A CONTRIBUTION TO OUTER SURFACE CRACK HEIGHT SIZING BY PAUT

Transcription

1 A CONTRIBUTION TO OUTER SURFACE CRACK HEIGHT SIZING BY PAUT Peter Ciorau - Ontario Power Generation Pickering Canada peter.ciorau@opg.com Jerome Poguet - Imasonic - Besancon France jerome.poguet@imasonic.com Lou Pullia - Ontario Power Generation -Pickering - Canada lou.pullia@opg.com Jessica Lam - Ontario Power Generation - Pickering - Canada jessica.lam@opg.com Chris Eaton - Ontario Power Generation - Pickering - Canada chris.eaton@opg.com ABSTRACT: The paper presents four problem-solving cases for sizing the outer surface cracks for the following components of CANDU nuclear generation station: steam generator lug welds, outlet weld of steam chest valve, bleed condenser inlet nozzle weld and primary circuits piping welds mock-ups for inspection qualification. The design, manufacture and performance assessment of miniature and sub-miniature 1-D linear phased array probes of high frequency (5-12 MHz) are commented and illustrated. A novel calibration technique on EDM notches and validated on fatigue cracks with known height is commented and illustrated. PAUT data were used for return-to-service decision for ECA engineering. It was found the PAUT is undersizing by mm the real fatigue cracks and oversizing by 1 to 3 mm the implanted cracks. KEYWORDS: Fatigue crack, SCC, outer surface, welds (outlet pipe, bleed condenser, SG lugs, primary circuits piping), EDM notches, mechanical fatigue cracks, implanted cracks, 1-D LPAP, crack height sizing, ECA (Engineering Critical Assessment). PROBLEM STATEMENT Large-scale applications of PAUT on turbine components identified the needs to design, manufacture and use smaller 1-D linear array probes [ref.1] to detect and namely to size possible flaws in rotor steeple grooves and blade roots.. These probes were used for another firefighting problem-solving during the in-service inspections. During the outage QC NDT team found outer surface cracks on different components. Trying to grind was the first action, thinking the crack has a superficial height (shallow). The damage was done and after another NDT checking by liquid penetrants or fluorescent magnetic particles, the crack was still there. PAUT team was called to size the height and provide reliable number to ECA (Engineering Critical Assessment) team for a correct decision. One or two millimetre in height measurement could mean a return-to-service or an extended outage due to repair, post-heat treatment and re-checking by NDT methods. Over a 10-year period, OPG diversified the variety of miniature and subminiature probes. The problems identified during the inspection were communicated to Imasonic helping them to improve the quality of these small probes to withstand harsh field conditions and a longer usage. A large variety of small probes (about 20 types, including cable orientation) were manufactured, tested by Imasonic and field-commissioned by OPG based on in-house highstandard procedure with tight tolerances. The paper presents practical applications of these probes on four CANDU components: steam generator lug weld (lab measurements), commissioning aspect for ACFM method, outlet weld of main valve, sizing height of a SCC on inlet nozzle of bleed condenser and sizing OD implanted cracks on IQ mock-ups of ferritic steel piping welds (primary circuits). CIORAU-POGUET-PULLIA-LAM-EATON-PAUT-OD CRACK SIZING1.doc 1

2 DESIGN, MANUFACTURE AND PERFORMANCE ASSESSMENT OF MINIATURE AND SUB-MINIATURE PROBES The need to develop miniature probes was identified early in 1998 for side technique of L-1 steeple in the first 15 mm from steeple/blade face. Imasonic-Besancon-France accepted the OPG challenge and developed over a 12-year period a large variety of miniature and sub-miniature probes (see Table 1 and Figure 1). Probe ID Table 1: OPG Miniature and Sub-miniature Probes (Examples) Fc MHz Nr. elements Pitch Active x passive [ mm ] Soft/hard Remarks P x 6 hard L-waves P2B x 6 soft Shear waves P2D/2E x 6 soft Same Hypertronix P 10 A / B x 5 hard L- waves P 12A/B x 4 hard L-waves P x 6 soft Shear waves P x 3 soft Shear waves P x 5 soft Integral wedge plex.36 P x 4 soft Shear wedge P x 4 hard L-waves P x 3 soft Integral wedge 36 plex P x 3 soft Integral wedge 36 plex P71/ x 5 hard L/S waves P x 5 hard L/S waves P x 5 hard L/S waves P x 5 hard L/S waves P x 5 hard L/S waves P x 4 soft Integral wedge 32.5 plex Figure 1: Examples of miniature and sub-miniature probes. CIORAU-POGUET-PULLIA-LAM-EATON-PAUT-OD CRACK SIZING1.doc 2

3 The probes were checked according to in-house Imasonic procedures, a common designed OPG- Imasonic Procedure and OPG in-house characterization procedures. Some issues were detailed in ref.1 to ref. 6. Special measures were taken to have a good detection in surface-wave domain (75-89 deg) and a corrected calibrated depth reading in shear waves domain. Figure 2 and 3 present the NS-2 block with small SDH of 0.5 mm and calibration on TED-1 to TED-3 blocks and TOFD-1 to TOFD-3 blocks for EDM notches. After the ideal calibration, the probes were tested on blocks with fatigue cracks of known height (see example in Figure 4).. Figure 2: Location of 0.5 mm-sdh on NS-2 block for angle, index, and depth calibration. Figure 3: Examples of depth reading of 1-mm (right) and 2-mm (left) EDM notches. Figure 4: Examples of crack height evaluation with probe P72-60T ; Undersizing by 0.2 mm. Crack tilt angle is also displayed (specular-left; diffracted-right). CIORAU-POGUET-PULLIA-LAM-EATON-PAUT-OD CRACK SIZING1.doc 3

4 FIELD EXAMPLES OUTLET PIPE of MAIN VALVE Crack in Excavation Figure 5 illustrates the crack sizing and plotting into 3-D. Detection was performed by probe 52-60T (special round and contour wedge). Crack was removed. Figure 5: See text above. STRESS CORROSION CRACK on INLET NOZZLE WELD-BLEED CONDENSER. The crack was found on the inlet nozzle weld (see Figure 6). During the inspection, it was found the crack height < 3 mm using a correction curve (see Figure 7). Crack was not repair, saving station 3 days outage time. Figure 6: Location of SCC and principle of height sizing by a sub-miniature probe. CIORAU-POGUET-PULLIA-LAM-EATON-PAUT-OD CRACK SIZING1.doc 4

5 Figure 7: Correlation between PAUT value and crack height (right), and an example of crack closure tip (undersizing by PAUT by 0.4 mm). SG LUG WELDS-CRACK SIZING ON MOCK-UPS (LAB) Toe cracks were found on fillet welds of SG Lugs. Two reference blocks were made with 7 implanted cracks on each block of known height and length (see Table 2 and Figure 8). The crack shape was a rectangular one. ACFM method was used for capability demonstration. It was required by ECA to size cracks with height > 1 mm. Table 2: Dimensions of implanted cracks in two reference blocks of SG Lug Welds. Figure 8: Reference blocks T4077 and T 4078 with 14 implanted cracks. CIORAU-POGUET-PULLIA-LAM-EATON-PAUT-OD CRACK SIZING1.doc 5

6 It was found the ACFM was reading a larger length and larger height versus the design and QC documented value of implanted crack. PAUT was asked to check and confirm the crack height and length. It was found the implant gauging changed the microstructure and local magnetic permeability (see Figure 9-as an example), which might explain the length oversizing by a factor of 2-3. The height of implanted cracks was found larger than design requirements (see Figure 10). Figure 9: Additional indications around the implanted cracks nr. 5 and nr. 6 T4078. Figure 10: Correlation between PAUT and implanted crack height (left); example of crack height sizing (design = 1.8 mm; PAUT=2.3 mm). IQ PIPING MOCK-UPS OUTER SURFACE CRACKS (LAB) Outer surface cracks (see Figure 11 for some examples) were implanted either in HAZ or at t/2 distance from the weld. Some of the cracks were tilt 12.5 or 37.5 and skewed by PAUT measured the crack height in direct hit, either with crack under the probe wedge (short cracks) or with the crack in front of the probe (see Figure 12). CIORAU-POGUET-PULLIA-LAM-EATON-PAUT-OD CRACK SIZING1.doc 6

7 Figure 11: Examples of outer surface cracks on IQ piping mock-ups. Figure 12: Example of crack height sizing (h PAUT = 6.3 mm; h design = 5 mm / 12.5 in HAZ) with crack under the wedge. Scanning performed from pipe side. PAUT found the implanted cracks have a height larger than required and QC documented. The height is increasing with crack height/length and with the challenge of skewing the crack. The tolerances are within acceptable limits. Some examples are presented in Figure 13. Figure 13: Examples of IQ cracks sizing by PAUT (OD surface breaking); left 7-mm crack sized as 8.2 mm; right; 1.5-mm crack sized as 1.9 by PAUT. CIORAU-POGUET-PULLIA-LAM-EATON-PAUT-OD CRACK SIZING1.doc 7

8 CONCLUDED REMARKS Examples given in this paper concluded: PAUT could reliable size cracks under the probe if the crack height is greater than 1.5 mm. PAUT is undersizing fatigue cracks by mm. A safety factor of 1 mm for field applications will provide a more conservative approach to ECA. Implanted cracks are oversized; we don t know the reality, unless a mock-up will be destroyed and machined in fine steps or cut in slices by wire EDM. Miniature and sub-miniature probes could size the crack height in excavation, closer to fillet weld and on the nozzle weld with good repeatability. Imasonic probes provided high performance and over a 2-year interval [ ] reproducible results on IQ OD cracks. PAUT results were used for ECA in real life (bleed condenser, outlet pipe weld) as well as in feasibility study for SG Lug crack sizing. Implanting cracks on outer surface is not quite under control. Additional micro-porosity and slag are detected by PAUT. Magnetic properties are changed, which may influence the ACFM performance. Crack opening on OD is quite large ( mm) and visible on the pipe surface (see Figure 11). REFERENCES 1. OlympusNDT: Advances in Phased Array Ultrasonic Applications, chapter Miniature and Subminiature Probes, Waltham, USA, Aug Poguet,J., Ciorau, P.: Reproducibility and Reliability of NDT phased array probes 16-th WCNDT, Montreal, Aug 30-Sept.03, 2004., NDT.net Ciorau,P., Pullia,L., Poguet, J.: A Contribution to Repeatability of 1-D Linear Array Probes Used on Large-Scale Inspection of Low-Pressure Turbine Components NDT.net, vol.11, no.10 (Oct.2006) 4. Ciorau,P., Pullia,L., Poguet, J.: Linear Phased Array Probes and Inspection Results on Siemens-Parson Turbine Blades - 4-th PA seminar-epri-miami Dec 2005, NDT.net Fleury,G., Poguet,J., Ciorau, P.: A Practical Proposal for Designing, Testing and Certification Phased Array Probes Used in Nuclear Applications. 4-th Int. NDE Conf. Nuclear, London, Dec, 2004, NDT.net, ACKNOWLEDGEMENT: 1. The authors wish to thank OPG-IMS Management for granting the publication of this paper. 2. One of the author (P. Ciorau) wish to thank the following people: Wence Daks and Howard Smith-CADWIRE for 3-D drawings, Steve Hiroz, Jim Newsome, Steve Walling and Derek Roy-OPG IMS PAUT technicians for their contribution (PAUT, MP, photos) to this project. CIORAU-POGUET-PULLIA-LAM-EATON-PAUT-OD CRACK SIZING1.doc 8