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Simulation Model for SG Eddy Current SG Inspection ... Simulation Model for SG Eddy Current SG Inspection Saptarshi Mukherji, Anton Efremov, Pavel Roy, Portia Banerjee, Anders Rosell,

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  • 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

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  • 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

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  • 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 √ √ √ √ √ √ √ √ √

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