Center for Nondestructive Evaluation

Transcription

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6 U.S. Nuclear Industry Capacity Factors , Percent

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8 Date (yea ar) Vibration fatigue TP304 IGSCC Corr.- fatigue Erosioncorr. MIC TP347 IGSCC PWSCC

9 Flow Accelerated Corrosion Stress Corrosion Cracking 21.4% 32.5% Vibration Fatigue (incl. Fretting) 18.7% Corrosion (Crevice, MIC, Pitting) 14.8% Design & Construction 6.5% Thermal Fatigue Erosion-Cavitation Over-stressed / Over-pressurized Water Hammer Human Error Unreported Corrosion Fatigue Severe Weather (Freezing) 1.5% 1.4% 0.8% 08% 0.8% 0.7% 0.4% 0.3% 0.1% 5164 reported failures 0% 5% 10% 15% 20% 25% 30% 35%

10 Aging US nuclear fleet will continue to operate beyond the initial design life from 40 to 60 years and eventually to 80+ years Need capacity factor 90%+ for economics and maintain safety Deploy monitoring avoid surprises and the unknown!

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12 Available Research Window Supporting Utility and Regulator Plant Life Extension Decisions ( ) Financial Markets / PSC / PUC Influences on Stock Pricing, Rates of Return, Capital Recovery and Utility Valuation Utility Action: First Actionable Date of Utility Submission for 20 Year Life Extension Utility Action: First Publically Discussed Date of Utility Submission for 20 Year Life Extension Key Utility Action: Create Plant License Extension NRC Submittal Key Utility Decision: Build new generation vs. extension of existing nuclear plant lifetimes Consequences Path New Generating Plant Licensing, Construction and Startup Activities 2020 Utility Decision Consequences: Industry- Wide Loss of Clean Power Generation from 25% of Existing Nuclear Plants With 20 Year Life Extension Start of Industry / DOE / NRC Collaborative Research Programs Prioritized to Importance and Duration Prior Research Integration Life Extension Research Programs: Materials Aging and Degradation Advanced Inspection and Evaluation Alternate Cooling Technologies Concrete and Structural Aging Plant Component Aging Key Utility Decision : Risk & Cost / Benefit Analyses Consequences Path Consequen nces Path Initial Loss of Clean Power Generation from Existing Nuclear Plants With 20 Year Life Extension Power Generation Basis: Upgraded Existing Fleet; New Nuclear Plants; New Coal Plants Alternative Energy Sources 2040 Future Power Generation Applications Pathway to Utility Actions and Decisions NRC Regulatory Requirements re: Confirmatory Research on Aging (Public Health and Safety Oversight) 2020 Utility Decision Consequences Extending Years: Power Sourcing Reliability; Long Term Environmental Influences; Consumer Economics; Utility Financial Standing NRC Regulatory Oversight of Existing Nuclear Plants, New Construction, and Legacy Sites 4/1/2008 *US NRC Amy Hull

13 IEEE Spectrum August 2012

14 Nuclear Power Plant Systems

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16 Goal is to proactively address potential future degradation in operating plants to avoid failures and to maintain integrity, operability and safety Damage Reactive Proactive actions Structural Integrity Limit NDE Resolution Limit Now Time Move beyond philosophy of Find and Fix : Finding damage at an outage is expensive longer outages more inspection

17 TIME On-line monitoring sensors provide data as a function of time at discrete locations NDE provides data as a function of location at discrete times SPACE

18 On-Line Monitoring (OLM) Data Monitoring and Detection Is there an anomaly or fault? Diagnostics What is the fault or degradation? Prognostics What is the Remaining Useful Life (RUL)? Risk Mitigation How can the effects of degradation be mitigated? Diagnostics and Prognostics (D/P) *Baldwin et al., 2010

19 Which are the potential critical Systems, Structures and Components that can significantly impact the cost, schedule and ultimate viability of fthe LTO? Significant ifi Impact?

20 Significant Impact? *Of Burns and Roe

21 Crack Length Crack Length I Development of crack nucleation sites II Corrosion Research Development of crack precursors Units of Time (or Fraction of Life) Development and linkage of small cracks III Units of Time (or Fraction of Life) Issue Programs IV Growth of large cracks Detection Limit Cost

22 IAEA Proceedings Series (2005)

23 fatigue precrack SCC region

24 NDT detection limit

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27 Source: Shah VN and CJ Hookham "Long-term Aging of Light Water Reactor Concrete Containments. " Nuclear Engineeing and Design 185:51-81.

28 IAEA Assessment and Management of Ageing of Major Nuclear Power Plant Components Important to Safety: In-containment Instrumentation and Control Cables. IAEA- TECDOC-1188, International Atomic Energy Agency, Vienna, Austria EPRI. 2010a. Plant Support Engineering: Aging Management Program Development guidance for AC and DC Low-Voltage Power Cable Systems for Nuclear Power Plants. EPRI , Electric Power Research Institute, Charlotte, North Carolina. EPRI. 2010b. Plant Support Engineering: Aging Management Program Guidance for Medium- Voltage Cable Systems for Nuclear Power Plants. EPRI , Electric Power Research Institute, Charlotte, North Carolina. Source: Fantoni P Cable Aging Assessment and Condition Monitoring in Nuclear Power Plants. Presented at June 10, 2010, Seattle, WA

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30 Common Degradation Mechanisms Unacceptable Degradation Unacceptable Degradation Unacceptable Degradation Stabilizes at an unacceptable level Degradation Degradation Degradation Stabilizes at an acceptable level Level of Level of Crack Propagation Level of Early Trend Line Initiation Time Crack Propagation Initiation Time Early Rapid Loss of FR Slower Loss of FR With Possible Stabilization Time Time Time Fatigue Cracking Stress Corrosion Reduction in Cracking Fracture Toughness

31 Visual Testing Source: M.T. Anderson, S.E. Cumblidge, and S.R. Doctor, An Assessment of Remote Visual Testing System Capability for the Detection of Service Induced d Cracking, Back to Basics, The American Society for Nondestructive Testing, Columbus, Ohio, September Magnetic Particle Testing Source: Basic Principles, Iowa State University, Ames, Iowa ( e/magparticle/indications/dryexamples.htm).

32 Half Cell Potential Source: stemsubstructure/231directmeasurementmethods.htm htm Indenter Modulus Source: Fantoni P Cable Aging Assessment and Condition Monitoring in Nuclear Power Plants. Presented at June 10, 2010, Seattle, WA

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39 Proc. of SPIE Vol (2011)

40 System used in Limerick Unit 1 demonstration Present day system

41 Guided dw Wave Ultrasonics Acoustic Emission

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45 Becker et al. (2003), Amplitu ude (Volt) Time ( s) Weaver & Sachse (1995) 15 wt% showed that experimentally measured ultrasonic waves in cement can be interpreted using diffusion theory Amp FFT Amp Amp Frequency 0.06 e (A.U.) Amplitude M Hz Energy = 15 wt% Q -1 = /(2 = s -1 f = fre q u e 3 mm Glass Beads and Water inside the Styrofoam Test Cell Tim e ( s) Panetta et al. 2005

46 Amplitud de (volts) Time (us) PNNL experiment Data from Weaver & Sachse (1995) Frequency Separation Diffusivity i it (mm^2/us) Dissipation i (1/ms) Diffusivity (mm^2/us) Dissipation (1/ms) (khz) (mm) Diffusivity 95% Lower Bound 95% Upper Bound Dissipation 95% Lower Bound 95% Upper Bound / / / / / / / / / / 0.9

47 * P Ramuhalli et al (2010)

48 n x0 m y0 n x m y E x, y, t 1 4 cos cos cos cos e n1 m 1 l p l p n 2 n x D t 0 n x l 2cos cos e n 1 l l m 2cos 1 2 D m t m y 0 m y p cos e E0 p p e t D 2 n m 2 l p t

49 Curve Fit (2.2 MHz) Curve Fit (log-scale) (2.2 MHz)

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51 Stressor Estimates for k>j

52 Failure Density Measurements Accumulated operating time (fraction of life)

53 Actual System State (unknown) Measurement at time step 20 System State Monte Carlo Estimates Time Step

54 Assessment of State of Maturity for Diagnostic [D] and Prognostic [P] Technologies (adapted from (Howard 2005) Bond et al (2012))

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