RED DYE PENETRANT TESTING QUALIFICATION FOR THE IN-SERVICE INSPECTION OF FRENCH NUCLEAR POWER PLANT COMPONENTS OVERVIEW OF CURRENT PRACTICES

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1 More Info at Open Access Database RED DYE PENETRANT TESTING QUALIFICATION FOR THE IN-SERVICE INSPECTION OF FRENCH NUCLEAR POWER PLANT COMPONENTS OVERVIEW OF CURRENT PRACTICES C. Caperaa, Y. Forestier, L. Quemard, EDF - CEIDRE, France M. P. Leyris, EDF - CNEPE, France Non-destructive examination (NDE) techniques applied to components of the main primary and main secondary loops of Pressurized Water Reactors (PWR) in EDF-operated Nuclear Power Plants (NPP) have to go through a formal qualification process, following the RSE-M code methodology. The conformity of the NDE is assessed by a second-party accredited qualification body. This paper gives an overview on the methodology chosen by EDF/CEIDRE in order to successfully qualify a specific red dye penetrant testing (PT) procedure, which will ultimately be used during In-Service Inspections (ISI) for crack detection. Two cases of specific qualifications (one automated and one manual NDE) for EDF NPP components are described below as examples of red dye PT qualifications. Theoretical and experimental examples are given to illustrate the different types of justification that have been used recently. Keywords: PT, coloured dye, steam generator, steam relief valve, fatigue crack, SCC, qualification, influential parameters, surface wettability, defect width, hygrometry ratio, mockup OBJECTIVE AND PRINCIPLE OF A SPECIFIC QUALIFICATION A specific qualification relates to the case where a real defect has been found in a specified area of the component. This defect: - relates to a damage mechanism that has been identified, - is generic for a given type of component, - has well-known characteristics (size, position, propagation path), obtained e.g. through (destructive) metallurgical examinations, - has potential consequences on the safety of the nuclear power plant (generally, the plant operator also carries out structural integrity studies in parallel with the NDE development). The main objective of a specific qualification is to demonstrate the ability of the NDE technique, implemented by personnel with a specified skill level, to detect indications corresponding to the targeted defect in the concerned area of the component. A specific qualification can be considered as a sum of technical and practical justifications (e.g. physical reasoning, tests on mockups ). In the case of both PT applications described in this paper, the performance demonstration was based on a notch, contained in the targeted defect. It has a well-defined geometry in terms of shape, orientation and size (length, depth, minimal and maximal width), as shown in Fig.1. Targeted defect (known geometry) Length Notch Notch contained in the targeted defect depth width Figure 1: Representation of the principle of the reference notch contained in the targeted defect 392

2 SPECIFIC QUALIFICATIONS OF RED DYE PT FOR FRENCH NUCLEAR POWER PLANTS COMPONENTS Two examples of specific situations (where a real defect was found and subsequently characterised) for components operated by EDF are described in this paper, as examples of red dye PT qualification. Case No.1 is a NDE of the partition stub / partition plate area in steam generator water boxes. The objective of this automated red dye PT is to detect stress corrosion cracks (SCC) parallel to the weld. The base metal is Inconel 600 or 690, the filler metal Inconel 182 or 152. Table 1, Figures 2 to 4, illustrates this case. Case No.2 deals with thermal fatigue cracks propagating in the hard-coated surface of main steam relief valves. In this case, manual red dye PT is performed. The description of these valves (taken from different reactor series) is presented in Table 1, Figures 5 to 7. In both cases, the PT product family designation is II-A-d, level 2 sensitivity, according to [1]. Case No.1: Stress corrosion cracking from weld in the area partition stub / partition plate from bottom end cover of steam generator tubesheet partition stub weld Case No.2: Thermal fatigue cracking in the hardcoated surface of main steam relief valves partition plate bottom end cover triple point Figure 2 : Representation of the partition stub / partition plate welded joint outer cone Figure 5 : Photograph of a main steam relief valve body step sealing surface 1 mm Figure 3 : Example of automated in-service inspection detection of a SCC crack (group indication 30 mm long) 5 mm 2 mm Figure 6 : Example of macroscopic aspect for thermal fatigue cracks 5 mm 2 mm 15 µm Figure 4 : Associated semi-elliptic notch (perpendicular to the surface) 5 µm Figure 7 : Associated rectangular notch for Stellite 25 and Inconel 82 hard-coated surface (perpendicular to the surface) Table 1: Two examples of specific situations for component operated by EDF related to red dye PT qualification 393

3 TECHNICAL JUSTIFICATIONS examples FOR A SPECIFIC QUALIFICATION General principles The purpose of the Technical Justifications is to establish the performances associated with the NDE application: 1. Sensitivity i.e. ensuring detection of the targeted defect 2. Zone coverage of the concerned area of the component 3. Localisation and sizing of indications As a rule, Technical Justifications may involve physical reasoning, experimental results (mockup trials, laboratory tests), numerical simulations, ISI feedback or a combination of these options. In the case of red dye PT qualifications, this part of the qualification process aims at studying the influential parameters related to the component, the notch characteristics (associated to the targeted defect), the red dye PT technique and the environment, as shown in Table 2. Component Notch Technique Environment Surface finishing and preliminary state Type of material and wettability Surface orientation Shadowed areas Surface temperature Profile (rectangular, semi-elliptic, trapezoidal) Minimal and maximal width Orientation with regard to the surface (propagation path) Available defect volume for penetrant retention Number of open defects sides (for example, surface-breaking or through-wall crack) Method for surface preparation Type of product family Method for penetrant application and dwell time Method for excess penetrant removal Method for developer application and development time Observation conditions (direct or remote display) In the case of an automated NDT, manipulator positioning accuracy Room temperature Hygrometry ratio Table 2: First-order influential parameters in a specific qualification for red dye PT Example No.1: «maximal width of the notch» justification A maximal detectable width of the notch has to be considered because a very wide surface-breaking crack may not be detected due to: - Over-washing of the penetrant removal during the excess penetrant removal step, - Lower capillary attraction during development step (the smaller the width, the higher the capillary rise force). For Case No. 1, an experimental trial was performed with a trapezoidal notch 5 mm long, 2 mm deep and 490 m wide, embedded into an Inconel 600 mockup. It was found that the selected level 2- sensitivity PT product family allows detection of this notch. With a conservative approach, in the case of Inconel 600, a 400 µm upper limit was adopted in terms of surface-breaking defect width. Furthermore, the technical justification for maximal detectable width in other materials than Inconel 600 was addressed in the type of material and wettability study (example 2 below). 394

4 Example No. 2: «type of material and wettability» justification Sensitivity of red dye PT highly depends on the ability of the penetrant product to spread out evenly on the examined surface and to seep into the discontinuities during the dwelling phase. Surface wettability is the physical property involved. Considering the (penetrant product, material) couple, two situations may be encountered: partial or total wetting, as described in Figure 8. Young s equation uses the surface tension between the three phases: solid, liquid and gas. The contact angle of a liquid droplet on a solid surface is related to all three surface energies LG, SG and SL, as shown in Figure 9. Based on these physical properties, the surface energy of different steels and nickel-based alloys was measured for both specific qualification cases. For case No.2, quantitative characterisations of surface wettability were performed in order to compare the real component materials (Stellite 25 and Inconel 82) to mockups with an embedded reference notch (nickel-chromium reference testblock, cf. [2]). The surface energies of these three materials were measured by Laboratoire Dubois (Switzerland) using the Owens-Wendt method. It was shown that nickel-chromium has the lowest surface energy of all three materials and thus, lower wetting properties than Stellite 25 and Inconel 82. Using this ranking information, it was concluded that if the reference notch embedded in a nickel-chromium reference testblock is associated with a PT indication, then the same reference notch would also be seen on a Stellite 25 or Inconel 82 surface (see also : example 5). gas liquid solid Figure 8: Partial wetting (left) and total wetting (right) of a liquid droplet set on a solid surface gas ɣ SG ɣ LG θc ɣ SL liquid solid Figure 9: Contact angle of a liquid droplet wetted to a solid surface Example No. 3: «hygrometry ratio» justification The hygrometry ratio in the surrounding environment, associated with the temperature of the component and of the PT products, have a combined influence on the sensitivity of the NDE. First of all, two potentially tricky situations were identified: Situation 1: High hygrometry ratios (85 à 100 % RH) and low temperatures (< 15 C). In this situation, PT classical systems could not be qualified without experimental data, because: - The presence of condensation on the surface may interfere with penetrant seepage into the defect, - Penetrant viscosity increases at lower temperatures, making penetrant seepage slower, - Developer drying time is longer. Situation 2: Low hygrometry ratios (< 20 % RH) and high temperatures (> 45 C). In this situation, PT sensitivity may also be reduced because of: 395

5 - Penetrant degradation, - Penetrant drying on the surface of the component, making excess penetrant removal more difficult, - Penetrant drying into the defect (blockage) - Penetrant capillary retention decrease (penetrant drawing out prematurely) Laboratory tests were performed in a climatic enclosure with 30 m and 50 m test cut-outs from type 1 reference blocks [2]. Based on the preceding discussion, the objective was to verify whether sensitivity level 2 from the selected product family was maintained in the hygrometry ratio/temperature combinations defined in Table 3. Climatic enclosure relative hygrometry ratio (% RH) 90% 50% 20% Climatic enclosure temperature ( C) Room temperature ( 22 C) Test No. 1 Test No. 2 Test No C Test No. 4 Not evaluated Not evaluated 45 C Not evaluated Not evaluated Test No. 5 Table 3: Combined hygrometry ratio-temperature experimental design Results of the evaluation of the percentage of discontinuities found from the type 1 reference block confirmed that level 2 sensitivity was maintained for every test. The sensitivity performance of the PT procedure is then considered as valid for: - Hygrometry ratios between 20% and 90% RH, - Temperatures between 10 C and 45 C. During the tests, it also appeared that for 90% RH and above, condensation droplets tended to form on the testblocks surface. These droplets would reappear immediately after wiping the surface with a clean, dry and lint-free cloth. This observation was used in the ISI manual PT procedure, as a practical and fast way of checking the acceptable humidity rates: After wiping, no condensation droplet should be found within the first 30 seconds. Otherwise, the actual hygrometry ratio has to be measured accurately and the value should be lower than 90%. Example No. 4: «method for products application» justification For qualification case No.1, an automated NDE is performed using the ICAR3G manipulator; the development and in-service inspection are performed by Westinghouse Electric France (WEF). The penetrant and developer products are applied with tools carrying an atomising nozzle moving horizontally (Figure 10). First, geometrical calculations were made for each type of steam generator to verify zone coverage in the vertical and horizontal directions. The PT products must be applied to a surface larger than the required examination surface of the partition stub/partition plate; figure 11 gives an example of such calculations. These theoretical considerations were then confirmed during the PT qualification trials for each new type of steam generator before the actual inspections took place. These trials include verifications for both sensitivity and zone coverage. 396

6 air tube air nozzle penetrant atomisation nozzle water nozzle penetrant tank Figure 10: ICAR3G manipulator - penetrant tool tubesheet partition stub inspected area partition plate Figure 11: ICAR3G manipulator Zone coverage calculation for penetrant product application EXPERIMENTAL JUSTIFICATIONS FOR A SPECIFIC PT QUALIFICATION General principles Using a practical approach for technical justifications is one way of demonstrating the ability of the NDE technique to retain the required performances in operational conditions representative of the ISI of a NPP component. As a consequence, in addition to the procedure contents, the NDE equipment (possibly including a manipulator) and the global environment (radiation, accessibility conditions ) must also be taken into account. Influential parameters of the real ISI that are not consistently reproduced during the trials will have to be justified by means of additional analysis. Experimental justifications are generally based on trials on mockups (open or blind testblocks). 397

7 Example No. 5: Practical Justifications for Case No. 2 For qualification case No. 2, thermal fatigue cracks were the targeted defect. Practical trials were performed using a real-size mockup of a main steam relief valve. The objective of the first trial was to check the correct application of testing products on the examined area. Figure 12 (left) shows that penetrant application is satisfactory. The second trial was a sensitivity demonstration (detection of the targeted defect using a level 2-sensitivity system). A nickel-chromium mockup (15 mm long and 5 mm wide), containing a reference crack, was positioned upon the examination area of the valve. Figure 12 (right) illustrates that the mockup crack did create a penetrant indication as expected. Finally, technical justifications were added in order to compare the characteristics of the mockup crack and of those of the reference rectangular notch for the main steam relief valve (see Table 4). PT indication Figure 12: PT trial on main steam relief valve (left) adding nickel-chromium mockup embedding a reference crack (right) Material Reference crack/notch Wettability Main steam relief valve Nickel-chromium mockup Inconel 82 and Stellite 25 presents higher wettability than nickel-chromium Worst case configuration for PT sensitivity of detection Nickel-chromium mockup Roughness Ra < 3,2 µm No difference Shape Parallelepiped No difference Orientation Perpendicular with regard to the surface No difference Length 5 mm 5,03 mm No difference Width 5 µm 4 µm Nickel-chromium mockup Depth 2 mm 30 µm Nickel-chromium mockup Type of reservoir Reservoir opened on 1 or 2 sides Reservoir opened on top + 2 lateral sides Nickel-chromium mockup Table 4: Characteristics comparison between main steam relief valve and nickel-chromium mockup Therefore, Table 4 establishes that the reference notch for the main steam relief valve should always be easier to detect than the nickel-chromium mockup crack with red dye PT. The reasons for this are: - Higher material wettability for Stellite/Inconel than nickel-chromium, - Higher defect volume (width, depth) available for penetrant retention, - Same number (or fewer) sides of the defect are surface-breaking, All of these parameters are more favorable with regard to PT sensitivity. As a conclusion, in Case No. 2, the practical trials with added technical justifications demonstrated the PT procedure s ability to detect the targeted defect in main stream relief valves. 398

8 CONCLUSIONS Two examples of EDF s approach for specific qualification of manual or automated red dye penetrant testing were presented in this paper. As a rule, a mixture of technical and practical justifications is a good compromise. This illustrates the fact that it is compulsory to understand the physical principles associated with penetrant testing, and subsequently to analyze individually the influential parameters that may influence the overall performances of the ISI. The main advantage of this kind of demonstration is that it allows for the use of a very limited number of mocks-ups, with simple reference defects, cutting down fabrication time and costs. REFERENCES 1) ISO : Non-destructive testing - Penetrant testing - Part 1: general principles 2) ISO : Non-destructive testing - Penetrant testing - Part 3: reference test blocks 3) Cahiers de la COFREND manuel de ressuage 399

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