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© 2016 Electric Power Research Institute, Inc. All rights reserved.
Phil AshwinTechnical Executive – NDE
Dan NowakowskiFlorida Power & Light
TAC Vice Chairman
Nuclear Power Council Advisory MeetingMonday, August 29, 2016
EPRI NDE ProgramReliability Technical Advisory
Committee (TAC) Meeting
Date: September 14, 2016 - Final
2© 2016 Electric Power Research Institute, Inc. All rights reserved.
Welcome to New Orleans
Opening Comments and Introductions
3© 2016 Electric Power Research Institute, Inc. All rights reserved.
Safety First!
• Emergency Exit
• Typical in-room meeting hazards
• Trip hazards / Wires / Luggage
• Hot coffee!
• Medical ResourcesPharmacyCVS Pharmacy800 Canal StreetTel: (504) 528-7099
Urgent CareNew Orleans Urgent Care201 Decatur StTel: (504) 609-3833
HospitalTulane Medical Center1415 Tulane AveTel: (504) 988-5263
4© 2016 Electric Power Research Institute, Inc. All rights reserved.
Get Connected…
5© 2016 Electric Power Research Institute, Inc. All rights reserved.
Agenda and Meeting ObjectivesMonday August 29
NDE Reliability TAC NDE Technology TAC
Lunch
6© 2016 Electric Power Research Institute, Inc. All rights reserved.
Operational Experience (OE)
Objectives Share your own NDE-related operational
experiences (OE) that may be useful to other nuclear power plant operators– By speaking, here in this room– By publication in the Minutes (optional; please
use the form provided and submit it to Lynette Gulledge [email protected])
Learn from the other members’ experiences– Make note of items that you can apply at your
plants– Make note of who’s speaking, so you can follow
up later if you wish
Process Steve will lead the session Steve will call on each utility’s IC member
– The member may call upon company colleagues for additional information
Ask questions– Try to wait for a logical interruption point; at the
end of the member’s presentation, or at the end of one unit’s OE within a multiple-unit presentation
Try not to use too many US-centric terms– We have members present from many nations
mailto:[email protected]
7© 2016 Electric Power Research Institute, Inc. All rights reserved.
Meeting Agenda and ObjectivesTime Topic Objectives Lead
10:00 AM NDE RELIABILITY TAC WELCOME & INTRODUCTIONS NOWAKOWSKI
10:10 AM 2016 NDE WORKPLAN PROGRESS REPORT WE WILL DISCUSS CHANGES TO THE 2016 WORKPLAN PROJECTSINDICATED ON THE SECOND QUARTER PROJECT STATUS UPDATES
ASHWIN
11:00 AM 2017 NDE WORKPLAN PROJECTS ASSIGNED TO THE RELIABILITYTAC
WE WILL REVIEW THE NEW PROJECTS PLANNED TO START IN2017 WITH A FOCUS ON OPPORTUNITIES FOR ADVISORENGAGEMENT AND TECHNOLOGY TRANSFER
ALL
11:45 AM LUNCH
1:00 PM 2017 NDE WORKPLAN PROJECTS ASSIGNED TO THE RELIABILITYTAC, CONT’D WE WILL REVIEW THE NEW PROJECTS PLANNED TO START IN2017 WITH A FOCUS ON OPPORTUNITIES FOR ADVISORENGAGEMENT AND TECHNOLOGY TRANSFER
ALL2:45 PM BREAK
3:00 PM 2017 NDE WORKPLAN PROJECTS ASSIGNED TO THE RELIABILITYTAC, CONT’D
3:30 PM EMERGENT ISSUES AND NEW PROJECT IDEAS WE WILL DISCUSS SUGGESTIONS FOR NEW NDE RESEARCHPROJECTS
ALL
4:00 PM MEETING SUMMARY AND REPORT TO THE NDE CC COORDINATING COMMITTEE NOWAKOWSKI AND ASHWIN
4:30 PM ADJOURN
8© 2016 Electric Power Research Institute, Inc. All rights reserved.
Integration Committee Members Assigned to the Reliability TAC
Organization Role Organization RoleAl Brooks DTE Electric Company Chairman Jason Heffron Wolf Creek Nuclear Operating Corp. Member
Dan Nowakowski Florida Power & Light Co. V.Chairman Tomokazu Iwata The Japan Atomic Power Company Member
Patrick Graedel BKW Energie AG NUC Gary Lofthus Southern Nuclear Operating Co. At-large
Yasukazu Takada The Kansai Electric Power Co. Inc. NUC Akira Nishikawa Chubu Electric Power Co. Inc. Member
Tony Oliveri PSEG Nuclear LLC APC Liason Jorge Pereira Jr. Eletrobras Termonuclear S.A. Member
Wiley Ahlstrom Pinnacle West Capital Corporation Member Koji Saito Electric Power Development Co. Ltd. Member
Christopher Brown Idaho National Laboratory Member Joerg Schors Kernkraftwerk Leibstadt AG Member
Blane Cesnik Xcel Energy Services Inc. Member Lyle Spiess STP Nuclear Operating Company Member
Shane Charbonnet Nebraska Public Power District Member Timothy Terryah Talen Energy Corporation Member
Sheng-Hsiung Chen Taiwan Power Company Member Aaron Thomas Luminant Holding Company LLC Member
Carlos Favaro Nucleoelectrica Argentina S.A. Member Jesus Vazquez Tecnatom SA Member
Kresimir Gudek Nuklearna Elektrarna Krsko Member Graham Wilson Eskom Holdings SOC Limited Member
Alan Guy Axpo Power AG Member Xue Xincai China National Nuclear Power Company Ltd. Member
Kevin Hacker Dominion Generation At-large Kengo Yamazaki J-Power Member
Hiroshi Hamaguchi Shikoku Electric Power Co. Inc. Member Masaki Zasu Hokuriku Electric Power Co. Member
9© 2016 Electric Power Research Institute, Inc. All rights reserved.
Meeting Agenda and Objectives
Opening remarks
10© 2016 Electric Power Research Institute, Inc. All rights reserved.
Meeting Agenda and Objectives
Time Topic Objectives Lead
10:00 AM NDE RELIABILITY TAC WELCOME & INTRODUCTIONS NOWAKOWSKI
10:10 AM 2016 NDE WORKPLAN PROGRESS REPORTWE WILL DISCUSS CHANGES TO THE 2016 WORKPLANPROJECTS INDICATED ON THE SECOND QUARTER PROJECTSTATUS UPDATES
ASHWIN
11:00 AM 2017 NDE WORKPLAN PROJECTS ASSIGNED TO THE RELIABILITYTAC
WE WILL REVIEW THE NEW PROJECTS PLANNED TO START IN2017 WITH A FOCUS ON OPPORTUNITIES FOR ADVISORENGAGEMENT AND TECHNOLOGY TRANSFER
ALL
11:45 AM LUNCH
1:00 PM 2017 NDE WORKPLAN PROJECTS ASSIGNED TO THE RELIABILITYTAC, CONT’D WE WILL REVIEW THE NEW PROJECTS PLANNED TO START IN2017 WITH A FOCUS ON OPPORTUNITIES FOR ADVISORENGAGEMENT AND TECHNOLOGY TRANSFER
ALL2:45 PM BREAK
3:00 PM 2017 NDE WORKPLAN PROJECTS ASSIGNED TO THE RELIABILITYTAC, CONT’D
3:30 PM EMERGENT ISSUES AND NEW PROJECT IDEAS WE WILL DISCUSS SUGGESTIONS FOR NEW NDE RESEARCHPROJECTS
ALL
4:00 PM MEETING SUMMARY AND REPORT TO THE NDE CC COORDINATING COMMITTEE NOWAKOWSKI AND ASHWIN
4:30 PM ADJOURN
11© 2016 Electric Power Research Institute, Inc. All rights reserved.
2016 NDE Workplan Progress Report
We will discuss changes to the 2016 Workplan projects indicated on the second quarter project status updates and also provide updates on
recent and near term deliverables
Additionally we will discuss projects identified by members
12© 2016 Electric Power Research Institute, Inc. All rights reserved.
NDE Program Status Update Report 2016 Workplan includes 72 Active Projects
– 44 projects have deliverables 5 Assembled Packages 2 Software
– 1 eMedia– 1 CBT
30 Technical Reports– 1 Category 1 May be published in 2017
– 2 Category 2– 23 Reference– 4 Strategic Long Term
7 Technical Updates Of the 72 active projects, 11 have a “yellow status”
in the Q2 PSU
https://membercenter.epri.com/Programs/061154/pages/projectstatus.aspx
https://membercenter.epri.com/Programs/061154/pages/projectstatus.aspx
13© 2016 Electric Power Research Institute, Inc. All rights reserved.
Benchmarking Structural Models for Evaluating Inspection Data to Determine the Integrity of Concrete StructuresManager: Maria Guimaraes Biagini, 704-595-2708, [email protected]
SCOPE - Green Green – No change in scope (key activities or deliverables) since last update.
BUDGET - Green Green – Project funding and spending are in line with the project plan.
SCHEDULE - Yellow Yellow – Contract delayed impacting a 2016 delivery. Rescheduled for Q1 2017.
DescriptionKey ActivitiesStatus Issues / Resolution, Deliverables
mailto:[email protected]
14© 2016 Electric Power Research Institute, Inc. All rights reserved.
Description Several inspection techniques (including nondestructive and destructive core-drillings)
are performed to evaluate the safety margin of a degraded civil structure. Modeling is used to assimilate these data and to perform complex structural analyses to determine the structural integrity of the component. Several utilities have already used modeling tools to assess the integrity of concrete structures with different levels of success.
This project will inform utilities on the applications, experience, and lessons learned of using different models to determine structural behavior and integrity of structures for typical concrete degradation issues.
A technical report summarizing the applications, experience, and lessons learned of using available models to determine the integrity of concrete structures. Available in December 2016.
Benchmarking Structural Models for Evaluating Inspection Data to Determine the Integrity of Concrete StructuresManager: Maria Guimaraes Biagini, 704-595-2708, [email protected]
mailto:[email protected]
15© 2016 Electric Power Research Institute, Inc. All rights reserved.
Key Activity
Benchmarking Structural Models for Evaluating Inspection Data to Determine the Integrity of Concrete StructuresManager: Maria Guimaraes Biagini, 704-595-2708, [email protected]
Activity Name Short Description Date
Review of structural models used during containment de-tensioning
Information on structural models used at Crystal River is being researched.
April 2016
Site visit Site visit to Gentilly 2 in Canada May 2016
Review of structural models used for ASR affected structures
Information on structural models used at Gentilly 2 (Hydro Quebec) is being collected.
September 2016
mailto:[email protected]
16© 2016 Electric Power Research Institute, Inc. All rights reserved.
Status The summary of available models is underway.
The contract required for a portion of this project is being delayed and it can potentially impact our ability to finish on time. A decision will be taken by the end of June on whether we will move the deliverable to the end of 1Q 2017.
EPRI recently hired Hasan Charkas. Hasan is a subject matter expert in modeling of civil structures and is working in this project.
Benchmarking Structural Models for Evaluating Inspection Data to Determine the Integrity of Concrete StructuresManager: Maria Guimaraes Biagini, 704-595-2708, [email protected]
mailto:[email protected]
17© 2016 Electric Power Research Institute, Inc. All rights reserved.
Issues / Resolution The contract required for a portion of this project is being delayed and it can potentially impact our
ability to finish on time. A decision will be taken by the end of June on whether we will move the deliverable to the end of 1Q 2017.
Deliverables Report Number: 3002007777 Product Name: Structural Models to Determine the Integrity of Concrete Structures Publish Date: 30-Mar-2017
Benchmarking Structural Models for Evaluating Inspection Data to Determine the Integrity of Concrete StructuresManager: Maria Guimaraes Biagini, 704-595-2708, [email protected]
mailto:[email protected]
18© 2016 Electric Power Research Institute, Inc. All rights reserved.
BOP Heat Exchanger Tubing Inspection Techniques UpdateManager: Nathan Maruthamuthu, 704-595-2546, [email protected]
SCOPE - Yellow Yellow – Seeking support from members for additional EC Inspectiontechniques.
BUDGET - Green Green – Project funding and spending are in line with the project plan.
SCHEDULE - Green Green – Project’s key activities or deliverables are on or ahead of schedule.
DescriptionKey ActivitiesStatus Issues / Resolution, Deliverables
mailto:[email protected]
19© 2016 Electric Power Research Institute, Inc. All rights reserved.
Description This project provides an update to the existing reference guide (Rev. 3), that was
previously published in December 2009, EPRI Product ID #1019124. The updated Rev. 4 guide will continue to provide useful information that members can use to expand their knowledge about the eddy current test method and its application to tubing inspection.
Even more advantageous to members are the eddy current inspection techniques that they can use immediately to test their own heat exchanger tubing. Informed decisions can be made by using industry proven and optimized inspection techniques to prevent tube leaks that leads to unscheduled shutdowns and/or expensive repair and replacement costs.
An added feature that may be derived from using this report is to promote common data analysis practice and skill sets across the entire nuclear fleet to improve and maintain the knowledge and proficiency of BOP data analysts. A technical report, product ID #3002007796 will be published in Dec 18, 2016.
BOP Heat Exchanger Tubing Inspection Techniques UpdateManager: Nathan Maruthamuthu, 704-595-2546, [email protected]
mailto:[email protected]
20© 2016 Electric Power Research Institute, Inc. All rights reserved.
Key Activities
BOP Heat Exchanger Tubing Inspection Techniques UpdateManager: Nathan Maruthamuthu, 704-595-2546, [email protected]
Activity Name Short Description Date
Introduction to Heat Exchangers Training Class (hosted by EPRI’s Plant Technology Program)
PM provided 4 hours eddy current training to heat exchanger system engineers and owners during the Introduction to Heat Exchanger Training Class hosted by EPRI’s Plant Technology Program.
5/24/2016
Sent out request to all NDE IC members requesting for evaluated inspection and analysis technique sheet.
Utility members work directly with their eddy current inspection vendors to perform tubing inspections but the techniques are not shared with the industry. EPRI sent a request out to all NDE IC members seeking for input in order to capture improved inspection techniques, metallurgical results from destructive analysis and any operating experience (OE) that can be included in Rev. 4. Till date, 17 technique sheets have been received.
Ongoing
Array probe performance evaluation
PM will visit CoreStar during first week in August to witness and collect information about their newly designed array probe for tubesheet and tube interface inspection.
8/1/2016
Prepare final report Final report preparation in progress. Ongoing
mailto:[email protected]
21© 2016 Electric Power Research Institute, Inc. All rights reserved.
Status This project is tracking on schedule with several notable accomplishments achieved in in
Q1 and Q2 2016. EPRI provided two separate training classes to early career engineers on eddy current inspections and data analysis. These trainings were hosted by EPRI’s Plant Technology Program. EPRI also supported a member utility to define eddy current probes and standards to support their condenser equipped with titanium tubing that had cracks in the tube sheet region. An array designed bobbin probe was used for this task. PM continues to engage with members on an individual basis to seek for technique sheets and metallurgical reports to be included in the Rev. 4 guide. The final report preparation commenced in Q2 towards meeting the deliverable date of December 18, 2016.
BOP Heat Exchanger Tubing Inspection Techniques UpdateManager: Nathan Maruthamuthu, 704-595-2546, [email protected]
mailto:[email protected]
22© 2016 Electric Power Research Institute, Inc. All rights reserved.
Issues / Resolution Since the last report was published in 2009, advancements to sensor designs including
the array technology, improvements to inspection and analysis techniques, improved understanding of the damage morphologies through destructive analysis, performance of new replacement tubing materials, repairs and replacements have occurred, but are not known or shared to the entire industry. EPRI seeks support from members to provide EPRI with eddy current technique sheets,
metallurgical reports, or any other valuable information that can be captured into this resourceful guide and shared with all members.
Deliverables Report Number: 3002007796 Product Name: BOP Heat Exchanger Tubing Inspection Techniques Update, Rev 4 Publish Date: 18-Dec-2016
BOP Heat Exchanger Tubing Inspection Techniques UpdateManager: Nathan Maruthamuthu, 704-595-2546, [email protected]
mailto:[email protected]
23© 2016 Electric Power Research Institute, Inc. All rights reserved.
Expansion and Refinement of Virtual MockManager: James Esp, 704-595-2697, [email protected]
SCOPE - Green Green – No change in scope (key activities or deliverables) since last update.
BUDGET - Yellow Yellow – Pushing scope into 2017 as well as the associated budget.
SCHEDULE - Green Green – Project’s key activities or deliverables are on or ahead of schedule.
DescriptionKey ActivitiesStatus Issues / Resolution
mailto:[email protected]
24© 2016 Electric Power Research Institute, Inc. All rights reserved.
Description This project is a continuation of previous research performed in the area of virtual flaws that is necessary to
provide solutions to process gaps that exist that prevent the viable use of virtual mockups/data sets. Currently, the main objectives of this project are expected to be:
Work with other groups who have performed similar applications to ensure collaboration where synergies exist.
Refine and optimize the process of volumetric manipulation for multiple beams, multiple wave modes, multiple angles, etc. This includes the potential for 3D visualization of the virtual volume.
Adapt simulated results from simulation software as a basis for virtual flaws; determine how best to interrogate with existing experimental data for the highest quality virtual datasets and mockups.
Extend the capability of the volumetric manipulation in terms of the actions and procedures to be executed.
Determine an effective combination of simulated results and experimental results for a unified approach to generation of virtual data sets.
Identify a process that can be used to generate new data sets/mockups on an as-needed basis at a significant cost saving versus manufacturing new samples.
Expansion and Refinement of Virtual MockManager: James Esp, 704-595-2697, [email protected]
mailto:[email protected]
25© 2016 Electric Power Research Institute, Inc. All rights reserved.
Key Activities
Expansion and Refinement of Virtual MockManager: James Esp, 704-595-2697, [email protected]
Activity Name Short Description Date
Refined generation of new data files
Interface with software vendors and developers to enable file metadata to be copied to new generated data files. Assess to what extent a greater proportion of functionality within the software can be integrated.
Q1 2016 through Q4 2017
Integration of simulation software
Generate simulated data corresponding to the virtual mockup and devise a mechanism for importing these data into a data file. Test and refine a procedure to integrate the simulated results with experimental data to determine how they are best combined.
Q3 2016 through Q4 2018
Optimization of generation and feedback processes
Address remaining gaps in capabilities of the volumetric manipulation process and address the shortcomings of the current process. This may involve 3D visualization, refinement, and increased computation power of the existing method.
Q1 2016 through Q3 2018
Deliverables Tech Update Report, Technical Report, Assembled Package Q4 2017, Q4 2018, Q4 2018
mailto:[email protected]
26© 2016 Electric Power Research Institute, Inc. All rights reserved.
Status Project has been planned internally and project kickoff meeting has been held with all
staff performing support work in 2016. Work has commenced on the “Refined Generation of New Data Files” task. Statement of Work agreement with the software developer completed. Project staff is working on finalizing contractual details with software developer. Contract
to be in place with developer in July. Tech transfer opportunities are being explored – currently we are looking for member
input on suggested virtual data sets. If you have a suggestion for a particular configuration you would like to have used during the course of this project, please contact the project manager. Mr. Lofthus from Southern Company has agreed to chair a working group to provide
input to the project team as the project progresses. Project manager has been and will continue to be reaching out to members and vendors
to participate in this working group with a expected webcast in July to kick things off.
Expansion and Refinement of Virtual MockManager: James Esp, 704-595-2697, [email protected]
mailto:[email protected]
27© 2016 Electric Power Research Institute, Inc. All rights reserved.
Issues / Resolution It has taken longer than expected to define and agree to the scope of work on the
software developers kit with the outside vendor. Due to this delay and the delivery date of the new software developers kit from the outside vendor some of the planned 2016 workscope will need to be pushed to 2017 to accommodate the change. This change will reduce the 2016 budget and increase the 2017 budget but will not have an effect on the deliverables of the project or their due dates.
Expansion and Refinement of Virtual MockManager: James Esp, 704-595-2697, [email protected]
mailto:[email protected]
28© 2016 Electric Power Research Institute, Inc. All rights reserved.
NDE Site Level III and ISI Coordinator Succession Plan TemplateManager: John Langevin, 704-595-2693, [email protected]
SCOPE - Green Green – No change in scope (key activities or deliverables) since last update.
BUDGET - Green Green – Project funding and spending are in line with the project plan.
SCHEDULE - Yellow Yellow – Schedule impacted by an unplanned retirement, new PM needs additional time.
DescriptionKey ActivitiesStatus Issues / Resolution
mailto:[email protected]
29© 2016 Electric Power Research Institute, Inc. All rights reserved.
Description This project provides a detailed guideline and template to aid utility managers in
preparing candidates to replace or augment incumbent NDE/ISI personnel. The relational database will highlight attributes recommended for each position and provide links to potential resources for those missing attributes. The product can then be used directly by utility management to develop and implement a NDE/ISI personnel succession plan.
The project deliverable will consist of a technical report, including interactive templates.
NDE Site Level III and ISI Coordinator Succession Plan TemplateManager: John Langevin, 704-595-2693, [email protected]
mailto:[email protected]
30© 2016 Electric Power Research Institute, Inc. All rights reserved.
Key Activities
NDE Site Level III and ISI Coordinator Succession Plan TemplateManager: John Langevin, 704-595-2693, [email protected]
Activity Name Short Description Date
Solicit Input Obtain input from industry Level IIIs/ISI program coordinators May 2016
Create list of attributes Attributes associated with an NDE Level III and a ISI program coordinator July 2016
Develop database Build database framework November 2016
mailto:[email protected]
31© 2016 Electric Power Research Institute, Inc. All rights reserved.
Status Tasks currently in progress:
– Solicit utility industry input on attributes Initiate contact with utility/vendor ISI/NDE managers for their specific input
– NDE Level IIIs– ISI Coordinator
– Categorize attributes Major categories Experience, Training, Certifications and Education
– Establish subcategories– Develop technical content for the database
Establish primary key and relational tables– Upcoming tasks:– Create relational database
Database template developed in Excel– Develop resource list
Generate a list of resources for each attribute Resources will include EPRI, ASME, INPO, etc.
– Assemble/compile industry input Update attribute lists
NDE Site Level III and ISI Coordinator Succession Plan TemplateManager: John Langevin, 704-595-2693, [email protected]
mailto:[email protected]
32© 2016 Electric Power Research Institute, Inc. All rights reserved.
Issues / Resolution Project delayed
– Project manager retired– Software programmer availability
Project completion date move to 1/2017– Provided an update to the Reliability TAC at April/June meetings Approved by Reliability TAC Will leave status as yellow to reflect change in deliverable date
NDE Site Level III and ISI Coordinator Succession Plan TemplateManager: John Langevin, 704-595-2693, [email protected]
mailto:[email protected]
33© 2016 Electric Power Research Institute, Inc. All rights reserved.
Demonstrate Detection of Planar Flaws Located Under Laminar Flaws in Weld Overlay RepairsManager: Bret Flesner, 704-595-2601, [email protected]
SCOPE - Green Green – No change in scope (key activities or deliverables) since last update.
BUDGET - Yellow Yellow – project finished over budget beyond project management criteria.
SCHEDULE - Green Green – Project’s key activities or deliverables are on or ahead of schedule.
DescriptionKey ActivitiesStatus Issues / Resolution, Deliverables
mailto:[email protected]
34© 2016 Electric Power Research Institute, Inc. All rights reserved.
Demonstrate Detection of Planar Flaws Located Under Laminar Flaws in Weld Overlay RepairsManager: Bret Flesner, 704-595-2601, [email protected] This project was performed to assess the ability to identify planar flaws that may be
located in the hidden regions under acceptable laminar flaws in new weld overlays. The objective was to minimize the number of unnecessary repairs performed on new weld overlays as a result of postulated planar flaws that must be assumed to exist in the hidden regions under acceptable laminar flaws.
The results of the project were complied in a report. The report documents the results of this research as well as enable inspection vendors to include guidance in examination procedures so that examiners can more effectively interrogate hidden regions under laminar flaws. Two weld overlay mockups were fabricated that can be used for practice or further inspection vendor technique development.
mailto:[email protected]
35© 2016 Electric Power Research Institute, Inc. All rights reserved.
Demonstrate Detection of Planar Flaws Located Under Laminar Flaws in Weld Overlay RepairsManager: Bret Flesner, 704-595-2601, [email protected]
Key Activities
Activity Name Short Description Date
Mockup fabrication Fabrication of NDE mockups Completed December 2014
NDE research Perform NDE research Completed December 2015
Report Complete report Completed June 2016
mailto:[email protected]
36© 2016 Electric Power Research Institute, Inc. All rights reserved.
Demonstrate Detection of Planar Flaws Located Under Laminar Flaws in Weld Overlay RepairsManager: Bret Flesner, 704-595-2601, [email protected] Status The report has been completed and is now available for member download; the project is now
complete. The research concluded that currently qualified examination techniques are capable of effectively interrogating the hidden regions under the majority of acceptable laminar flaws in small diameter weld overlays. The conclusion section of the report summarizes a UT modeling and simulation process that can be used to first validate that the currently qualified techniques are capable of interrogating a hidden region under each specific laminar flaw, then provides recommendations for completing the examination.
The research also concluded that using larger aperture search units than those currently qualified greatly increases the ability to effectively interrogate the hidden regions under acceptable laminar flaws. The improvement that was realized during practical experiments using an optimized search unit made it possible to effectively interrogate hidden regions located in the larger diameter weld overlay configuration. The published report contains information relating to search unit design that would benefit inspection vendors who plan to conduct a new weld overlay qualifications. Incorporating the information gained during the conduct of this research into new weld overlay examination procedures would significantly reduce the uninspectable volume, thereby greatly reducing the risk that emergent repairs be required to newly installed weld overlays.
mailto:[email protected]
37© 2016 Electric Power Research Institute, Inc. All rights reserved.
Demonstrate Detection of Planar Flaws Located Under Laminar Flaws in Weld Overlay RepairsManager: Bret Flesner, 704-595-2601, [email protected] / Resolution The limited scope of work that was planned for 2016 is ~20% over budget; however, the overall
project cost has finished within the desired range. Student employees (interns) who completed the final modeling and simulation tasks needed to complete the project were transitioned to permanent EPRI employees late last year. The original 2016 work plan didn’t account for the transition.
Deliverables Report Number: 3002007823
Product Name: Nondestructive Evaluation: Detection Capability Assessment of Planar Flaws Located Under Laminar Flaws in Structural Weld Overlay Repairs
Publish Date: Published
mailto:[email protected]://membercenter.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000003002007823
38© 2016 Electric Power Research Institute, Inc. All rights reserved.
Training for the Ultrasonic Examination of Cast Austenitic Stainless Steel WeldsManager: John Langevin, 704-595-2693, [email protected]
SCOPE - Green Green – No change in scope (key activities or deliverables) since last update.
BUDGET - Green Green – Project funding and spending are in line with the project plan.
SCHEDULE - Yellow Yellow – project is dependent on CASS Round Robin project which is delayed.
DescriptionKey ActivitiesStatus Issues / Resolution
mailto:[email protected]
39© 2016 Electric Power Research Institute, Inc. All rights reserved.
Description This project will provide quality NDE/ISI training course materials that address the current and
emerging technologies associated with the ultrasonic examination (UT) of cast austenitic stainless steels (CASS).
Cast stainless steels are very difficult to examine ultrasonically due to highly attenuative materials and complex configurations. Currently, there is little in the way of training materials for the UT of cast stainless steels. This project will capture important information, theory, and concepts from research conducted by EPRI on cast stainless steels (see TR 1026772, Recent Developments in the Inspection of Cast Austenitic Steel Components).
These training materials can be used by utilities to meet the requirements of Code Case N-824.
The project deliverables will consist of:
Training course materials that will be available 2nd Quarter 2016, modular format
Fabrication of several flawed CASS samples
Computer-based training delivered in fall 2017
Training for the Ultrasonic Examination of Cast Austenitic Stainless Steel WeldsManager: John Langevin, 704-595-2693, [email protected]
mailto:[email protected]
40© 2016 Electric Power Research Institute, Inc. All rights reserved.
Key Activities
Training for the Ultrasonic Examination of Cast Austenitic Stainless Steel WeldsManager: John Langevin, 704-595-2693, [email protected]
Activity Name Short Description Date
Material development Develop modules using existing EPRI research and reports September 2016
Design new samples Fill gaps in existing CASS sample inventory Completed
Fabrication of new samples Fabricate new CASS samples with flaws Completed
Develop CBT Convert training materials to CBT October 2017
mailto:[email protected]
41© 2016 Electric Power Research Institute, Inc. All rights reserved.
Status Discovery and Development
– Ongoing process of gathering EPRI reports and other documents associated with the manual conventional ultrasonic examination of CASS welds Material development
– Module development Writing information sheets on CASS materials
• Associated material properties and characteristics• Impact on ultrasonic examinations
Researching industry issues on the examination/inspection of CASS materials Sample design and fabrication
Determined existing gaps– Three new samples (360 segments) were designed to fill existing gap
Design drawings complete Sample fabrication completed
– Samples have completed receipt inspection at EPRI These 3 new samples will generate 8 new CASS samples
– Supplement to the existing CASS samples Total of 22 samples
• 12" OD, 28" OD and 36" OD• Thickness range from 1.3" to 2.8"
– Samples are scheduled to be fingerprinted by the end of July 2016
Training for the Ultrasonic Examination of Cast Austenitic Stainless Steel WeldsManager: John Langevin, 704-595-2693, [email protected]
mailto:[email protected]
42© 2016 Electric Power Research Institute, Inc. All rights reserved.
Issues / Resolution CASS Round Robin
– Postponed some module development until the CASS round robins are complete CASS round robin demonstrations are scheduled for the spring/winter of 2016 Important to capture lessons learned from these round robin demonstrations
– Incorporate into the CASS training materials Will delay material development by six months
– Reliability TAC concurred and approved– Revised project scope to include provisions to capture data from the round robin
demos These delays have been communicated to the Reliability TAC and the new
projected schedule has been approved Leaving status as yellow for documentation purposes.
Training for the Ultrasonic Examination of Cast Austenitic Stainless Steel WeldsManager: John Langevin, 704-595-2693, [email protected]
mailto:[email protected]
43© 2016 Electric Power Research Institute, Inc. All rights reserved.
Work in progress projects identified by members
OE Collation Configured for Pre-Job Briefings
Mike Orihuela
Industry Encoded Procedures for Similar and Dissimilar Metal Piping Welds
Mark Dennis
Expansion of Qualified Manual Phased Array UT Piping Procedures
Mark Dennis
Angle and Distance Encoder Feasibility Study for IVVI
Matt McCallum
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Mike Orihuela
August 29, 2016
OE Collation Configured for Pre-Job Briefings
45© 2016 Electric Power Research Institute, Inc. All rights reserved.
OE Collation Configured for Pre-Job BriefingsWhat is it?
– Web based tool that contains NDE Operating Experience (OE) from actual examinations NDE Specific Searchable Easy to access Easy to use Accessible by our International members
What will it do?– This website is a human performance tool to assist Inservice Inspection management
personnel with: Review relative operation experience Pre-job briefs Prepare NDE practitioners for field examinations Root Cause evaluations
46© 2016 Electric Power Research Institute, Inc. All rights reserved.
Status The OE website has
been developed and is being loaded
The beta testing phase will begin in Q3 or Q4 of 2016
Advanced search features being added
47© 2016 Electric Power Research Institute, Inc. All rights reserved.
Example Report
48© 2016 Electric Power Research Institute, Inc. All rights reserved.
Future
Once completed, it could replace the Inspection Issue Support report that is published every two yearsProvide a central location where utilities can report OE in a
standard format prior to meetings
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Mark Dennis
August 29, 2016
Industry Encoded Procedures for Similar and
Dissimilar Metal Piping Welds
50© 2016 Electric Power Research Institute, Inc. All rights reserved.
Outline
Project OverviewProject Benefits and ValueProject Status
51© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Overview Fully automated systems frequently provide
the most reliable data for ultrasonic inspections and are often used to better characterize defects and resolve indications.
Coupling automation with ultrasonic phased array technology can improve the overall technique and yield valuable volumetric information with less physical scanning.
The objective of this project is to expand existing EPRI encoded ultrasonic phased array procedures for similar and dissimilar metal piping welds to include equipment from other manufacturers.
The goal of this project will be to increase the number of available qualified phased array instruments that can be used with a given procedure.
52© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Benefits and Value This project is needed because encoded examinations are generally
preferred for complex examinations such as dissimilar metal weld piping. Having only a handful of qualified instruments from one equipment manufacturer to support the nuclear industry does not provide the fleet with many options. A method of easily adding new instruments to existing encoded ultrasonic phased array procedures for piping applications is needed so that the industry can continue to use these procedures even as new equipment is offered.
The value of completing this project is that a more standardized procedure will make implementing ultrasonic phased array technology easier since more instruments will be available for use. The objective of industry standard procedures is ultimately to help reduce the number of different techniques that utility personnel will need to review and to provide a larger pool of qualified individuals to perform the inspections.
53© 2016 Electric Power Research Institute, Inc. All rights reserved.
Status
The first phase of this project is intended to focus on the more challenging dissimilar metal piping weld inspections. EPRI has secured resources familiar with the commonly used encoded ultrasonic phased array procedures and how they are implemented in the field. EPRI is in the process of modifying the existing encoded dissimilar metal weld procedure for use with other instruments. This involves building delay laws, setups, layouts, and collecting corresponding data for comparison with existing results with other instruments. While the process changes with the instrument and software that is used, data collected on a limited number of flaws suggest that equivalency can be achieved. With input from inspection services vendors, EPRI has reconfigured the documents to
be more efficient, compact, and user friendly. Adding instruments will also be much easier with this new format.– Reduced the number of pages. Only select the pages needed for your specific configuration.– Easier to determine equipment applicability.
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Mark Dennis
August 29, 2016
Expansion of Qualified Manual Phased Array UT
Piping Procedures
55© 2016 Electric Power Research Institute, Inc. All rights reserved.
Outline
Project OverviewProject Benefits and ValueProject Status
56© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Overview This project supports the “Nondestructive
Evaluation, Guideline for Conducting Ultrasonic Examinations of Dissimilar Metal Welds”. Appendix A of this report includes a decision process (categorized as NEI 03-08 "Needed") for selecting encoded or non-encoded ultrasonic technology for examination of dissimilar metal welds. For those situations where an encoded examination cannot be conducted due to a lack of equipment or physical obstructions, the NEI 03-08 "Needed" guidance is to utilize manual ultrasonic phased array technology which provides the inspector with a real-time image. Because of this recommendation it is anticipated that the EPRI qualified manual phased array procedures will be utilized even more.
57© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Benefits and Value
The current project has qualified a set of standard manual techniques using the common features of today’s portable ultrasonic phased array instruments for similar/dissimilar metal pipe welds and weld overlays. Many of you have successfully utilized these procedures at your plant and they have allowed you to collect data images in situations where you could not with conventional manual UT or automated UT.
58© 2016 Electric Power Research Institute, Inc. All rights reserved.
Status
EPRI has procured Olympus ultrasonic phased array transducers and wedges for austenitic piping applications. The goal is to use these transducers along with the automatic detection feature of the Olympus OmniScan MX2 to enable users to build setups more easily. The more portable OmniScan SX will also be considered. This activity is in line with an EPRI member’s request to have the Olympus instruments included in the EPRI manual phased array procedures. EPRI is in the process of evaluating the M2M Gekko ultrasonic phased array
instrument for manual inspection of weld overlays and dissimilar metal welds. In addition to having the ability to generate standard sector scans, this instrument can also produce real-time total focusing method (TFM) images for improved resolution of defects. EPRI has also started working with equipment manufacturers on adding
simple encoders to ultrasonic phased array transducers for easy data collection.
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Matt McCallumProject Engineer
NPC TAC MeetingsOctober 2016
Angle & Distance Encoding Technologies
60© 2016 Electric Power Research Institute, Inc. All rights reserved.
Angle & Distance Encoding Technologies Background
– EVT-1 and VT-1 inspections require the inspection camera be within a specific range of distance from the surface and angle off of perpendicular to the component
– To date, these distance and angle measurements have not been recorded or encoded during inspections
– This project aims to provide insight as to the feasibility of recording such measurements as well as the expected level of accuracy of such measurements should a feasible solution be available
– RFP processed by Nine Sigma in order to maximize number of proposals from wide array of solution providers
61© 2016 Electric Power Research Institute, Inc. All rights reserved.
Angle & Distance Encoding Technologies Status
– Preliminary testing in air is underway with underwater testing scheduled to conclude in early/mid September Scanner is calibrated for in-air or underwater use
– Angle and distance measurements taken to date have shown to be accurate within the bounds specified in the request for proposal
– Scanner was requested to be a standalone unit without recording/encoding capabilities specifically for this feasibility study to maintain simplicity
– Results to be published in Improvement to Remote VT report due at end of 2016
62© 2016 Electric Power Research Institute, Inc. All rights reserved.
Angle & Distance Encoding Technologies
Projected laser beams are offset from center of inspection camera’s
field of view
Angle & distance scanner with bracket attached for Diakont
inspection camera
Testing angle and distance measurement accuracy and precision in air
63© 2016 Electric Power Research Institute, Inc. All rights reserved.
Angle & Distance Encoding Technologies
Control Panel Display
Blue dots indicate data being calculated for angle and distance measurement
Scanner
64© 2016 Electric Power Research Institute, Inc. All rights reserved.
Angle & Distance Encoding Technologies Current Limitations
– Angle and distance measurements are only accurate on flat surfaces - this renders this particular device most useful for shroud exams
– Decreased accuracy higher angles (>25°) due to the laser beams being projected further and further away from the center of the inspection camera’s field of view
Potential Improvements– Incorporate scanner capabilities into an inspection camera housing or add lighting and
a higher resolution camera to the scanner for an all-in-one unit– Focus measurements to center of inspection camera field of view (not projected and
calculated based on assumption of flat surface) Benefits of the study
– Shows potential for further development in angle and distance measuring technologies – perhaps other approaches or continued development will allow for an ideal method of measuring and encoding distance and angle
– Proves that angle and distance can be measured remotely from an inspection camera– Proves that full compliance with visual inspection procedures is possible
65© 2016 Electric Power Research Institute, Inc. All rights reserved.
Year-to-Date and Near Term DeliverablesProduct ID Name
Implementation Category
Implementation Type
Completion Date
3002007804 Feasibility Study for Control Rod and Control Blade Inspection Techniques REFERENCE EARLY R&D 8/31/2016
3002007806Concrete NDE for Damage due to Pattern Cracking - ASR and FT Damage REFERENCE PLANNING
GUIDES8/31/2016
3002007814Remote Visual Testing Image Analysis REFERENCE TECHNICAL
BASIS7/28/2016
3002006655 PRE-SW: Weld Overlay Repair (WOR) version 1.0 - Beta 7/1/2016
3002007816Nondestructive Evaluation: Investigation of Acoustic Emission Technologies for Monitoring Inaccessible Regions of Dry Fuel Storage S ystems
STRATEGIC LONG 6/28/2016
3002008734Virtual Nondestructive Evaluation Ultrasonic Data Player Software Manual v1.0 (Japanese Translation)
6/10/2016
3002008323Nondestructive Evaluation: Procedure for Manual Phased Array UT of Weld Overlays: Technical Basis Document
REFERENCE TECHNICAL BASIS
6/9/2016
3002008330Nondestructive Evaluation: Procedure for Manual Phased Array Ultrasonic Testing of Weld Overlays - Procedure: EPRI-WOL-PA-1
REFERENCE TECHNICAL BASIS
6/9/2016
3002007819Program on Technology Innovation: Retrofitted Sensors for Nuclear Containment Structures REFERENCE EARLY R&D 5/27/2016
3002007823Nondestructive Evaluation: Detection Capability Assessment of Planar Flaws Located Under Laminar Flaws in Structural Weld Overlay Repairs
REFERENCE TECHNICAL BASIS
5/27/2016
3002008768Nondestructive Evaluation: Phased Array Technologies: Essential Variables Defined REFERENCE TECHNICAL
BASIS5/27/2016
3002007821Nondestructive Evaluation: EPRI NDE Program Product Catalog - 2015 Update REFERENCE PLANNING
GUIDES5/26/2016
3002007329Nondestructive Evaluation: Industry Best Practices for Performing Reliable NDE -Implementation Guide
REFERENCE PLANNING GUIDES
4/29/2016
3002007626Nondestructive Evaluation: Reactor Pressure Vessel Threads in Flange Examination Requirements
CATEGORY 2 PLANT OPTIMIZATION
3/30/2016
3002007205 Exploratory Study on Vision-Based Algorithms to Size Cracks in Different Materials REFERENCE EARLY R&D 3/29/20163002007437 PRE-SW: Automated Crack Detection Version 2015 - Beta 1/15/2016
New since Savannah Meeting
66© 2016 Electric Power Research Institute, Inc. All rights reserved.
Investigation of Acoustic Emission Technologies for Monitoring Inaccessible Regions of Dry Fuel Storage Systems - 3002007816 Primary Audience: Nuclear Power Utility Used Fuel Management Staff Secondary Audience: Nondestructive Testing and Plant Maintenance Personnel Key Research Question
– This report documents research to evaluate the feasibility of using acoustic emission testing (AE) to assess the structural integrity of dry cask storage system canisters. AE sensors are highly sensitive to the stress wave response of crack propagation events; therefore, AE sensors are not required to be deployed in close proximity to localized degradation as with typical nondestructive methods, such as ultrasonic testing or eddy current testing. This makes AE an attractive approach to assess the structural integrity of dry cask storage systems without the need for advanced sensor delivery devices.
Research Overview– The research documented in this report was performed through a series of three field trials. These trials
were performed at geographic locations with access to mockups of dry storage canisters or canisters that had not yet been loaded with spent fuel. Testing consisted of attaching sensors to various locations of the dry storage canister system and introducing artificial AE sources to areas of interest. This first test was used to determine which sensors had the highest sensitivity. Subsequent testing was used to evaluate the attenuation of the signal response as the artificial source was moved farther away from the sensor. Signal response and amplitude were recorded to characterize the capability of the dry storage system to transmit AE signals.
67© 2016 Electric Power Research Institute, Inc. All rights reserved.
Investigation of Acoustic Emission Technologies for Monitoring Inaccessible Regions of Dry Fuel Storage Systems - 3002007816 Key Findings
– Three first-of-a-kind field trials have been successfully completed to show the feasibility of deploying AE as means to monitor the structural integrity of dry cask storage systems.
– Various AE sensors have been evaluated to determine which resonant frequencies provide the highest amplitude response, using various artificial sources to simulate cracking events.
– Multiple AE data acquisition systems have been studied to evaluate wired and wireless hardware applications.
– This feasibility study determined that AE is capable of monitoring structural integrity and that further research is warranted to enhance the monitoring technique for specific applications and different dry storage canister configurations.
Why This Matters– This research evaluates structural health monitoring methods that would support independent spent fuel
storage installation license renewal commitments to support aging management of welded stainless steel canisters.
How to Apply Results– Structural monitoring methods using these technologies may be needed as part of a pre-application
process and/or as part of the implementation of an aging management program. Being familiar with the current research results and future follow-on project results will support that need.
Learning and Engagement Opportunities– The work discussed in this report is coordinated with other nondestructive evaluation (NDE) development
opportunities via EPRI's Extended Storage Collaboration Program NDE Subcommittee
68© 2016 Electric Power Research Institute, Inc. All rights reserved.
PRE-SW: Weld Overlay Repair (WOR) version 1.0 – Beta 3002006655 The Weld Overlay Repairs computer
based training (CBT) is a browser-based course that describes weld overlay repairs and the issues that may arise when applying them. It offers solutions for optimizing the application of weld overlays based on plant conditions.
Benefits and Value– EPRI Weld Overlay Repairs CBT will
allow for the following:– Ability for the learner to access the
training materials on an as needed basis
– Ability for EPRI to update and maintain the course over time
69© 2016 Electric Power Research Institute, Inc. All rights reserved.
Remote Visual Testing Image Analysis3002007814 Abstract Remote visual testing (VT) is routinely used by nuclear utilities to find cracks, damage, and deformation in
reactor internals and to inspect for other conditions such as wear, embrittlement, void swelling, and the presence of foreign materials. The remote visual inspection method is the predominant nondestructive technique for the inspection of both PWRs and BWRs. Common applications include nozzle inside corner region surface inspection and internal components in PWRs such as core barrel welds and baffle plate assemblies, as well as internal components in BWRs such as core shroud and core spray piping welds. The application of remote VT typically requires the use of radiation-tolerant video systems, including cameras, monitors, and recording hardware. A variety of cameras are deployed, some with zoom capabilities and others with fixed focal distances. The recorded images are viewed by trained analysts that examine specific components and welds to document the presence of surface cracking or other damage mechanisms.
Background Remote visual inspection is widely used to inspect reactor pressure vessel internals. For many years, this
method has successfully been used to detect surface cracking in aging components. The success of the remote enhanced visual testing techniques (EVT-1) in detecting in-service cracking relies on the skills and performance of the qualified data analyst who views all video data. The investigation described in this report focused on technologies that have the potential to assist the analyst in minimizing human performance errors associated with detecting cracking in both live and recorded video. In general, this report focuses on hardware options for collecting displacement data and increased resolution as well as software used for automated crack detection and video filtering.
70© 2016 Electric Power Research Institute, Inc. All rights reserved.
Remote Visual Testing Image Analysis3002007814 Objective
– To document technology, both software and hardware, that has the potential to improve image analysis capabilities of qualified visual testing (VT) analysts
Approach– This report describes an investigation of hardware and software technologies that could have a positive
effect on the ability of VT analysts to reliably detect cracks. Methodologies explored were the use of a 3-D laser topography for imaging cracks, an assessment of 4000-pixel resolution action cameras, the discussion of automated crack detection using image processing techniques, and image filtering for the removal of radiation-induced “noise.”
Results– This report describes several promising technologies that could have a beneficial effect on data quality
and analysis consistency. Hardware and software tools that either complement current technologies, improve image quality with increased capability, or assist the analyst with computer-based flaw detection are described.
Applications, Value, and Use– All utilities that perform remote VT to inspect plant components may be interested in the details provided.
The results of this investigation have the potential to enhance visual examination of reactor internal components by minimizing human performance errors through an assortment of technological tools
71© 2016 Electric Power Research Institute, Inc. All rights reserved.
Evaluation of Platforms for Aging Management of Concrete Structures3002007810 Key Research Question
– The design of an aging management approach for civil structures may need the implementation of an aging management program into a platform that allows for improved data collection, storage and data use. Software platforms for aging management can house all of the relevant data in one centralized location as well as assist engineers with analysis of aging management data. The main research question addressed in this report is:
– What are the benefits and factors that need to be considered before adopting a software platform for aging management programs of civil infrastructure?
Research Overview– This project evaluates the benefits and limitations of commercially available software platforms
for aging management programs of civil structures. First, EPRI explored the different types of data formats used for aging management
purposes and collected a dataset from a nuclear containment building for the assessment. The data set included construction data, inspection and repair data over period of 30 years. Next, a survey on commercially available platforms was performed and four platforms
covering a broad range of functionalities were selected. The dataset was implemented into each of these platforms and key functionalities for aging management were assessed.
72© 2016 Electric Power Research Institute, Inc. All rights reserved.
Evaluation of Platforms for Aging Management of Concrete Structures3002007810 Key Findings
– Overall, all software platform analyzed can perform most functionalities necessary for aging management of civil structures.
– Because the aging management approach to civil structures is not uniform among utilities, no single platform may be the best option for all utilities. Utilities are encouraged to analyze the benefits and limitations associated with each platform.
– A main concern for utilities with many years of operations is the large amount of historical data that needs to be transferred to a centralized location and incorporated into aging management activities. The implementation of historical data into these platforms can be a time consuming process that need to be carefully evaluated.
Why this matters– Large repairs or replacement of plant infrastructure may not be economically viable and could lead to early
retirements. Aging management of plant infrastructure can ensure that degradation is detected and mitigated before structures lose their intended functionalities. The data associated with aging management such as inspection, monitoring and trending data are critical and should be housed in a centralized location to make analysis easier for plant personnel. An evaluation of the availability of software platforms is needed when designing aging management programs. This report supports this evaluation.
How to Apply the results– Plant personnel in charge of designing the approach and implementation of aging management programs
should focus on chapter 4, where the main functionalities of each type of platform is analyzed
73© 2016 Electric Power Research Institute, Inc. All rights reserved.
Concrete NDE for Damage due to Pattern Cracking - ASR and FT Damage3002007806 Key research Question
– Concrete deterioration caused by freeze thaw damage and alkali silica reaction (ASR) may be found in structures across the different energy sectors and is typically documented with visual inspection as pattern cracking on the surface of the concrete.
– Some of the research questions addressed in this report are: Can these deterioration mechanisms be characterized using nondestructive evaluation (NDE) methods? Can NDE techniques be used to monitor the progression of alkali silica reaction? What methods can be used to characterize and monitor the progression of the damage? What are the limitations of these NDE techniques when used for the characterization and monitoring of concrete
with ASR and freeze thaw damage? Research Overview
– Mockup specimens with different levels of deterioration due to freeze thaw and ASR were fabricated. The deterioration was induced by selecting mix design materials that would assist the deterioration process. Further, the samples were subjected to an environment that would accelerate deterioration and tested with different NDE methods. The NDE test method results were compared to the results of the visual inspection.
– For the freeze thaw damage, samples were fabricated with non-air entrained concrete and subjected to freeze thaw cycles in an environmental chamber. The progression of deterioration was monitored and the samples were removed from the chamber after reaching different levels of deterioration.
– The ASR samples were fabricated with concrete containing reactive aggregates and high levels of alkalis. The samples were subjected to a high moisture (~ 98% RH) and high temperature (~38˚C) to promote the ASR reaction. The progression of deterioration was monitored by taking expansion measurements and, in most cases, data was collected at different points in time in an effort to characterize the progression of the damage.
74© 2016 Electric Power Research Institute, Inc. All rights reserved.
Concrete NDE for Damage due to Pattern Cracking - ASR and FT Damage3002007806 Why this matters
– This research study provides information on deteriorated concrete, describes testing processes, and test parameters used to characterize damage due to freeze thaw and ASR. These techniques can be deployed on large structures and are commercially available. Therefore, these results can be applied by any interested party with knowledge in the use of concrete NDE.
– The techniques covered in this study range from techniques that have been used in other research studies for similar applications to state of the art techniques for which limited information has been published. The study provides information on how the data was used to characterize and monitor the deterioration.
How to apply the results– Parties interested in the inspection of concrete with freeze thaw damage should refer to Part I of this
report.– Members interested to monitor freeze-thaw in their structures, can use the EPRI mockups for training
before testing at the site.– Parties interested in the inspection and monitoring of ASR affected structures should refer to Part II of this
report.– The report includes the methodology used to prepare large scale ASR affected samples. This can be
used by utilities and researchers interested in fabricating mockups with ASR damage.
75© 2016 Electric Power Research Institute, Inc. All rights reserved.
Feasibility Study for Control Rod & Control Blade Inspection Techniques, 3002007804
76© 2016 Electric Power Research Institute, Inc. All rights reserved.
Meeting Agenda and Objectives
Time Topic Objectives Lead
10:00 AM NDE RELIABILITY TAC WELCOME & INTRODUCTIONS NOWAKOWSKI
10:10 AM 2016 NDE WORKPLAN PROGRESS REPORT WE WILL DISCUSS CHANGES TO THE 2016 WORKPLAN PROJECTSINDICATED ON THE SECOND QUARTER PROJECT STATUS UPDATES
ASHWIN
11:00 AM 2017 NDE WORKPLAN PROJECTS ASSIGNED TO THE RELIABILITYTAC
WE WILL REVIEW THE NEW PROJECTS PLANNED TO START IN2017 WITH A FOCUS ON OPPORTUNITIES FOR ADVISORENGAGEMENT AND TECHNOLOGY TRANSFER
ALL
11:45 AM LUNCH
1:00 PM 2017 NDE WORKPLAN PROJECTS ASSIGNED TO THE RELIABILITYTAC, CONT’D WE WILL REVIEW THE NEW PROJECTS PLANNED TO START IN2017 WITH A FOCUS ON OPPORTUNITIES FOR ADVISORENGAGEMENT AND TECHNOLOGY TRANSFER
ALL2:45 PM BREAK
3:00 PM 2017 NDE WORKPLAN PROJECTS ASSIGNED TO THE RELIABILITYTAC, CONT’D
3:30 PM EMERGENT ISSUES AND NEW PROJECT IDEAS WE WILL DISCUSS SUGGESTIONS FOR NEW NDE RESEARCHPROJECTS
ALL
4:00 PM MEETING SUMMARY AND REPORT TO THE NDE CC COORDINATING COMMITTEE NOWAKOWSKI AND ASHWIN
4:30 PM ADJOURN
77© 2016 Electric Power Research Institute, Inc. All rights reserved.
2017 NDE Workplan Projects Assigned to the Reliability TAC
We will review the new projects planned to start in 2017 with a focus on opportunities for advisor
engagement and technology transfer
78© 2016 Electric Power Research Institute, Inc. All rights reserved.
Preparing for 2017…
The roles and responsibilities of the TACs include:– Defining industry needs and emerging issues to formulate strategic research
plans– Ensuring that research activities are aligned with Program strategic objectives– Advising on scope, schedule, and technology transfer for R&D projects– Advising on sequencing of research projects within RFAs – Advising EPRI project managers on research activities, and assisting in
resolving issues as needed– Acting as the sponsor of projects within the responsibility of the TAC, such as
reviewing project performance including deliverable status and scheduleAs we get ready to start the 2017 new projects each TAC has been
asked to take a look at the new projects with a focus opportunities for advisor engagement and technology transfer
79© 2016 Electric Power Research Institute, Inc. All rights reserved.
Implementation Categories
Projects results delivered as a technical report or technical update are assigned an implementation category
80© 2016 Electric Power Research Institute, Inc. All rights reserved.
What is an Impact Project? Some NDE Program work activities
may potentially have a negative impact on one or more member utilities. For example, a negative impact could arise as a result of late deliverables or if research results affected the operating basis of one or more units.
Section 8 of the NDE Administration procedure (3002006936) describes a process to classify NDE projects as “Impact Projects”
Projects within the scope of this procedure should receive an Impact evaluation using Consequence and Probability of Occurrence as defined in Figure 8-1
https://membercenter.epri.com/Programs/061154/pages/productabstract.aspx?ProductId=000000003002006936
https://membercenter.epri.com/Programs/061154/pages/productabstract.aspx?ProductId=000000003002006936
81© 2016 Electric Power Research Institute, Inc. All rights reserved.
Classification of an Impact Project The initial determination should be made in
collaboration between the EPRI project manager and the project manager’s supervisor and documented using the Impact Evaluation Record form (see Figure 8-1). In addition, TACs may recommend projects for
Impact status. NDE program managers should communicate the results of the impact screen with the Director, EPRI NDE. The Director, EPRI NDE should communicate the list of Impact projects to the APC.
Think globally!
82© 2016 Electric Power Research Institute, Inc. All rights reserved.
NDE Program’s Process for PlanningTechnology Transfer – Thinking Ahead . . .
Project Deliverable Types /
Technology Transfer MethodLic
ensin
g / R
oyalt
ies
NDE A
lert
News
letter
IR R
eport
TU / T
R Re
port
TU / T
R wit
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Exec
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/ Web
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Appli
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CBT /
Mult
imed
ia
Works
hop /
Con
feren
ce
Form
al Tra
ining
/ Cert
ificati
on
Proc
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Demo
nstra
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User/
Worki
ng G
roup
Vend
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/ Site
visit
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Raw / Preliminary ResearchTechnology to be developed and commercialized
Technology ImprovementsTechnology assessments
Leveraging Existing Technologies into derivative product 5 5 5 5 5 5 5Technology / Technique targeting NDE Efficiencies ($$$) 6 6 6 6 6 6 6 6
Technique developmentTechnique Improvements 1, 2 1, 2 1, 2 1, 2 1, 2
Leveraging Existing Techniques into derivative productCapability Studies / Assessments / Demonstrations
Technical Basis Development (PD, Relief Request, . . .) 4 4 4 4 4 4 4 4NDE Industry Guidelines
Round Robin StudiesReference Material
Training Materials 3 3 3 3 3 3 3 3Service
Human Performance Improvement 7 7 7 7 7 7 7 7 7Hardware
Assembled Package
Recently we have asked each project manager to think ahead and identify the methods for transferring the research results from to members and other stakeholders
The presents more opportunity for Advisor input – Applications / First use
83© 2016 Electric Power Research Institute, Inc. All rights reserved.
Reliability TAC – 2017 New Projects (12)
1. Improving NDE Reliability– Visual Round Robin Follow UP– Field Application of Remote Visual Examination
Technology– Walk Down information Field Guide for As-built
dimensions to support NDE2. Workforce Proficiency
– BOP Electromagnetic NDE Guide for Engineers– Containment Inspection Program Guide Update– BOP Data Analyst Software Upgrade to V2.0
4. Cast Stainless Steel– Cast Austenitic Stainless Steel PD Program
Development– Ultrasonic Characterization and Acoustical
Equivalency of Cass for improved UT inspection
5. Performance Demonstration – Reconcile the EPRI PD Program with the
revised 10cfr50.55a Federal requirements6. NDE Efficiency
– Expansion of Qualified Manual Phased Array Piping Procedures
– Align Certain Encoded UT Procedures with Non-Encoded Counterparts for Limited Exam Pickups
– Examination Coverage Capture N711 Process and Tool
10. Fuels and Dry Storage – Concrete NDE for Dry Cask Storage Systems
Reliability TAC Projects
Technology TAC Project for discussion by all
Everything else
Suggested Review Process/Priority
84© 2016 Electric Power Research Institute, Inc. All rights reserved.
Improving NDE Reliability RFA priority: 1
Reliability TAC Projects
Request from member to discuss
Technology TAC Project for discussion
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Chris JoffeTechnical Leader
Remote Visual Examination Follow Up
86© 2016 Electric Power Research Institute, Inc. All rights reserved.
Remote Visual Examination Follow Up
Background: The Remote Visual Examination Round Robin study concludes in 2016 and will answer many questions about the current status of remote visual examinations.
Due to limitations in time, budget and scope; new and advancing technologies were not tested; and some opportunities for technology improvements have been proposed. To proactively evaluate technology improvements, this project will demonstrate the capabilities of newly available high definition/resolution camera technology to validate and quantify these remote visual examination improvements.
Project Details: This project will invite vendors to test on the blind remote visual examination test specimens using full high definition/resolution camera systems. Data and results would be compared to the previous remote VT test results and documented in an EPRI report; along with lessons learned about the data collection and analysis process.
The second aspect of this project will include use of the new HD video data to improve the current algorithms used in automated analysis, and compare the algorithms against human analysis.
The final part of this project is to create a program to quantitatively measure the quality of the video image resolution to develop a process to maintain optimum image quality during data collection.
87© 2016 Electric Power Research Institute, Inc. All rights reserved.
Remote Visual Examination Follow UpWhy
– Almost ALL vendors who participated in the Remote VT Round Robin are planning to implement HD video in the near future. – The Remote VT Round Robin data was based on older technology Round Robin results have showed poor detection on tight cracks using
standard definition cameras During Round Robin testing, vendors expressed their interest in returning to
EPRI to test capabilities of HD systems on the remote visual test specimens– The major high-radiation underwater camera manufacturers such as Ahlberg,
Mirion, and Diakont are all highly marketing their HD cameras. Thus, all new camera development moving forward will be at least HD quality. However, HD may mean different resolutions (720, 1080, 4K)
– HD camera systems could become less expensive than some current standard systems. Some utilities already use HD, therefore it is not a technology that is too expensive to adapt
Value– The benefit to the industry is in demonstrating, validating, and documenting the
resolution improvements with HD technology, and quantifying enhancements in the probability of detection for remote VT flaw detection
88© 2016 Electric Power Research Institute, Inc. All rights reserved.
Remote Visual Examination Follow Up HD video will aid in the
development of the algorithms used to build the VT automated analysis tool, thus improving accuracy and reliability.– The performance of the
automated analysis program can then be tested against the performance of the inspection vendors using the same HD video data set and help identify and address any gaps
Developing the capability to quantify image resolution will assist in removing subjectivity in resolution demonstration checks and may also aid in addressing the differences in image resolution between live and recorded videos.
89© 2016 Electric Power Research Institute, Inc. All rights reserved.
Visual Round Robin Follow Up
90© 2016 Electric Power Research Institute, Inc. All rights reserved.
Visual Round Robin Follow Up
91© 2016 Electric Power Research Institute, Inc. All rights reserved.
Visual Round Robin Follow Up, Technology Transfer Plan
Project Deliverable Types /
Technology Transfer Method
Lice
nsin
g / R
oyal
ties
NDE
Ale
rt
New
slett
er
IR R
epor
t
TU /
TR R
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ith E
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Post
ed o
n EP
RIQ
.com
Exec
utab
le /
Web
site
/ App
licat
ion
CBT
/ Mul
timed
ia
Wor
ksho
p / C
onfe
renc
e
Form
al T
rain
ing
/ Cer
tific
atio
n
Proc
edur
alize
d
Dem
onst
ratio
n
Use
r/W
orki
ng G
roup
Vend
or
colla
bora
tion
Cust
omer
Ass
istan
ce /
Site
visi
t
ASM
E Co
de
Regu
lato
ry B
ody
Endo
rsem
ent
Avai
labi
lity
of H
ardw
are
Oth
er
Raw / Preliminary ResearchTechnology to be developed and commercialized
Technology ImprovementsTechnology assessments
Leveraging Existing Technologies into derivative productTechnology / Technique targeting NDE Efficiencies ($$$)
Technique developmentTechnique Improvements
Leveraging Existing Techniques into derivative productCapability Studies / Assessments / Demonstrations
Technical Basis Development (PD, Relief Request, . . .)NDE Industry Guidelines
Round Robin Studies P18 P17, P18Reference Material
Training MaterialsService
Human Performance ImprovementHardware
Assembled Package
92© 2016 Electric Power Research Institute, Inc. All rights reserved.
Field Application of Remote Visual Examination (VT) Automated Data Analysis Technology
93© 2016 Electric Power Research Institute, Inc. All rights reserved.
Field Application of Remote Visual Examination (VT) Automated Data Analysis Technology
94© 2016 Electric Power Research Institute, Inc. All rights reserved.
Field Application of Remote Visual Examination (VT) Automated Data Analysis Technology, Technology Transfer Plan
Project Deliverable Types /
Technology Transfer Method
Lice
nsin
g / R
oyal
ties
NDE
Ale
rt
New
slett
er
IR R
epor
t
TU /
TR R
epor
t
TU /
TR w
ith E
mbe
dded
Vid
eo
Vide
o (e
.g.
PPT
"Mix
", E
PRI
Yout
ube,
. . .
)
Dist
ribut
ed a
s an
Issu
e Pr
ogra
m
Whi
te P
aper
Cock
pit
Post
ed o
n EP
RIQ
.com
Exec
utab
le /
Web
site
/ App
licat
ion
CBT
/ Mul
timed
ia
Wor
ksho
p / C
onfe
renc
e
Form
al T
rain
ing
/ Cer
tific
atio
n
Proc
edur
alize
d
Dem
onst
ratio
n
Use
r/W
orki
ng G
roup
Vend
or
colla
bora
tion
Cust
omer
Ass
istan
ce /
Site
visi
t
ASM
E Co
de
Regu
lato
ry B
ody
Endo
rsem
ent
Avai
labi
lity
of H
ardw
are
Oth
er
Raw / Preliminary ResearchTechnology to be developed and commercialized
Technology ImprovementsTechnology assessments
Leveraging Existing Technologies into derivative productTechnology / Technique targeting NDE Efficiencies ($$$)
Technique developmentTechnique Improvements
Leveraging Existing Techniques into derivative productCapability Studies / Assessments / Demonstrations
Technical Basis Development (PD, Relief Request, . . .)NDE Industry Guidelines
Round Robin StudiesReference Material
Training MaterialsService
Human Performance ImprovementHardware
Assembled Package P19 P19 P18, P19 P18 P17, P18
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Nathan MuthuProgram Manager
NDE TAC MeetingAugust 23, 2016
Socket Weld Examination for IGSCC
Supplemental Information
96© 2016 Electric Power Research Institute, Inc. All rights reserved.
Socket Weld Examination for IGSCC
Supplemental Information Driver
– To meet license renewal requirements, the GALL Report (NUREG-1801) in Section XI M35-1 specifically calls for plants to perform a one-time volumetric inspection of small bore socket welds to detect cracking resulting from intergranular stress corrosion (IGSCC)
– Austenitic steels socket welds in high temperature and stagnant environments are susceptible to SCC
– The stress concentration at the weld root promotes SCC propagation Crack Morphology
– SCC is highly branched and can be intergranular (IGSCC) or trans granular (TGSCC)– The EPRI work up till now applies only to Vibration Fatigue which forms as a single crack This work cannot be used as a basis for examining for SCC
Implications / Value– Lack of an SCC examination procedure will result in use of "destructive examination" to meet
the Aging Management Program (AMP) requirements, – This in essence means that the industry is going to be cutting a lot perfectly good welds
unnecessarily, which could potentially introduce additional problems.
97© 2016 Electric Power Research Institute, Inc. All rights reserved.
Davis Besse Socket Weld SCC Findings at Steam Generator DrainsAREVA Presentation at the EPRI International Materials Reliability Conference – August 1-4, 2016
98© 2016 Electric Power Research Institute, Inc. All rights reserved.
Walk Down Information Field Guide for As-Built Dimensions to Support NDE
99© 2016 Electric Power Research Institute, Inc. All rights reserved.
Walk Down Information Field Guide for As-Built Dimensions to Support NDE
100© 2016 Electric Power Research Institute, Inc. All rights reserved.
Walk Down Information Field Guide for As-Built Dimensions to Support NDE, Technology Transfer Plan
Project Deliverable Types /
Technology Transfer Method
Lice
nsin
g / R
oyal
ties
NDE
Ale
rt
New
slett
er
IR R
epor
t
TU /
TR R
epor
t
TU /
TR w
ith E
mbe
dded
Vid
eo
Vide
o (e
.g.
PPT
"Mix
", E
PRI
Yout
ube,
. . .
)Di
strib
uted
as a
n Is
sue
Prog
ram
Whi
te P
aper
Cock
pit
Post
ed o
n EP
RIQ
.com
Exec
utab
le /
Web
site
/ Ap
plic
atio
n
CBT
/ Mul
timed
ia
Wor
ksho
p / C
onfe
renc
e
Form
al T
rain
ing
/ Cer
tific
atio
n
Proc
edur
alize
d
Dem
onst
ratio
n
Use
r/W
orki
ng G
roup
Vend
or
colla
bora
tion
Cust
omer
Ass
istan
ce /
Site
vi
sit
ASM
E Co
de
Regu
lato
ry B
ody
Endo
rsem
ent
Avai
labi
lity
of H
ardw
are
Oth
er
Raw / Preliminary ResearchTechnology to be developed and commercialized
Technology ImprovementsTechnology assessments
Leveraging Existing Technologies into derivative productTechnology / Technique targeting NDE Efficiencies ($$$)
Technique developmentTechnique Improvements
Leveraging Existing Techniques into derivative productCapability Studies / Assessments / Demonstrations
Technical Basis Development (PD, Relief Request, . . .)NDE Industry Guidelines
Round Robin StudiesReference Material
Training Materials P18 P18 P18Service
Human Performance ImprovementHardware
Assembled Package
101© 2016 Electric Power Research Institute, Inc. All rights reserved.
Lunch 11:45 am to 1:00 pm
102© 2016 Electric Power Research Institute, Inc. All rights reserved.
Meeting Agenda and Objectives
Time Topic Objectives Lead
10:00 AM NDE RELIABILITY TAC WELCOME & INTRODUCTIONS NOWAKOWSKI
10:10 AM 2016 NDE WORKPLAN PROGRESS REPORT WE WILL DISCUSS CHANGES TO THE 2016 WORKPLAN PROJECTSINDICATED ON THE SECOND QUARTER PROJECT STATUS UPDATES
ASHWIN
11:00 AM 2017 NDE WORKPLAN PROJECTS ASSIGNED TO THE RELIABILITYTAC
WE WILL REVIEW THE NEW PROJECTS PLANNED TO START IN2017 WITH A FOCUS ON OPPORTUNITIES FOR ADVISORENGAGEMENT AND TECHNOLOGY TRANSFER
ALL
11:45 AM LUNCH
1:00 PM 2017 NDE WORKPLAN PROJECTS ASSIGNED TO THE RELIABILITYTAC, CONT’D WE WILL REVIEW THE NEW PROJECTS PLANNED TO START IN2017 WITH A FOCUS ON OPPORTUNITIES FOR ADVISORENGAGEMENT AND TECHNOLOGY TRANSFER
ALL2:45 PM BREAK
3:00 PM 2017 NDE WORKPLAN PROJECTS ASSIGNED TO THE RELIABILITYTAC, CONT’D
3:30 PM EMERGENT ISSUES AND NEW PROJECT IDEAS WE WILL DISCUSS SUGGESTIONS FOR NEW NDE RESEARCHPROJECTS
ALL
4:00 PM MEETING SUMMARY AND REPORT TO THE NDE CC COORDINATING COMMITTEE NOWAKOWSKI AND ASHWIN
4:30 PM ADJOURN
103© 2016 Electric Power Research Institute, Inc. All rights reserved.
Workforce Proficiency RFA priority: 2
Reliability TAC Projects
Technology TAC Project for discussion
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Mark Dennis
August 29, 2016
NDE Data Analysis Workshop
105© 2016 Electric Power Research Institute, Inc. All rights reserved.
Outline
Project OverviewProject Benefits and Value
106© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Overview The purpose of this project is to develop a
workshop to provide an opportunity for EPRI utility members to increase their effectiveness in reviewing ultrasonic and eddy current data.
Recognizing this issue, this project seeks to:– Work with utility members and vendors to
assemble NDE data from typical applications to develop the workshop materials.
– Conduct classroom style, interactive training sessions with ultrasonic and eddy current data review.
– Gather feedback and incorporate into future sessions to improve the workshops.
107© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Benefits and Value Participants can serve as another
reviewer of NDE data collected at their site:– Flaw characterization evaluations.– Adequate sensor contact (lift-off).– Typical geometry signals (data
landmarks). Participants will be able to make
more informed decisions regarding NDE results.
Utilities may be able to better track indications.
The overall reliability of inspections is expected to increase with this added level of oversight.