Acoustic emission monitoring of ZB-1 intermediate scale vessel test

A program to develop the use of acoustic emission (AE) flaw detection methods for continuous surveillance of reactor pressure boundaries is in process in the United States. Evaluation of laboratory developed relationships for data verification and interpretation was performed by participation in a German intermediate scale vessel (ZB-1) test. The test sequence consisted of repeated blocks of a hydrostatic test followed by two sets of cyclic loading at different R-ratios. Testing was performed in cooperation with the German Materialprüfungsanstalt at the Grosskraftwerk facility in Mannheim, West Germany. This paper discusses preliminary results obtained during the first half of the test which was performed at 70°C. The AE system detected crack growth from machined flaws and also spontaneous crack growth in a fabrication weld. AE signals from cracking were consistently high amplitude and occurred at or near peak load. Crack growth rates estimated from AE data were consistent with values derived from crackopening-displacement gauges. The test produced unique and important data needed to develop reliable application of AE methods for continuous monitoring of reactor pressure systems.     

An assessment of acoustic emission for nuclear pressure vessel monitoring

Recent research has greatly improved our understanding of the basic mechanisms of deformation and fracture that generate detectable acoustic emission signals in structural steels. A critical review of the application of acoustic emission (AE) to the fabrication, proof testing and in-service monitoring of nuclear pressure vessels is presented in the light of this improved understanding. The detectability of deformation and fracture processes in pressure vessel steels is discussed, and recommendations made for improving source location accuracy and the development of quantitative source assessment techniques.

Published data suggest that AE can make an important contribution to weld fabrication monitoring, and to the detection of defects in lower toughness materials during vessel proof testing. In high toughness materials, however, the signals generated during ductile crack growth may frequently be too weak for reliable detection. The feasibility of AE for continuous monitoring has not yet been adequately demonstrated because of high background noise levels and uncertainty about AE signal strengths from the defect growth processes that occur in service. In-service leak detection by AE shows considerable promise.

It is recommended that further tests are carried out with realistic defects, and under realistic conditions of loading (including thermal shock and fatigue) and of environment.     

Intermediate size pressure vessel programme (ZB 1)

One of the focal points in the discussion about the safety of nuclear power plants is the integrity of the reactor pressure vessel.In order to prove its integrity tests are in progress in an underground test facility of the main power station in Mannheim with an intermediate size vessel from the research programme “Integrity of Components”. Patches of A 533 B and modified A 508 B material were welded into the vessel ZB 1, the test temperatures are approximately 70 and 290°C. The main goal of the tests is to measure the behaviour of artificial and natural flaws during static hydrotests and simulated operational (cyclic) conditions.In the first half of the research programme the objective is to produce a crack growth of some centimetres by cyclic loading between a variable minimum pressure and a maximum pressure of about 24 MPa. The total number of load cycles will be approximately 30 000.In the second half of the tests the vessel will be loaded by a number of pressure cycles which correspond to the loading a reactor pressure vessel experiences during 40 years of operation.During the static and cyclic loading acoustic emission monitoring is being made by German and American laboratories.This paper presents details of the vessel, the test loop, results of the nondestructive examinations conducted to quantify the crack depths and results of the acoustic emission monitoring.     

Experimental study on the application of acoustic emission during the hydraulic pressurization of a reactor pressure vessel

The investigations were aimed at demonstrating the state of the art of acoustic emission testing (AET) of reactor pressure vessels. The object under investigation was the large reactor pressure vessel of the MPA in Stuttgart, a boiling-water reactor pressure vessel, which was provided with a multitude of flaws in weld seams and in the base material. Six hydrostatic tests approximately up to the working pressure of a boiling-water reactor (71 bar) were carried out. In addition to the global multichannel locating technique, also local monitoring techniques were applied. Global location permitted a large number of different indications to be detected simultaneously. Not all of the known flaws did, however, show the expected number of AE events. On the other hand, it was possible to detect flaws previously unknown to the AE staff in some weld seams; these indications were confirmed by nondestructive testing. It was demonstrated that the locating accuracy of local monitoring using signal analysis was improved by a factor of 20 to 30 compared to global monitoring.     

Experience with the dismantling of three secondary steam generators in unit A in Gundremmingen by the ‘ice-sawing’ technique

The unit A in Gundremmingen (KRB A), was the first commercial nuclear power plant in Germany. It had an electrical power of 250 MW_e and was in operation from 1966–1977. The plant was equipped with a dual cycle boiling water reactor of a former General Electric design and includes three recirculation lines each with a big recirculation pump and a steam generator comparable with those of pressurized water reactors. Therefore dismantling experience is gained for systems and components of boiling water reactors as well as pressurized water reactors.

In early 1980, it was decided to decommission the plant. Actual decommissioning work started in 1983 with the removal of the components and systems in the turbine house. Since 1990 the decommissioning activities have been expanded to all primary water systems inside the reactor building. In 1992 , KRB A obtained a licence for dismantling the remaining activated components like the reactor pressure vessel and the biological shield.

Meanwhile more than 5200 tons of contaminated components have been dismantled. Special cutting and handling tools were tested, developed and optimized for the purpose of working in radiation fields and under water. The dismantling work of the contaminated systems and components ends up in about 6000 tons of material with a rather low amount of waste, especially due to optimized decontamination techniques Eickelpasch et al. (1992). For the dismantling of the three secondary steam generators in the reactor building the ‘ice-sawing’ technique was developed and patented.     

Operating performance and reliability of CANDU PHWR fuel channels in canada

CANDU nuclear plants use many, small-diameter high-pressure fuel channels unlike PWR nuclear plants which have a single, large pressure vessel. Good operating performance from the CANDU fuel channels has made a major contribution to the world-leading operating record of the CANDU nuclear power plants. As of 1982 December 31, there were 7,480 fuel channels installed in 18 CANDU reactors over 500 MW(e) in size. Eight of these reactors have been declared in-service and have accumulated 24,000 fuel channel-years of operation. The only significant operating problems with fuel channels have been the occurrence of leaking cracks in 70 fuel channels and a larger amount of axial creep on the early reactors than was originally provided for in the design. Both of these problems have been corrected on all CANDU reactors built since the Bruce GS ‘A’ station and the newer reactors should exhibit even better performance.     

核电厂中流固耦合现象数值模拟研究综述

流固耦合现象在核电厂中广泛存在，该现象引起的结构动力学问题对核电厂结构完整性和安全性有重要影响。目前，国内外对核电厂中流固耦合现象的研究给予越来越多的关注。本文介绍华北电力大学在该方面的一些研究进展，例如，快堆燃料组件抗震分析新的流体附加质量计算方法研究；蒸汽发生器换热管双管漩涡脱落的数值模拟；一个先进堆燃料组件平行板上流动引起的漩涡脱落数值模拟；由地震引起的自由表面对快堆主容器冲击现象的研究；移动粒子法求解液面晃动及晃动引起离散现象的研究等。     

Vibration- and pressure signals as sources of information for an on-line vibration monitoring system in PWR power plants

Higher demands with regard to the safety and reliability of reactor primary components require methods to get an idea of the mechanical state of the plant at any time during operation and to recognize failures already in their developing phase. Reactor vibration monitoring systems are being developed which are based on the analysis of vibration signals, neutron noise and pressure fluctuation signals. The special role vibration and pressure signals can play in such a system is investigated by the analysis of extensive preoperational tests at different PWRs. The theoretical foundation for the application of these signals to vibration monitoring are developed in the special case of the Stade nuclear power plant. The pressure vessel of this reactor performs pendular and verical vibrations. They are excited mainly by pressure fluctuations generated by the coolant flow, by standing waves, or by the revolution of the coolant pumps.

For interpreting the spectra measured during the preoperational test and during power operation and for clearing up changes of these spectra, which will signalise incipient failures, model investigations are of predominant importance. Two mechanical models, a pendular and a vertical one, simulate the two kinds of vibration sufficiently which can be seen in comparing the calculated frequency response with the measured vibrations.     

Repair and replacement of reactor internals for plant life extension

Recent experience from early Swedish BWRs corroborate that all components in a nuclear power plant can be repaired or replaced with new ones. Oskarshamn 1 has gone through a thorough refurbishment project. A number of internals were repaired or replaced including the core shroud support which was welded to the bottom of the reactor pressure vessel. The project verifies that it is fully possible to carry out complicated inspection and repair work inside a nuclear pressure vessel which has been in operation for more than 20 years. Along with increased capacity factor, operating nuclear power plants get the financial conditions needed for extensive repair and modernization projects. Large power output leads to short pay-back times for the investments. The FENIX project at Oskarshamn 1 is such a project. There are utilities whose policy is to keep their plants in as-new condition for an unlimited length of time.     

Risk assessment in setting inservice inspection priorities at light water reactors

As part of the Nondestructive Evaluation Reliability Program, sponsored by the U.S. Nuclear Regulatory Commission, Pacific Northwest Laboratory is developing a method that uses risk-based approaches to establish inservice inspection plans for nuclear power plant components. The method first uses probabilistic risk assessment (PRA) results and Failure Modes and Effects Analysis (FEMA) techniques to identify and prioritize the most risk-important systems and components for inspection. The acceptable level of risk from structural failure for important systems and components is then apportioned as a small fraction of the total PRA estimated risk for core damage. This process determines the target (acceptable) risk and failure probability values for individual components. The Surry Unit 1 Nuclear Power Station was selected for pilot applications of the method. The specific systems addressed are the reactor pressure vessel, the reactor coolant, the low-pressure injection, and the auxiliary feedwater. The results provide a risk-based ranking of components within these systems and relate the target risk to target failure probability values for individual components. These results will be used to guide the development of improved inspection plans for nuclear power plants.     

New generation of monitoring systems with on-line diagnostics

For more than 15 years, systems for monitoring the integrity of the primary system and for the diagnosis of nuclear power plant components have been manufactured by Siemens (KWU). These systems record the vibrational behaviour of reactors and their internals and of principal components of the primary system (SÜS), indicate the presence of loose parts or parts that have become detached within the pressure boundary of the primary system (KÜS), detect and locate leaks in piping, tanks and vessels (ALÜS, FLÜS), and evaluate the fatigue of nuclear power plant components as a result of the pressure and thermal stresses to which they are subjected (FAMOS).     

Plant life management activities of LWR plants in Japan

Plant life management activities of Japanese LWR plants have been conducted since the early 1990s by the utilities and MITI (Ministry of International Trade and Industry) cooperatively. In Japan, where the regulatory practices are different from those in the US, there is neither law nor regulation that prescribes a licensed plant life for nuclear power plants. When an annual inspection is completed without any problem, the next cycle of operation would be permitted and this cycle can be repeated. However, it is generally known that mechanical components and structures deteriorate as they get older. So, we consider it very important to evaluate the long-term integrity of major systems, structures and components of old nuclear power plants. Japanese plant life management study consists of two parts. Both parts of the study were carried out confirming the integrity for the long-term operation of the three oldest Japanese LWR plants: Tsuruga Power Station Unit No.1 (BWR), Mihama Power Station Unit No.1 (PWR) and Fukushima Dai-ichi Nuclear Power Station Unit No.1 (BWR). The Part 1 study was conducted for the purpose of obtaining an outlook for long-term safety operation and was completed in 1996. The Part 2 study was conducted ensuring the plant integrity for the long-term operation in terms of, not only safety, but also reliability. The results of the Part 2 study were made public in February, 1999. Then, the recommended maintenance items were to be added to the existing maintenance programs of the three LWR plants.     

Application of high strength MnMoNi steel to pressure vessels for nuclear power plant

Recent increase in output of nuclear power plant has been attained by enlargement of major components such as pressure vessels. Such large components have almost reached a size limit from the points of manufacturing capacity and cost in both forgemasters and fabricaters. In order to solve this problem, it must be beneficial to apply design by use of material of higher strength, which brings reduction of pressure vessel thickness and weight. The Japan Steel Works Ltd. (JSW) has many manufacturing experiences of large integrated forgings made from high strength MnMoNi steel with tensile strength level of 620 MPa for steam generator (SG) pressure vessel, and has performed confirmation tests of its material properties. This paper describes the confirmation test results such as tensile and impact properties, nil-ductility transition temperature (NDT-T), static and dynamic fracture toughness, weldability including under-clad cracking (UCC) sensitivity, as well as metallurgical factors which influence on such material properties.     

Methods for leak detection for KWU pressurized and boiling water reactors

Leakage monitoring is an essential criterion to rule out the possibility of double ended pipe rupture in the primary coolant system. Subcritical cracks can be detecred with a considerable margin before they extend to critical crack lengths resulting in spontaneous failure. In those KWU PWRs which went into operation recently, a Leakage Monitoring System was installed that is based on thermodynamic analysis. It utilizes the following measured parameters: dew point temperature, accumulated condensate inside aircoolers, air temperature, sump water level, gully monitoring. In KWU's BWRs, although the measurement concept has to be slightly changed because of a different design of buildings and components, the same instrumentation will be used. Besides this installed monitoring system, different approaches like acoustic leak detection systems or the application of moisture sensitive instrumentation have been considered. Both systems have been successfully tested.     

Evolution in the design and development of the in-service inspection device for the Indian 500 MWe Fast Breeder Reactor

In-service inspection (ISI) plays a major role in monitoring the condition of nuclear power plant structures and components. Based on the information gathered during inspection and the studies carried out, it is possible to assess the extent of damage and take corrective measures to keep effects of ageing under control. In nuclear power plants comprehensive ISI is dictated by issues of increased safety to personnel and equipment, and efficiently enhances the plant life. A special emphasis has been laid on the development of robotic devices for the ISI of the indigenous Indian 500 MWe Prototype Fast Breeder Reactor (FBR) components. This paper traces the experiments and simulations in the key developments of a robotic device, for the ISI of main vessel and safety vessel of FBRs, carried out at Indira Gandhi Centre for Atomic Research, India.     

Proactive approaches to assure the structural integrity of Boiling Water Reactor components

Pressure vessel components in operating Boiling Water Reactor (BWR) plants are subjected to a variety of loading and environmental conditions which could lead to degradation over time. The significant damage mechanisms such as fatigue, stress corrosion cracking (SCC) and irradiation embrittlement are considered in the design basis of the reactor components and thus provide adequate structural margins over the operating life of the plant. Nevertheless, when the design basis assumptions are exceeded, e.g., thermal cycles, vibratory loading or chemistry transients, cracking may occur in pressure boundary components. Several proactive measures are being implemented to address this concern and assure the structural margins in BWR plants. These measures include: (i) control of materials and design to mitigate SCC and improvement of the environmental conditions through the implementation of Hydrogen Water Chemistry, (ii) advances in automated ultrasonic inspection of the BWR pressure vessel and piping, (iii) improved monitoring techniques for tracking fatigue usage and SCC effects in the piping and in the core, and (iv) development and qualification of durable repairs and specialized techniques such as use of high purity materials and temper bead repair. This paper describes current progress in implementing these proactive approaches for Boiling Water Reactors.     

Application of annealing for extension of WWER vessel lives

The safe operation of nuclear power plants (NPP) is dependent upon the assurance that the reactor pressure vessel will not fail in a brittle manner when the effects of radiation embrittlement are taken into account. The recovery of the properties of the irradiated materials is an important way of extending the operating life of a reactor vessel. The intent of this paper is to demonstrate the efficiency of thermal annealing for the recovery of reactor vessel material properties and to present the implications for extended service life.In order to substantiate the application of annealing to the extensior of the service life of vessels, detailed investigations were conducted which involved thermal annealing temperature and time, fast neutron fluence, and metallurgical factors (i.e. impurity contents) on the recovery of properties after the annealing of irradiated materials. Similar studies were continued to determine predictive methods for radiation embrittlement after repeated annealings.In May 19876 the first pilot annealing of a commercial reactor vessel (Novo-Voronezhskaya, III, NPP) was performed. The development of the annealing equipment and investigations performed to test the annealing process proved successful, and an improved safe operation period for the reactor vessel was thus attained providing for an extended service life.     

Static and cyclic crack growth of low alloy steels in high-oxygen water simulating HDR test conditions

Steel samples of reactor pressure vessel and piping steels from the German HDR programme have been tested in high oxygen water at different temperatures simulating HDR test conditions. The specimens have been exposed to sequences of static and cyclic loading or to purely cyclic loading. During the tests, threshold stress intensity values for stress corrosion cracking and crack growth rates with various cyclic loading parameters were determined. Extensive fracture surface and oxide layer investigations were also performed. Water chemistry parameters such as dissolved oxygen content, pH and conductivity were continuously monitored during the tests. Finally, the measured laboratory water chemistry parameters were compared to those measured in the HDR plant during full scale testing of components and the relevance of the results for normally operating plants is discussed.     

Department of energy’s annealing prototype demonstration projects

One of the challenges utilities face in addressing technical issues associated with the aging of nuclear power plants is the long-term effect of plant operation on reactor pressure vessels. These vessels are exposed to neutrons during the operation of a reactor. For certain plants, this exposure can cause embrittlement of some of the vessel welds, which can shorten the useful life of the vessel. This reactor pressure vessel embrittlement issue has the potential to affect the continued operation of a number of US pressurized water reactor plants. However, the properties that are degraded by long-term irradiation can be recovered through a thermal annealing treatment of the vessel steel. Although a dozen Russian-designed and several US military vessels have been successfully annealed, US utilities concluded that an annealing demonstration using a US reactor pressure vessel was a prerequisite before annealing a licensed US nuclear power plant. In May 1995, the Department of Energy and Sandia National Laboratories initiated a program to evaluate the feasibility of annealing US licensed plants using two different heating technologies. One team completed its annealing prototype demonstration in July 1996, using an indirect gas-fired furnace at the uncompleted Public Service of Indiana’s Marble Hill nuclear power plant in southern Indiana. The second team’s annealing prototype demonstration using a direct heat electrical furnace at the uncompleted Consumers Power Company’s nuclear power plant at Midland, Michigan, was scheduled to be completed in early 1997, but has now been delayed indefinitely. This paper describes the Department of Energy’s annealing prototype demonstration program and the results to date for each project.