20 Years of Performance Demonstration Activities in NDT in ... · PDF fileNDT in Canada 2016 & 6th International CANDU In-Service Inspection Workshop, ... ASME Code Europe: ... ASME

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

Carl LatiolaisSenior Program Manager NDE Reliability

6th International CANDU ISI Workshop/NDT in Canada 2016 Conference

November 2016

20 Years of Performance Demonstration Activities in

the United States“Where we have been and where we are going”

NDT in Canada 2016 & 6th International CANDU In-Service Inspection Workshop, Nov 15-17, 2016, Burlington, ON (Canada)

www.ndt.net/app.NDTCanada2016

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

What is Performance Demonstration?

Performance demonstration is the proof that NDE procedures, equipment, and personnelare capable of achieving a specified level of performance– Flaw detection reliability– Flaw sizing accuracy– Low number of “false calls”

‘Performance demonstration’ and ‘qualification’ are similar– Performance demonstration is the practical part of qualification


Worldwide Demand for Performance Demonstration The demand for rigorous performance

demonstration is increasing– New regulations and requirements– Long term operation– Expansion of the nuclear fleet– Increasing need for statistical measures of NDE

reliability Impact of the demand

– Utilities and NDE vendors are scheduling well in advance

– Mockup manufacturers are operating at full capacity

Expect this trend to continue


Generic Process for Developing New PD Programs

Determine the Need

Determine Failure Mechanisms

Develop Acceptance Criteria

Survey the Fleet

Design and Fabricate Specimens

Develop Procedures

Qualify Procedures

Qualify Personnel

Tasks performed by other EPRI Programs, or locally by members

and regulators

Tasks performed bythe EPRI NDE Program

A performance demonstration program may be required for various reasons:

• Plant failures• Risk• Safety concern• Life extension issue

Industry decision

The entire process may

require several years of

work

PD Performance demonstration


Generic Process for Developing New PD Programs

Examples of time tables for some of the major activities– Code (minimum of 1 year for code case approval)– Survey of configurations

Could be up to 2 years depending on outage schedules Depends on population and amount of data available from previous

examinations– Procedure development (could be up to 2 years)

Funding needed Depends on the complexity of the examination Samples needed for development

– Qualifications Procedure qualifications take 2-6 months Personnel qualifications take about one week per person, per procedure



Types of Performance Demonstration

Each country’s requirements are different, but always it is some combination of two primary approaches:

Practicaldemonstration(physical trials)

Technicaljustification

(theoretical argument)

USA:ASME Code

Europe:ENIQEPRI NDE Program is the

original provider of performance demonstration services for compliance with ASME Code requirements for most of the primary pressure boundary

EPRI NDE Program has helped utilities in many nations, with both ASME and non-ASME requirements:- Developing new performance demonstration programs,

processes and organizations

- Providing justifications for applying EPRI’s PD methods in the local regulatory environment

ASME American Society of Mechanical Engineers ENIQ European Network for Inspection QualificationPD Performance demonstration


Scope of the EPRI NDE Performance Demonstration Team Qualifications of ultrasonic procedures,

equipment and personnel – ASME Section XI, Appendix VIII– RPV upper head penetrations– International qualification support– Any future formal qualification – Mockup design and fabrication

coordination for entire EPRI NDE group

Strategic AlliancesCRIEPI

(Japan Qualification Body)

KHNP Research(Korea Qualification Body)

SQC(Sweden Qualification Body)

QST(Switzerland Qualification Body)

ASME American Society of Mechanical Engineers

ENIQ European Network for Inspection Qualification



Performance Demonstration Facility


PD Program Review, Acceptance and Operation EPRI has been the PD leader since the 1970s

– 1970s – Steam Generator Management Program NDE activities– 1980s – UT qualifications for BWR piping welds

Three-party agreement between NRC, BWR Owners Group and EPRI– 1990s – Administration of all qualifications in accordance with ASME Section XI,

Appendix VIII, under the Performance Demonstration Initiative (PDI) Pressure vessels, piping, bolting, nozzles

– 2000s – Assistance to utilities worldwide in complying with local qualification regulations

– 2010s – PWR RPV head penetration J-welds

Over 20,000 qualifications have been performedOver 1,000 qualification candidates (personnel)Over 100 procedures have been qualified

ASME American Society of Mechanical EngineersBWR Boiling Water Reactor NRC Nuclear Regulatory CommissionPD Performance demonstrationPDI Performance Demonstration InitiativePWR Pressurized water reactorRPV Reactor pressure vesselUT Ultrasonic examination


ASME Code Section XI, Appendix VIIIDefines Separate Demonstrations for:

Piping Supplements– 2, Wrought austenitic piping welds– 3, Wrought ferritic piping welds– 9, Cast austenitic piping– 10, Bimetallic piping welds– 11, Overlaid wrought austenitic piping

welds

• Reactor Vessel Supplements– 4, Clad/base metal interface of reactor vessel– 5, Nozzle examination from the outside

surface– 6, Reactor vessel welds other than clad/base

metal interface – 7, Nozzle examination from the inside surface

• Other– 8, Bolts and studs

And within each qualification there are:- Procedure, personnel, and equipment qualifications

- Flaw detection, flaw length sizing, and flaw depth sizing qualificationsASME American Society of Mechanical Engineers


Ultrasonic Examination Technique CategoriesEncoded Non-Encoded

Phasedarray

Conventional

Data is recorded for offline analysis and archiving Data is interpreted in real time and is not recorded

Creates a ‘fan’ of sound beams

Creates a sound beam at a single angle

Displays a cross-section of the material; more intuitive than conventional UT

Displays a single beam angle’s response; examiner builds a mental image

3D data reconstruction$$$$

$$$ $

$$UTtechnology

Scanningtechnology

3D data reconstruction


ASME Code Section XI, Appendix VIII

Qualified Non-encoded UT Procedures

Generic procedures were developed and qualified for most manual examinations – Developed and agreed upon by entire

industry– Cost effective– Qualifications are transferable from

one organization to another– Almost all of the qualified manual

examiners in the industry are qualified to these procedures

• PDI-UT-1: UT Ferritic Pipe Welds • PDI-UT-2: UT Austenitic Pipe Welds • PDI-UT-3: UT Through Wall Sizing in Pipe Welds • PDI-UT-4: UT Bolts and Studs from the Bore• PDI-UT-5: Straight Beam UT Bolts and Studs• PDI-UT-6: UT Reactor Pressure Vessel Welds • PDI-UT-7: Manual UT Through Wall and Length

Sizing in Reactor Pressure Vessel Welds• PDI-UT-8: UT Weld Overlaid Similar and Dissimilar

Metal Welds• PDI-UT-10: UT Dissimilar Metal Welds • PDI-UT-11: UT Detection and Sizing Of Reactor

Pressure Vessel Nozzle to Shell Welds and Nozzle Inner Radius

ASME American Society of Mechanical EngineersUT Ultrasonic examination


ASME Code Section XI, Appendix VIII

Qualified Encoded UT Procedures

Vessel, piping, vessel head penetrations Primarily vendor-owned Specialized and specific to equipment being used Expensive to qualify EPRI has developed and qualified some procedures that can be

used by any member– Automated phased array for piping weld examination– Encoded manual phased array piping weld examination– Encoded manual phased array dissimilar metal weld examination

ASME American Society of Mechanical EngineersUT Ultrasonic examination


RPV Head Penetrations

In USA UT of reactor vessel head penetration tubes must be performed with qualified procedures, personnel and equipment– Governed by NRC (10CFR50.55a), ASME Code (Code Case N-

729-1), and the MRP Protocol EPRI Mockup Library

– Control Rod Drive Mechanism (CRDM), Control Element Drive Mechanism (CEDM), and In-Core Instrumentation (ICI) Nozzles are represented

– Can qualify rotating probes or blade probes Six vendors are fully qualified with both open-housing and blade UT probes

– All USA configurations are qualified, with Technical Justifications for diameter tolerances

– Exception: to date, no vendors have qualified for CE design ICI

ASME American Society of Mechanical Engineers CE Combustion EngineeringICI In-core instrumentation MRP Materials Reliability ProgramNRC Nuclear Regulatory CommissionRPV Reactor pressure vesselUT Ultrasonic examination


New Development: Virtual Mockups

Physical mockups are very expensive

Virtual mockups will be less expensive– Add or delete flaws: “cut and

paste”– Change flaw size or location– Insert simulated data

This approach can generate an unlimited number of practice samples at a lower cost

In the example above, one data file is real, the other is virtual.

Which one is real?


Virtual NDE Ultrasonic Data Players A windows-based software that allows users

to simulate conditions of manual ultrasonic examinations by providing practice opportunities without requiring access to physical ultrasonic instruments or pipe specimens


EPRI PD Program Summary

Strong technical basis, developed over 20 years Proven and accepted in many nations The facility, inventory and staff expertise can be used to customize a demonstration

to meet the requirements of any specific plant or regulatory requirement All fabrication and demonstration activities are performed in accordance with written

instructions and procedures, which provides a clear QA audit path The program contributes significantly to the overall quality of ultrasonic

examinations in the nuclear industry– Through extensive engagement with industry and regulators– Through outage support with urgent examination issues– Through research projects aimed at improving performance demonstration

methods, advancing NDE technology, and improving NDE reliabilityPD Performance demonstration


Together…Shaping the Future of Electricity

Documents

20 Years of Performance Demonstration Activities in NDT in ... · PDF fileNDT in Canada 2016 & 6th International CANDU In-Service Inspection Workshop, ... ASME Code Europe: ... ASME