoring in Nuclear Power Plants

4

5

6

Contents


Location of Nuclear Power Plants

PWRKEDO Project

PWR

Ulchin

PHWR

PWRPWR

Yeonggwang

In Operation : 20 (17,716MW)

# 1,2,3,4 & 5 & 6

Wolsong#1,2,3 & 4#1& 2

Kori#1,2,3 & 4

#1,2,3,4,5 & 6

Construction Plan : 8 (9,200 MW)

#1,2,3 & 4


Kori SiteKori Site ViewView--PWRPWR

Nuclear Power Plants Site View


Wolsong SiteWolsong Site ViewView--PHWRPHWR

Nuclear Power Plants Site View


Electricity Production

� Total Electricity Production: 342.0 TWh (As of December, 2004)


NPPs in Operation : 20 Units (17,716 MW)

R eactorType

Capacity(MW)

Pro jec tManagemen t

NS S SS u pp lier

Plan tA/E

Commercia lOperat ion

#1 PWR 587 WH WH Gilbert Ap r. 1978

#2 PWR 650 WH WH Gilbert J u l . 1983

#3 PWR 950 KEPCO WH Bech tel/KOPEC S ep . 1985

#4 PWR 950 KEPCO WH Bech tel/KOPEC Apr. 1986

#1 PHWR 678.7 AECL AECL AECL Apr. 1983

#2 PHWR 700 KEPCO AECL/HANJ UNG AECL/KOPEC Ju n . 1997

#3 PHWR 700 KEPCO AECL/HANJ UNG AECL/KOPEC J u l . 1998

#4 PHWR 700 KEPCO AECL/HANJ UNG AECL/KOPEC Oct. 1999

#1 PWR 950 KEPCO WH Bech tel/KOPEC Au g . 1986

#2 PWR 950 KEPCO WH Bech tel/KOPEC Ju n . 1987

#3 PWR 1,000 KEPCO HANJ UNG/CE KOPEC/S &L Mar. 1995

#4 PWR 1,000 KEPCO HANJ UNG/CE KOPEC/S &L Ju n . 1996

#5 PWR 1,000 KEPCO HANJ UNG/CE KOPEC/S &L May. 2002

#6 PWR 1,000 KEPCO HANJ UNG/CE KOPEC/S &L Dec . 2002

#1 PWR 950 KEPCO Framatome Framatome S ep . 1988

#2 PWR 950 KEPCO Framatome Framatome S ep . 1989

#3 PWR 1,000 KEPCO HANJ UNG/CE KOPEC/S &L Au g . 1998

#4 PWR 1,000 KEPCO HANJ UNG/CE KOPEC/S &L Dec . 1999

#5 PWR 1,000 KEPCO Doo ju ng Doo ju ng J u l . 2004

#6 PWR 1,000 KEPCO Doo ju ng Doo ju ng J u l . 2005

Ulch in

Plan t

Kori

Wo lson g

Yon ggwang


NPPs in Planning : 8 Units (9,600 MW)

� To complete 4 KSNP+ units & 4 APR1400 units by 2015

Plant ReactorType

Shin-Kori#1#2#3#4

PWRPWRPWRPWR

Capacity(MW)

CommercialOperation

1,0001,0001,4001,400

Oct. 2010Oct. 2011Jun. 2012Jun. 2013

Shin-Wolsong

#1#2

PWRPWR

1,0001,000

Mar. 2011Mar. 2012

NewProject

#1#2

PWRPWR

1,4001,400

Jun. 2014Jun. 2015

Remarks

KSNP+

KSNP+

APR1400APR1400

KSNP+

KSNP+

APR1400APR1400

Pusan National University Quality Engineering & Failure Prevention LabPusan National University Quality Engineering & Failure Prevention Lab.11

•Piping, Bolt•Reactor Vessel•Dissimilar Piping Weld

UT PD

•QDA(Qualified Data Analyst)

•SSPD(Site Specific PD)

ECT PD

PWR : ASME Sec. XI, App. VIII 2) or (KEPIC MI)

PHWR :CSA/CAN-N285.43) 10CFR 50.55 a4)

MOST : 2004-13 PDI

1) ASME Section XI, App. VIII : PD for Ultrasonic Exam. Systems2) CSA/CAN 285.4 : Periodic Inspection of CANDU NPP Components3) 10CFR50.55a : Codes & Standards

Requirement of PDIat Nuclear Power Plants

� Performance Demonstration Initiative (PDI)


� MOST 2004-13

The Present Status of PDI in Korea

COMPONENTS Date

1. Pipe, Bolts 2004.7.1

2. Steam Generator Tube 2004.7.13. Reactor Vessel 2005.7.14. Reactor Vessel -Nozzle welds 2006.7.1

5. Reactor Vessel -Nozzle Inside Radius Region 2006.7.1

6. Pipe-Dissimilar Metal welds 2006.7.1

7. Austenitic Pipe -Overlay welds 2006.7.1

Pusan National University Quality Engineering & Failure Prevention LabPusan National University13

The Present Status of PDI in U.S.

COMPONENTS SUPPLEMENTS Date� Piping Welds- Wrought Austenitic 2 ’00.5.22- Ferrite 3 “- Dissimilar Metal 10 ’02.11.22- Overlay 11 ’01.11.22- Cooperated Implementation 12 ’02.11.22� Vessels- Clad to Base Metal Interface Region 4 ’00.11.22- Nozzle Inside Radius Region 5 ’02.11.22- Reactor Vessel Welds other than 6 ’00.11.22 Clad/Base Metal Interface

- Nozzle-to-Vessel Weld 7 ’02.11.22- Cooperated Implementation 13 ‘02.11.22� Bolts and Studs 8 ’00.05.22


Etc.,

43%Valve

12%

S/G

10%Turbine

9%

I&C

8%

Pump

4%

• ASME OM Code, ISTC• MOV / AOV / Check Valve• Safety Valve• Ultrasonic Test• Accelerometer Test• Magnet Test…

• S/G• Eddy Current• Ultrasonic Test…

• Turbine Blade• Ultrasonic Test• Phased Array…

- Recorder- Switch…

• Reactor Vessel / Bolts / Stud / Pipe…• Ultrasonic Test• Phase Array Inspection / TOFD• Eddy Current …

• Pump• Ultrasonic Test• Accelerometer Test• Vibration Test…

Application of NDT Techniques for Each Component


� Reactor Vessel- VT (Visual Test) : Reactor Vessel Internal Part- Upper Internal GTSP Inspection- Baffle Former Bolt Inspection

� Automatic Ultrasonic Test (AUT)- Pressure Vessel Weld Joint (UDRPS System (W)- Pipe Weld Joint (Tomoscan)- Reactor Vessel Inspection

� Manual Ultrasonic Test (MUT)- Pressure Vessel UT test- Thermal Stratification Pipe UT test- Swirl Vane UT test- Turbine Blade UT test

� Radiograph Test (RT)- Pipe Weld Joint, Pressure Vessel, Valve, Pump…

� Special Inspection- IGSCC Inspection - TBN-GEN NDT

� Eddy Current Test (ECT)- Steam Generator (S/G), Sleeve, In-core Thimble

� Visual Test (VT)- Borescope, Fiberscope, CCTV System : Support, Hanger, Weld Joint…

� Leak Test (LT)- Bubble Test, Pressure Change Measurement Test …

NDT in Nuclear Power Plants


Pump Inspection :UT / RT / Leak Test

Turbine Inspection : UT (Phased Array), PT

Generator / Motor RT, UT, ECT, PT

Steam Generator (S/G) Eddy Current Test

Stud / Bolt Inspection :UT / Phased Array

Valve Inspection :UT / RT / ECT / Leak Test

Application of NDTin Nuclear Power Plants


� In carbon steel pipes of nuclear power plants, local wall thinning may result from erosion-corrosion or FAC (Flow Accelerated Corrosion) damage.� A case accident of erosion-corrosion wall thinning

- In 1986, U.S.A, the rupture accident of pipe system in Surry nuclear power plant- In 2004, Japan, the rupture accident of secondary cooling pipe system in Mihama

Pipe failure (FAC)Flow Accelerated Corrosion Mechanism

FAC (Flow Accelerated Corrosion)


Condition monitoring of a secondary piping elbow (passive component)in a non-safety–related environment (FAC)

FAC Monitoring

Carbon Steel Piping Elbow- Temperature : 150°C (or 200 °C )- Pressure : 20 bar (or 30bar)- Flow velocity : ~10 m/s- Water Chemistry

- pH adjusted with NH3- Potential adjusted with H2 or O2 gas

Instrumentations for FAC Monitoring- Electrochemical Sensors: Ag / AgCl (water) electrodeGold-plated Ni electrode- Ultrasonic sensor : On-line monitoring of wall thickness


Key Factors Influencing FAC

TemperatureTemperature Dissolved OxygenDissolved Oxygen

ECPECP pHpHOxygen content, ppb

Potential (volt/SHE)


FAC Monitoring System

Stainless Steel tubing

Flow Meter

Magnetic Filter

Safety Container

P

P

Heater

Circulation Pump

Insulation

EREPRTD

AUEN Micro Pressure Sensor ArrayAccelerometer

Optical SensorUltrasonic Sensor

Specimen

Charging Pump

N 2/H 2

P

DI water

P

Vent

Stainless Steel tubing

Filter

Solution Sampling

Accumulator

PRelief Valve

Cooling Water

T/C

Pressure Gauge

Filter

Back PressureRegulator

1/4” ODSTS 316 tubing

Drain

Solution SamplingResin

Column

1 1/2” OD 316 SS tubing


Steam Generator Tube Rupture of Ulchin Unit 4

� The first steam generator tube rupture in Korea occurred at UCN 4 on April 5, 2002 just before the fourth overhaul for refueling. � Complex failure mode : longitudinal and circumferential failure� No leak-before-break (LBB)� No noticeable indications in previous� Rapid growth of SCC through the tube wall

Dimension of removed tube 112mm

80.03mm

TopBottom


Borescopic photo

Ruptured tube(after withdrawal)

Sketch of ruptured part

Shape & Size of Broken Tube


Ruptured TubeRow14, Column38

� Ruptured tube in Row 14, Column 38 of Hot Leg side

� Longitudinal split about 75mm long and about 7mm wide, 360 degree double ended break at the top of the split

� It is assumed that the longitudinal split started first and 360 degree crack followed according to the analysis of primary parameters.

Shape & Size of Broken Tube (cont.)


Crack

� Longitudinal CrackThe rupture was caused mainly

by SCC developed in the longitudinaldirection from the top of tube sheet to the location of circumferentialseverance on the inside diameter of the tube.

� Circumferential Crack


Lessons Learned from GTR of Ulchin Unit 4

� Upgrade in the ECT inspection technology- Improving the ECT inspection reliability- Increasing the quantity of the third party review on ECT data (defective signal-all data) - ECT on 100% of tubes with bobbin probe, 100% of hot leg tubes,20% of cold leg tubes with MRPC probe, and 100% of tubes withprofilometry

� Development of a more sensitive leak detection system capable of covering all the operating range


Major Research Activitiesfor ECT Reliability

� ECT Round Robin Program (2002.3-2008.2)- Development of guideline for optimal inspection- ECT signal evaluation for Bobbin and Plus Point probe

� Steam Generator Management Program(2002.3-2005.2)- Degradation Assessment (DA) - Condition Monitoring Assessment (CM)- Operation Assessment (OA)- SGMP Integrated Guidelines


Optimization of Thinned Pipe Management Program and Application Optimization of Thinned Pipe Management Program and Application

Thinned Pipe Management

Thinned Pipe Management Program

<Participation> PNU, KOPEC, Korea Univ., Chosun Univ., CNU

FAC Prediction &Trend Analysis

Criteria for the Ultrasonic Thickness

Measurement

Failure Criteria for Thinning Defect and

Comparison Test for Burst

Pressure of Pipe Bend

Development of Techniques for

Detecting, Correcting and Complementing N-597 Code

Alternative Local Wall-Thinning Assessment

Criteria based on Reference Stress-Strain Approach


1400

mm

Ø150 mm

Reactor vessel in NPP

crack

Stud bolt

Special transducer for inspection of stud bolts

axial bore hole for inspection Typical ultrasonic waveform for detecting

crack in stud bolts

Conventional UT technique for inspection of stud bolt

75 80 85 90-2.0

-1.5

-1.0

-0.5

0.0

0.5

1.0

1.5

2.0

Ampli

tude(v

)

Time(µsec)

2mm crack signal

Conventional shadow technique to detect crack in stud bolt

ASME Pressure Boiler and Vessel Code Section XI


Phased Array Ultrasonic Inspection-Stud Bolt Inspection

The ultrasonic phased array technique provides wide region of inspection


Sector Scanning Image(Crack depth : 1, 2, 3, 4, 5mm)

1mm

2mm

3mm 4mm

5mm

Maneuverable ultrasonic beam provides fast inspection due to wide scanning region.

1mm

2mm

Inspecting region : 80mm


Ultrasonic Phased Array Inspection for Turbine


Pipeline Inspection Using Guided Wave

Transmitter Receiver

- Long range inspection- Usually no surface preparation required- Couplant is not required (EMAT)- Mode identification

Comb Type Transducer

EMAT

Guided Wave Inspection


Feeder Pipe Crack Detection

Pipe Inspection

Feeder Pipe

Installation


Signal from bent pipe with no defect thickness

Signal from a notch of 5% of wall of bent a pipe

Phase velocity dispersion curve for feeder pipe

Group velocity dispersion curve for feeder pipe

Feeder Pipe Crack Detection


Amplitude image Harmonic ratio image

Scan parameters:System: fiberized scannerScan area: 4 mm x 60oImage size: 50 x 200 pointsDefect size: 0.75x0.05x0.38 mmReceiver: broadband PZT, 5 MHz

The bright areas on both images indicate the presence of the defect.

Application of Laser Based Ultrasonic Inspection


The Evolution of Nuclear Power Plants

Generation ⅠⅠⅠⅠ(1960)

Early Prototype Reactors

Generation ⅡⅡⅡⅡ(1980)

Commercial Power Reactors

Generation ⅢⅢⅢⅢ(2010)

Advanced LWRs

Generation ⅣⅣⅣⅣ(2030)

� Highlyeconomical� Enhancedsafety � Minimizedwastes� Proliferationresistant

- Shippingport- Dresden, Fermi ⅠⅠⅠⅠ- Magnox

- LWR-PWR,BWR- CANDU- WER/RBMK

- ABWR, System 80+- AP600, EPR- APR1400

PSI / ISINDT (off-line)

Condition Monitoring(On-line)


Issues of Condition Monitoring

Correlate Sensor Outputs to Degradation/Failure• Engineering understanding• Testing, demonstration, base-lining• Expert judgment• Automated processing

Condition Monitoring Output (MMI)- Trends- Required Action

RecordsAnalysesInterprets

Transmission/Recording of Signals- SMART Sensor- Wireless Comm.- Signal Processing- In-situ Processing- Multiplexing

Sensors/ Sensor Systems- Acoustic, AE, UT- Optical Fiber Interferometer- Electro Chemical- IR, UV, Laser- Magnetic- Multiple Sensors (AE, UT, Accel)- MEMS Sensor

Data Analysis Software- Multi-parameter- Algorithms (pattern recognition)- User Friendly- Artificial Intelligence- Trend Tracking- Supercomputing (parallel computing)

Condition-based Maintenance Predictive-based Maintenance


Project Identification Information(I-NERI)

� Project No. 2002-021-K(2002.6-2005.5)� Project Title: Condition Monitoring through Advanced Sensor and Computational

TechnologyLead U.S. Investigating Organization:

Sandia National Laboratories (SNL)Principal Investigator: Vincent K. Luk, Ph.D.

Lead Collaborating Korean Investigating Organization: Korea Atomic Energy Research Institute (KAERI)Principal Investigator: Jung-Taek Kim

Other Collaborating Organizations:Seoul National UniversityPusan National UniversityChungnam National UniversityPennsylvania State University


Project Goals and Objectives

� To develop and demonstrate advanced sensor and computational technology for continuous monitoring of the condition of components, structures, and systems in advanced and GEN IV nuclear power plants through

� Investigating several advanced sensor technologies from researchcommunities in Korea and U.S. � Evaluating signal characteristics of advanced sensors � Analyzing acquired sensor signals from condition monitoring tests � Investigating advanced sophisticated signal processing, noise reduction, and pattern recognition techniques and algorithms � Evaluating encryption and data authentication techniques for wireless transmission of sensor data� Conducting condition monitoring tests on check valve as active components and piping elbow as passive components


Joon-Hyun Lee

Project Organization


Scope of FAC Monitoring Program

Test condition and loop spec.

Development of Sensing Element

Sensor performance Monitoring test FAC rate

prediction

10.09.08.07.06.05.04.0

0.6

0.4

0.2

0.0

-0.2

-0.4

-0.6

-0.8

-1.0

-1.2

-1.4

Fe - H2O - System at 150.00 C

C:\Program Files\HSC4\Fe 150.iep pH

Eh (Volts)

Fe

Fe2O3

Fe3O4Fe(+2a)

FeO2(-a)

FeOH(+a)

HFeO2(-a)

ELEMENTS Molality PressureFe 1.000E-06 4.625E+00

10.09.08.07.06.05.04.0

0.6

0.4

0.2

0.0

-0.2

-0.4

-0.6

-0.8

-1.0

-1.2

-1.4

Fe - H2O - System at 150.00 C

C:\Program Files\HSC4\Fe 150.iep pH

Eh (Volts)

Fe

Fe2O3

Fe3O4Fe(+2a)

FeO2(-a)

FeOH(+a)

HFeO2(-a)

ELEMENTS Molality PressureFe 1.000E-06 4.625E+00

SignalPreprocessing

-0.35

-0.33

-0.31

-0.29

-0.27

-0.25

0

50

100

150

200

250

300

350

0 50 100 150 200 250 300 350

AUEN

vs. C

u/Cu 2

O/Zr

O 2 ( V

)

Temperature ( oC )

Time ( hours )

AUEN #1

AUEN #2

Temperature

Test Condition[H2]=2.653-2.868 ppm, [B]=1000 ppm, [Li]=2 ppm320 oC

Vibrating Tube

Roof of coolant chamber

Bundle of Optical Fibers

Housing Containing Dual Displacement Sensor

Face of Displacement Sensor Face of Displacement Sensor

V1V1V1V1 V2V2V2V2

50 50 50 50 µmsecmsecmsecmsec

LD

λ1

LD

λ2

HPF

HPF

circuit

Lock-in

amplifier

Chart

recorder

PBS

Fiber

coupler

Polarization-maint

aing fiber

Vibration

sample

Index

matchnig oil

splice

PBS

Lens

> 60Hz

Isolator

35 dB

Isolator

35 dB

Reference

22 BA +

<Two photodiode outputs><Two photodiode outputs><Two photodiode outputs><Two photodiode outputs>

SNU

CNU

KAERI

SNL

Environment

Vibration

FEM Analysis•Fiber Optic Displacement•Micro accelerometer•Capacitance Displacement•UT flowmeter

Data Analysis•Fiber Optic Interferometer

•UT Thickness

• Chemical Sensor(AUEN, EREP)


Development of Advanced Nondestructive Diagnosis Technology for NPP Piping System


Backgrounds

• Corrosion Fatigue : CF• Thermal Fatigue : TF• Stress corrosion cracking : SCC• Corrosion attack : COR• Erosion and cavitation : E-C• Flow accelerated corrosion : FAC• High cycle vibration fatigue : VF• Water hammer : WH• Design and construction errors : D&C• Other : OTH

• Published by Swedish Nuclear Power Inspectorate (SKI) / US commercial nuclear power plants• 1511 piping and piping components failures from 1961 to 1995

Nondestructive Techniques for early detection of damage and on line monitoring for safety and lifetime extension of NPP Piping System Nondestructive Techniques for early detection of damage and on lNondestructive Techniques for early detection of damage and on line ine monitoring for safety and lifetime extension of NPP Piping Systemonitoring for safety and lifetime extension of NPP Piping System m

Ohi-3, Japan (2005) Mihama, Japan (2004)

SCC

14%COR

6%

E-C

1%

E/C

23%VF

29%

WH

3%

CF

1%D&C

16%

OTH

4%TF

3%

FAC


� Safety is the most important concept for the next generation of NPP design� On line monitoring is the key concept due to long-term continuous reactor operation

� Limitation of conventional nondestructive testing for S.G tube of GEN IV� New sensor for harsh environment like high temp./high press.� Limitation of insertion into S.G. tube� New NDT for outside inspection Development of fundamental techniques for the inspection of nextDevelopment of fundamental techniques for the inspection of next

generation of NPP (SFR, SMART, IRIS etc.) S.G.tubegeneration of NPP (SFR, SMART, IRIS etc.) S.G.tube

Backgrounds


Concerning Facilities

• Leakage• Cracking• Boron-Acid• Wall Thinning

• Detection & Measuring • On-line Monitoring• New Concept


Concerning Facilities

Piping & Nozzle(Hot / Cold Leg)

Penetration & Nozzle(CRDM / BMI)

Steam Generator Tube

Test Bed / Verification

- On-line monitoring / Non contact / Long-range Inspection

Development of Advanced Nondestructive Diagnosis for NPP Piping System

NPPPiping System

Secondary System (FAC)

GEN IV(S.G tube)


1. Defect Detection in Dissimilar Metal Joints•• Highly Sensitive Ultrasonic Transducer Development Highly Sensitive Ultrasonic Transducer Development •• SonicSonic--IR Thermography IR Thermography •• Nonlinear Ultrasonics Nonlinear Ultrasonics •• Simulation of Ultrasonic Wave PropagationSimulation of Ultrasonic Wave Propagation

Objects

� Development of Advanced Nondestructive Diagnosis Technology based on On-line monitoring / Non contact / Long-range Inspection

•• New Concept of ECT New Concept of ECT •• EMATEMAT

2. Rapidly Detection of Circumferential Flaw in S.G tube

•• Optical Fiber AE Sensor Optical Fiber AE Sensor •• LIBS LIBS

3. On-line Monitoring Crack/Leakage in CRDM & BMI

•• Guided Wave Techniques Guided Wave Techniques •• Pulsed Eddy Current Pulsed Eddy Current

4. Detection of Thickness Reduction in Secondary System

•• Magnetic Detection Magnetic Detection •• EMAT / MsSEMAT / MsS

5. On-line Monitoring of S.G tube of Gen IV NPP

•• CRDM, CRDM, •• Test Bed for FACTest Bed for FAC

6. Design & Manufacturing of Test Bed for the Verification of the developed techniques


Organization

Development of Advanced Nondestructive Diagnosis Development of Advanced Nondestructive Diagnosis Technology for NPP Piping SystemTechnology for NPP Piping System

Nonlinear Ultrasonic TechnologyTechnology of closed micro-crack detection

Sub Contractor I

Evaluation of TransducerPerformance

Sub Contractor II

EMAT/MsSDetection of Circumferential Flaw

Technology ExchangeExperts Dispatch

ECTMagnetic Detection

On-line Monitoring of S.G tube of Gen IV NPP

On-line Monitoring Crack/Leakage in CRDM & BMI

Dissimilar Metal Joints

Rapidly Detection of Circumferential Flaw in S.G tube

Highly Sensitive Ultrasonic Transducer Development

Design & Manufacturing of Test Bed for the Verification of

the developed techniques

Detection of Thickness Reduction in Bended Tube (FAC)

Establish the cooperation system with related organization

(Domestic)

Build-up the Test BedOn-line Monitoring Crack/Leakage

in CRDM & BMIOn-line Monitoring Crack/Leakage

in CRDM & BMI

Hanyang Univ.Korea Univ. of Technology and Education

Seoul Nat’l Univ. of Technology

Rapidly Detection of Circumferential Flaw in S.G tube

Main Contrctor : KRISS

Establish the cooperation system with related organization

(International)

Pusan Nat’l Univ.Yeungnam Univ. Dong-Eui Univ.

Transducer Modeling(Ultrasonic/Eddy Current/MsS)


TransmitterReceiver

Nonlinear UTNonlinear UTModeling Based Modeling Based Ultrasonic NDTUltrasonic NDT

Ultrasound Ultrasound Infrared Infrared

ThermographyThermographyHighly Sensitive Highly Sensitive

Ultrasonic TransducerUltrasonic Transducer•• Production of Probe of 1, 2.25, 5 MHz Production of Probe of 1, 2.25, 5 MHz Production of Probe of 1, 2.25, 5 MHz Production of Probe of 1, 2.25, 5 MHz Production of Probe of 1, 2.25, 5 MHz Production of Probe of 1, 2.25, 5 MHz Production of Probe of 1, 2.25, 5 MHz Production of Probe of 1, 2.25, 5 MHz

with PMNwith PMNwith PMNwith PMNwith PMNwith PMNwith PMNwith PMN--------PTPTPTPTPTPTPTPT

Alloy 600

weld

Alloy 600

buttering

CladdingForged

SS

Stainless

steel weld

StainlessSteel

Low-alloy

Steel nozzle

UIT

Test Result

•• Detection & Imagination of Detection & Imagination of Detection & Imagination of Detection & Imagination of Detection & Imagination of Detection & Imagination of Detection & Imagination of Detection & Imagination of

Fatigue Crack Fatigue Crack Fatigue Crack Fatigue Crack Fatigue Crack Fatigue Crack Fatigue Crack Fatigue Crack

•• Harmonic Analysis for detection of closed Harmonic Analysis for detection of closed Harmonic Analysis for detection of closed Harmonic Analysis for detection of closed Harmonic Analysis for detection of closed Harmonic Analysis for detection of closed Harmonic Analysis for detection of closed Harmonic Analysis for detection of closed

micromicromicromicromicromicromicromicro--------crackcrackcrackcrackcrackcrackcrackcrack•• Development of Ultrasonic Multiple Development of Ultrasonic Multiple Development of Ultrasonic Multiple Development of Ultrasonic Multiple Development of Ultrasonic Multiple Development of Ultrasonic Multiple Development of Ultrasonic Multiple Development of Ultrasonic Multiple

Gaussian Beam ModelGaussian Beam ModelGaussian Beam ModelGaussian Beam ModelGaussian Beam ModelGaussian Beam ModelGaussian Beam ModelGaussian Beam Model

Defect Detection in Dissimilar Metal Welds


Rapidly Detection of Circumferential Flawin S.G tube

�� Eddy Current :Circumferential Eddy Current :Circumferential �� Sensitive to axial flawsSensitive to axial flaws�� Insensitive to circumferential flawsInsensitive to circumferential flaws

�� Eddy Current : Circular Eddy Current : Circular �� Sensitive to axial and circumferential Sensitive to axial and circumferential flawsflaws

�� Very low speed (1Very low speed (1””/sec)/sec)

�� Multi Channel TypeMulti Channel Type�� High SpeedHigh Speed�� Complex and expensiveComplex and expensive

�� Key Technology for ECT & EMATKey Technology for ECT & EMAT•• Eddy Current in tube must be axial directionEddy Current in tube must be axial direction•• Development of ECT Probe (low price, fast moving)Development of ECT Probe (low price, fast moving)•• EMAT for Circumferential Flaws EMAT for Circumferential Flaws

Bobbin ProbeBobbin Probe MRPCMRPC X X -- ProbeProbe


•• LIBS(Laser Induced Breakdown Spectroscopy)LIBS(Laser Induced Breakdown Spectroscopy)-- Detection of Boracic Acid extraction from leakage Detection of Boracic Acid extraction from leakage

CRDMCRDM

•• Fiber Optic Acoustic SensorFiber Optic Acoustic Sensor-- Crack Propagation / Leakage monitoring by elastic Crack Propagation / Leakage monitoring by elastic wave measurement wave measurement -- High sensitivity multiflexing fiber optic AE sensorHigh sensitivity multiflexing fiber optic AE sensor

Fiber

Optic

AE Sensor

Sensor

#1

Sensor

#2

Sensor

#3

Sensor

#n

CRDM & BMI PenetrationOn-line Monitoring Crack/Leakage


Detection of Thickness Reductionin Secondary System

Conventional Thickness Reduction Ultrasonic Evaluation • Transducer scanning after removing covering• Local testing• Time consuming, Comparatively expensive

• MsS Sensor • Phased Array Sensor System

Long range inspection by Guided wave and vibration

Pulsed Eddy Current•• Pulsed Eddy Current : Step Pulse into Coil • Shape of Pulse : Thickness, Material Property • Penetration depth is much deeper� Real Time Thickness monitoring of high temperature pipe � There is no need to remove covering


On-line Monitoring of S.G tube of Gen IV NPP

• Design and Manufacturing EMAT : only coil, no magnet (overcoming high temperature)• Guided wave based NDE : Long-range inspection• MsS : using Ferromagnetic Patch

Transducer

CrackWaveguide

Incident Reflected from Crack

ECT Sensor for detection of Magnetite• Anticipation of flaws from magnetite detection • On-line monitoring Concept• High Temperature ECT Sensor

Application to S.G tube in GEN IV (EMAT / MsS)

• New Sensor for harsh environment like high temp./high press• Limitation of Insertion into S.G tube• On-line monitoring is the key concept due to long- run continuous reactor operation

Ferromagnetic Patch

Actuating & Sensing Solenoid Bias

Solenoid


Design & Manufacturing of Test Bed for the Verification of the

developed techniques

Design & Manufacturing of Test Bed for the Verification of the developed techniques

Through Through CrackCrack& Leak& Leak

Hidden Hidden CrackCrack

• A Section with real size, same material • Simulation of diverse crack • CRDM• Bending Pipe of Secondary System (FAC)

CRDMCRDM


Anticipated Outputs

RV Head

CRDM

UIR inspection

system

J-groove

� Crack Detection System using Ultrasonic – IR Thermography

� Nonlinear Ultrasonic

� On-line monitoring of Crack & Leakage using multiple optical Fiber AE Sensor

� Boracic Acid Detection system using On-line monitoring / Long-range Inspection

probe

Laser module Control unit

Storage reelfor umbilical

code


New Eddy Current Transducer

�� EMAT Transducer for EMAT Transducer for circumferential flaw circumferential flaw

�� Rapidly Detection of Circumferential flaw Rapidly Detection of Circumferential flaw for New Concept ECT Probefor New Concept ECT Probe

Ferromagnetic Patch

Actuating & Sensing Solenoid Bias

Solenoid

�� MsS Sensor for the next MsS Sensor for the next generation of NPP S.G tube generation of NPP S.G tube

�� EMAT Transducer for the next EMAT Transducer for the next generation of NPP S.G tubegeneration of NPP S.G tube- Design and Manufacturing EMAT :only coil, no magnet(overcoming high temperature)

- New Concept (Magnetic field formation)Measurement technique

- Ultrasonic generation and receiving using Ferromagnetic Patch

- High-temp on-line monitoring sensor

Next Gen. Next Gen. RVRVS/GS/G

PWR RVPWR RVS/GS/G

-- Speed over 1 m/s- Circumferential / Axial Flaw detection

Anticipated Outputs


Strategies

Foreign Univ. & Foreign Univ. & Research InstituteResearch Institute

•• Iowa States Univ. (CNDE)Iowa States Univ. (CNDE)•• Northwestern Univ.Northwestern Univ.•• SwRISwRI

Subcontracted & Subcontracted & Cooperative OrganizationCooperative Organization

• Univ. : Hanyang, Pusan, Chonbuk, SNUT, KUT, Yeungnam, Dong-Eui, Kunsan

• KINS, KSNT etc.

International Societies International Societies & Conferences& Conferences

•• ASNT, QNDE, ASNT, QNDE, -- Participation and paper Participation and paper presentation presentation

•• Study of Recent Research Study of Recent Research Trend & International Trend & International Certification of Developed Certification of Developed Technologies Technologies

Cooperation with IndustriesCooperation with Industries• Interchange of Technology and information, verification of application with related company like KHNP, KEPRI, KPS etc.

• Technology Transfer for commercial use

WorldWorld--Class development of Advanced Class development of Advanced Nondestructive Diagnosis Technology Nondestructive Diagnosis Technology

for NPP Piping System for NPP Piping System

Development of Development of Advanced Nondestructive Diagnosis Advanced Nondestructive Diagnosis Technology for NPP Piping SystemTechnology for NPP Piping System

•• Defect Detection in Dissimilar Metal Joints.• Rapidly Detection of Circumferential flaw

in S.G tube • On-line monitoring of crack/leakage in CRDM & BMI • Detection of Thickness Reduction in Secondary

System • On-line monitoring of S.G tube of Gen IV NPP• Design & Manufacturing of Test Bed for the Verification of the developed techniques


Expectation

ExpectationExpectation

•• Secure the core and new Secure the core and new concept NDE technology for concept NDE technology for the diagnosis of NPP Piping the diagnosis of NPP Piping System System

•• Improvement of Reliability by Improvement of Reliability by developing microdeveloping micro--crack crack detection and ondetection and on--line line monitoring systemmonitoring system

•• Secure the competitive power Secure the competitive power by priorby prior--occupation of the occupation of the technologies technologies •• Secure the new market for Secure the new market for exports and replacement of exports and replacement of importsimports

•• Developed technologies make Developed technologies make ripple effect by being used for ripple effect by being used for thermal power plant, gas facilities, thermal power plant, gas facilities, heavy chemical facilities etc. heavy chemical facilities etc.

Core Core TechnologyTechnology

Reliability Reliability ImprovementImprovement

Competitive Competitive PowerPower

RippleRippleEffectEffect

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