Upload
others
View
26
Download
0
Embed Size (px)
Citation preview
Nondestructive Evaluation Laboratory
35th Annual EPRI Steam Generator NDE Workshop, Clearwater Beach, Florida July 2016
Simulation Model
for SG Eddy Current SG Inspection
Saptarshi Mukherji, Anton Efremov, Pavel Roy, Portia Banerjee, Anders Rosell, L.Udpa
Nondestructive Evaluation Laboratory
Michigan State University
&
Rick Williams, Nathan Driessen, James Benson
EPRI
Nondestructive Evaluation Laboratory
Outline
Benefits/Motivation
Applications of Simulation Model
Objectives
Summary of SGTSIM Features
Simulation Results
Current Ongoing work
Conclusions and Future Work
2
Nondestructive Evaluation Laboratory
Benefits of Simulation Models
What can simulation models do?
Predict EC probe signals for different defect geometry
Test bed for generating defect signatures
Effect of probe wobble, frequency, sludge characteristics on probe measurements
Training tool
Optimization of sensor/system design
Useful in Probability of Detection (POD) Models at low cost
Use in Reverse engineering models for finding root cause of complex signals
Key Advantages of Simulation Model:
Provides an inexpensive and fast method to simulate realistic defect geometries
3
Nondestructive Evaluation Laboratory
Practical Applications of Simulator Software
• Utility Engineers
‒ Assist in complex signal interpretation & Tube Integrity Assessments
‒ Assist in POD calculations
Inspection vendors
Assist in signal interpretation
Assist in SSPD development
• Probe developers
Aid in probe design
• NDE instructors
Training tool
Generate signals for training data
• Researchers / Qualifying Institute
Generate signals for probe technique qualification (ETSS’s)
Generate signals for performance demonstration (QDA/AAPDD)
4
Nondestructive Evaluation Laboratory
Continue development of a software tool that is capable of accurately simulating signals representing SG EC inspection data from various: Tube degradation mechanisms
SG tube geometries
Eddy current coil configurations
Sludge compositions
Foreign objects
Generate simulated EC signals in a format that is representative of signals generated by field SG eddy current test equipment. Simulated data will be formatted so that it can be read and
processed by commercial data analysis software
Project Objectives
5
Nondestructive Evaluation Laboratory
SGTSIM v4.0 (Beta) Features -Summary
Probes
Bobbin
Pancake (.115)
X-Probe .610 Tube Geometry
Support
Plate
Tube
Sheet
Free
Span
Defect Geometry
Location Freespan
TSP
TTS
ID/OD
Orientation Circ
Axial
Shape Circular
Elliptical
Rectangular
Real Cracks
Other features:
Data Export in MIZ Format
Batch Processing
Generate noise added signal
All results are experimentally validated
+ Point
MRPC
TSP TTS Free span
Bobbin probes - (0.510 TF, 0.560 TF, 0.560
HF, .610 MR, 0.610 TF, 0.610 HF, 0.350 MR,
0.380 MR, 0.480 MR, 0.540 TF, 0.710 MR,
0.720 MR)
6
Choose defect type as
“Real Crack”
Choose Defect orientation as
“ID” or “OD”
Example of User Interface Window Data Input screen
7
Axial Notch - ID Axial Notch - OD
Circumferential Notch - ID Circumferential Notch - OD
GUI for Real Cracks
Axial Notch - ID
8
Nondestructive Evaluation Laboratory
Using SGTSIM batch export feature, multi-frequency and multi-coil data can be generated and combined into a multi-channel data file in csv format
This csv file can be used to generate a corresponding MIZ-80 datafile by the ‘C2D converter’ from Zetec, and viewed in Eddynet display.
Develop export modules for multichannel probe
configurations
Generated
MIZ-80 Data
File Channel configuration
User selected files
CSV file Generator
Process & Other
Header Information
.csv file Simulated
signals
C2D
Converter
9
Nondestructive Evaluation Laboratory
Position Depth (%) Defect
Type Probe Frequency (Khz)
O.D./I.D. 100,60,40 Axial
.610 X-Probe 400, 300, 100, 50 Circ
O.D./I.D. 100,60,40 Axial
.610 TF Bobbin 550, 280, 140, 35 Circ
O.D. 100,60,40, 20(4) FBH .610 TF Bobbin 550, 280, 140, 35
O.D. 100,60,40, 20(4) FBH .560 HF Bobbin 650, 320, 170, 35
O.D. 100,60,40, 20(4) FBH .510 TF Bobbin 750, 380, 200, 50
O.D./I.D. 100, 60, 40, 20
Axial Rotating +Pt
(PP11A) 300, 200, 100, 35
Circ Rotating
Pancake (P115A)
n/a Radial exp
(0.016”)
360 deg
Expansion .610 X-Probe 400,300,100,50
Calibration Flaw Simulations – in Progress
Position Depth (%) Defect Type Probe Frequency
(Khz)
O.D. 30 Groove .610 X-Probe 400,300,100,50
Validation of SGTSIM • Database of simulated calibration standard flaws eddy current signals
10
Nondestructive Evaluation Laboratory
Exported Bobbin Signals displayed in Eddynet
Experimental Data
750kHz 380kHz 200kHz 50kHz 750kHz 380kHz 200kHz 50kHz
40% Circular Flaw- Diff channels
Simulated Data
380kHz 200kHz
11
Nondestructive Evaluation Laboratory
100% Axial Flaw
Exported 0.610 Array Signals displayed in Eddynet
Experimental Data Simulated Data
400kHz 400kHz 140kHz 140kHz
12
Nondestructive Evaluation Laboratory
Exported MRPC Signal displayed in Eddynet
080 PAN 115 PAN +Pt
115
PAN
115
PAN
+ Pt + Pt
Simulated Data Experimental Data 40% O.D. Axial Flaw
115 PAN +Pt
13
Nondestructive Evaluation Laboratory
Capability to Read Crack Profile from Excel File
Axial Notch Profile from
MET data - mesh
+Point Probe ; 300KHz ; FARLEY-1 # 25-51
Simulated Signals Experimental Signals
Profile Table
Length (mm) % TW
-6.7056 0
-5.8674 17
-5.0292 17
-4.191 38
-3.3528 67
-2.5146 67
-1.6764 77
-0.8382 73
0 62
0.8382 57
1.6764 57
2.5146 60
3.3528 28
4.191 22
5.0292 22
5.8674 20
6.7056 23
6.7564 0
14
Quantitative Metrics
Flaw size Coil type Magnitude Difference
(%)
Phase Difference
(º)
Axial notch Depth 100%
Length 0.38’’ Width 0.005
RPC +Point 0.6 1.6
RPC Pancake 2.9 1.7
Axial notch Depth 57% OD
Length 0.38’’ Width 0.005’’
RPC +Point 1.1 0.9
RPC Pancake 3.9 1.8
100% TW Circular hole X Probe
Axial
0.9 0
X Probe
Circumferential
1.4 0
100% TW hole .610 Bobbin probe
6.1 0.5
SG Exam Guidelines Data Quality Acceptance Criteria:
• Phase changes on normalized reference signal ±5°
• Amplitude changes on normalized reference signal ±20%
15
Nondestructive Evaluation Laboratory
Current Ongoing work
1. Setup SGTSIM to run in EPRI HPC
• Linux based SGTSIM developed for testing HPC
implementation
• Linux version installation at EPRI HPC
2. Training dataset- Signals generated where experimental data is
unavailable in ETSS dataset
3. Reverse engineering - determine root cause of complex field
signal
4. Noise incorporation in simulated signals for POD analysis
5. Simulation of :
Loose parts (Carbon steel, Stainless steel, Copper)
Complex signals
16
Nondestructive Evaluation Laboratory
1. Development of a new SGTSIM GUI • Cross- platform (Windows and Linux)
• Modular structure (Easy to extend the functionalities)
• Unified control over the Local and Remote machines
17
Nondestructive Evaluation Laboratory
2. SGTSIM for Training data generation
Flaw shape: Rectangular, Crack Width:0.005'',
Tube OD:0.75'',Tube wall Thickness:0.043
Position Length depth Frequency Orientation Probe
50 100 200 300 400 Axial Circ Pancake +Pt
OD
0.3’’
20 √ √ √ √ √ √ √ √ √
40 √ √ √ √ √ √ √ √ √
ID 40 √ √ √ √ √ √ √ √ √
20 √ √ √ √ √ √ √ √ √
OD 0.5’’
20 √ √ √ √ √ √ √ √
40 √ √ √ √ √ √ √ √
100 √ √ √ √ √ √ √ √
√: finished
Flaw shape: Rectangular ,Crack Length:0.5'',Crack Width:0.005'', Tube OD:0.875'',Tube wall Thickness:0.052
Position depth Frequency Orientation Probe
15 100 200 300 Axial Circ pancake +Pt
ID 39 √ √ √ √ √ √ √
√: finished
Flaw shape: FBH of diameter:0.05'', Tube OD:0.875'',Tube wall Thickness:0.052
depth Frequency Probe
15 100 200 300 pancake +Pt
100 √ √ √ √ √ √
√: finished
18
Nondestructive Evaluation Laboratory
3. Use of SGTSIM for Reverse Engineering of Complex Field Signals
A 150 kHz +Pt Mag Bias coil showing volumetric indication of 0.09 Volts was
observed 0.2 inch above the hot leg TTS in a one inch sludge collar
• Complex Field Data
ECT Graphics of 400 kHz +Pt coil w/ volumetric indication
19
Possible causes
Loose part wear in the sludge pile region
Pitting
Hard sludge collars with a small area where sludge deposits have
flaked off
Lap signals
Develop mesh for each test
case
ECT Simulations of test cases using
SGTSIM
Comparison of calibrated simulated
signals vs
Experimental signals for closest match
Determine possible cause of field data
Reverse Engineering Algorithm
3. Use of SGTSIM for Reverse Engineering of Complex Field Signals
20
Case I. Loose part wear in the sludge pile region
Sludge Sludge
Sludge
Tube Tube
Defe
ct
Mesh of the Geometry
Zoom
ed in
Sludge Properties: Permeability: 7, Conductivity: 0
Defect Dimensions:12 % TW 0.2” length, 0.005” width
3. Use of SGTSIM for Reverse Engineering of Complex Field Signals
21
Liz Plot
shows
defect
indication
Field data
Initial results
Simulation results
3. Use of SGTSIM for Reverse Engineering of Complex Field Signals
22
Nondestructive Evaluation Laboratory
• 1 D Random noise
Horizontal and vertical components of the signal are affected by noise
independently.
Variance of noise is changed to control power of the injected noise.
Noise variance = 0.152
Noise variance = 0.352
Noise Free SGTSIM
simulated bobbin
signal for 80%
through-wall OD
defect near TSP
Noise added to Hor. Com. Noise added to Vert. Com.
Noisy signal
4. Capability to Inject Simulated Noise into Simulated Signal
23
Nondestructive Evaluation Laboratory
Experimental field data AAPDD, + point probe
100KHz, Horizontal channel
ANO Defect
GUI for controlled Noise injected simulated data
+ point probe, 100KHz, Horizontal channel
User selected noise
parameters
Simulated Defect
4. Capability to Inject Simulated Noise into the
Simulated Signal – 2D Random & Periodic noise
24
Nondestructive Evaluation Laboratory
= + +
Simulation flaw signal
Random noise
Zero-mean additive
Gaussian noise Periodic noise Simulation signal with noise
4. Capability to Inject Simulated Noise into the
Simulated Signal – 2D Random & Periodic noise
Simulation flaw signal
Random noise
Zero-mean additive
Gaussian noise Periodic noise Simulation signal with noise
4. Capability to Inject Simulated Noise into the
Simulated Signal – 2D Random & Periodic noise
25
Nondestructive Evaluation Laboratory
Summary/Conclusions
A computational model for simulating SG tube inspection has been
developed and validated using experimental measurements
Experimental validation of Simulation results from a variety of probe
geometry, tube geometry and defect geometry has been presented
The model has several potential applications -
The model can be used as test-bed to generate signals from defects that are
expensive to fabricate
The model allows user to make controlled variations of material properties, defect
profiles and other operational parameters and observe effect of these changes on
the measured signal (useful in POD calculations)
The model can be used as a reverse engineering tool for determining root cause
of complex signals
26
Nondestructive Evaluation Laboratory
Future work 2017
• Develop capability to produce array probe signals from each of
the individual array coils
• Develop EC signal simulation capability for: • Simulation of AVBs and lattice grid geometries.
• A shielded rotating 0.080” pancake coil probe
• Demonstrate use of SGTSIM for MAPOD applications
2018
• Develop EC signal simulation capability for: • Tube U-bend region
• Wear flaws and cracks in U-bend region
• Broached tube supports
• Develop SGTSIM Solver for faster performance
• Release SGTSIM Ver 5.0
27
Nondestructive Evaluation Laboratory
Thank You
Questions?
28