Research and Development on NDE field

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1 VTT TECHNICAL RESEARCH CENTRE OF FINLAND LTD Research and Development on NDE field IAEA Technical Meeting on the Optimization of Non-Destructive Examination and In-Service Inspection to Improve Nuclear Power Plant Performance Ari Koskinen Technical Research Centre of Finland Ltd.

2 NDE possibilities at VTT Qualified NDE technology Ultrasonic and eddy current technology Mechanised ultrasonic inspections Analysing methods Qualification of NDE Simulation (UT and ET) Focus on UT/ET development for demanding components, analysis and risk based inspection Evaluation of condition using non-destructive evaluation 2

3 Ongoing project examples Program to Assess Reliability of Emerging Non-destructive Techniques for Dissimilar Metal Welds PARENT SAFIR2018 The Finnish Research Programme on Nuclear Power Plant Safety Development of NDE for the nuclear waste disposal canisters LNPP inspection development (ET)

4 SAFIR2018, WANDA NDE of NPP primary circuit components and concrete infrastructure WANDA WP 1 NDE on NPP primary circuit component materials WP 2 NDE of NPP concrete infrastructure Task 1 Artificial defects for primary circuits Task 2 NDE simulation Task 3 SG magnetite detection Task 4 NDE of DMWs Task 1&2 NDT methods for NPP RCS & mockup Task 3 NDE & RCS durability performance Task 4 Evaluation and calibration of monitoring sensor & systems Task 5 Performancebased design & control of concrete durability

5 NDE on primary circuit components - Piping butt weld test block 5

6 Fatigue cracks in austenitic butt weld A tubular austenitic steel specimen with butt weld Mechanical fatigue and Thermal fatigue cracks in fusion line of cooling line welding Different phased array ultrasonic techniques. Scanning also on the healthy weld Differences in reflector properties on indications, gain the information from different defects

7 Austenitic Stainless Steel weld US and POD 7

8 Austenitic weld inspection with US AISI 316L stainless steel weld with machined EDM-notches Used methods: 2,25 and 5 MHz linear phased array Conventional ultrasonic inspection probes 45 and 60 1,5 MHz 2D matrix phased array with skew angle 15 Simulation with 2,25 MHz phased array Evaluate how the weld affects the amplitude response from the different locations of the weld

9 Defects 4a 3a 2a 1a 4b 3b 2b 1b

10 2,25 MHz POD curve depending on the location

11 Magnetite Probe Steel tube Eddy Current modelling on SG Magnetite with CIVA and COMSOL 11

12 CIVA and COMSOL ET modelling - amplitudes Simulation of eddy current magnetite pile detection with a simple case symmetric magnetite pile around the tube Goal is to model a novel probe to detect the existence of the magnetite pile, also asymmetric cases Receiving and transmitting coils h=1.5 mm and N=70 turns

13 CIVA and COMSOL modelling -Total amplitude and phase angle Coil distance 20 mm. Coil distance 40 mm. Transmitting coil height 1.5 mm, turns 70 Receiving coil height 8 mm turns Magnetite layer thickness 3mm, ends in slope 13

14 NDE on NPP concrete infrastructure 14

15 NDE Research on Reinforced NPP Concrete Structures NDT methods for RCS Sensors & monitoring approaches for RCS Reinforced concrete full scale wall mockup Define the scope of the NDE mock-up study in geometry, concrete characteristics, reinforcement, NDE NPP Reinforced Concrete Structures presents challenges Large wall cross section (e.g. > 1.0 m) Increased reinforcement density with complex detailing Limited accessibility due to presence of liners or other components

16 NDE of steel cladded concrete beams Determining capability to asses condition of structural typology

17 NUGENIA+ project MAPAID Goal to model and validate phased array ultrasonic testing (PAUT) techniques for Non Destructive Evaluation (NDE) of dissimilar metal welds (DMW) of nuclear power plants (NPP) Bay Zoltán Nonprofit Ltd. for Applied Research, Hungary Commissariat à l Energie Atomique et aux Energies Alternatives, France ÚJV Řež, a.s., Czech Rep. VTT Technical Research Centre of Finland Ltd., Finland Including participation in international PARENT-project

18 Our approach in model assisted NDE 1. Crack simulations 3. Verification of simulation 2. Measurement of fatigue cracks 5. Series of simulations with variation in size 4. Knowledge of crack parameter variation 7. Realistic POD - curve 6. Statistical models

19 Measurements 1. Crack simulations 2. Measurement of fatigue cracks 3. Verification of simulation 5. Series of simulations with variation in size 4. Knowledge of crack parameter variation 6. Statistical models 7. Realistic POD&ROC - curve UT-measurement done at VTT CT-measurement from BAM Animation done at VTT

20 Simulations 1. Crack simulations 2. Measurement of fatigue cracks 3. Verification of simulation 5. Series of simulations with variation in size 4. Knowledge of crack parameter variation 6. Statistical models 7. Realistic POD&ROC - curve

21 Verification Needs still more work Weld 1. Crack simulations 2. Measurement of fatigue cracks Flaw position 3. Verification of simulation 5. Series of simulations with variation in size 4. Knowledge of crack parameter variation 6. Statistical models 7. Realistic POD&ROC - curve However, the results are promising

22 Crack parameters Swedish Nuclear Power Inspectorate (SKI) has done studies in order to determine typical cracks that have been observed in different plants (nuclear and non-nuclear) 229 flaws 7 types IGSCC TGSCC Solidification Fatigue 18 parameters Skew Tilt Roughness Opening Crack simulations 2. Measurement of fatigue cracks 3. Verification of simulation 5. Series of simulations with variation in size 4. Knowledge of crack parameter variation 6. Statistical models 7. Realistic POD&ROC - curve

23 POD curves 1. Crack simulations 2. Measurement of fatigue cracks 3. Verification of simulation 5. Series of simulations with variation in size 4. Knowledge of crack parameter variation 6. Statistical models 7. Realistic POD&ROC - curve How to verify these?

24 Finnish concept of nuclear waste disposal Based on deep geological storage Depth approximately 400 m Welded and inspected in encapsulation plant located above the repository Reliable NDT essential before the final disposal Posiva Oy

25 Disposal canister Oxygen free copper overpack for corrosion resistance Thickness 50 mm Welding with EBW or FSW Nodular cast iron insert for mechanical strenght Three types Posiva Oy

26 Non-destructive methods Visual testing (VT) All the components and welds Eddy current testing (ET) Copper overpack, lid and weld Ultrasonic testing (UT) All the components and welds Radiographic testing (RT) Welds

27 Visual testing (VT) Purpose to verify, document and evaluate the surface area Weld & upper part of the lid remotely Indications above the reporting level Location Dimension Defect type

28 Eddy current testing (ET) Surface inspection method Combination of low and high frequency measurements Lower frequency, better depth of penetration Higher frequency, better resolution Overpack, lid and especially weld

29 Ultrasonic testing (UT) For all the components Mechanised Mainly phased array UT Also conventional UT for insert Large variations in grain size (copper) can also be detected Weld the most critical area to inspect

30 Ultrasonic testing (UT) Cast iron insert Inspection from outer surface Steel channel edge location Channel distortion Different focus depths for certain areas Near surface area Transmission technique for defects between the channels

31 Radiographic testing (RT) For disposal canister welds 9 MeV linear accelerator Digital x-ray detector 10 degree angle used While inspection canister is rotated 100% of the weld, heat affected zone and 10 mm of the base material (both sides) inspected Image quality indicator placed on the detector side surface to verify the quality

32 Case examples 32

33 Ultrasonic inspection examples Composites i.e. Airbus 380, Hornet, Hawk, HN-90 Helicopter Scanning acoustic microscope (SAM) Coatings Dissimilar metal welds Strain measurements IRIS-inspections

34 Ultrasonic inspection examples

35 Eddy current inspection examples Heat-exchanger testing Turbines Surface inspections Copper canister Coating measurements Demanding geometries

36 Eddy current inspection development on thread Very good sensitivity Probes manufactured for each case Fast inspection method Applicable for metallic materials

37 Ultrasound (µm) 350 Elongation measurements on bolts (UT) Ultrasound = Elongation measured using UT Micrometer = Elongation measured using micrometer Error = SD of three measurements L1-L0 L2-L0 L3-L0 X = Y Micrometer (µm) L0 = original length L1 = length after tightening L2 = L1 + 24h L3 = length after removal

38 Example NDT/DT NDT Phased Array ultrasonic Conventional ultrasonic Computed tomography (Digital radiography) (Eddy Current) (Scanning Acoustic Microscopy) DT Scanning Electron Microscope Surface and fracture surface Stereo microscope 3D profilometry Cross-section investigation Optical Microscope MF crack

39 Destructive testing Sample Length (mm) Height (mm) Length /height MF A MF B TF

40 Ultrasonic Inspections Conventional ultrasound Phased array ultrasonic methods influence of different reflector properties on indications

41 Mechanical fatigue crack

42 Tomographic x-ray imaging

43 TECHNOLOGY FOR BUSINESS

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