Case Studies of Pulsed Eddy Current to Measure Wall Loss in Feedwater Heater Shells

2003 ◽  
Author(s):  
Marvin J. Cohn ◽  
Jordan W. Norton
Keyword(s):  
Eddy Current ◽  
Nuclear Power ◽  
Power Plants ◽  
Cost Effective ◽  
Accelerated Corrosion ◽  
Pulsed Eddy Current ◽  
Catastrophic Failures ◽  
Recent Developments ◽  
Wall Loss ◽  
Flow Accelerated Corrosion

There have been several feedwater heater shell failures in nuclear power plants caused by flow-accelerated corrosion (FAC). This failure mechanism may be one of the most important types of damage to mitigate because FAC damage has occasionally resulted in catastrophic failures and human fatalities. Predicting, detecting, and eliminating significant FAC damage can significantly reduce future forced outages and increase personnel safety. This paper describes the implementation of recent developments to perform cost-effective examinations. These advances include the use of specialized pulsed eddy current (PEC) hardware and software to scan for wall thinning without removing insulation. APTECH has performed more than 50 nuclear power plant projects on hundreds of feedwater shells, as well as numerous pipe examination projects, using the PEC equipment as a cost-effective screening tool for the detection of areas with significant wall loss. Results of shell wall loss measurements using ultrasonic examination (UT), the PEC average wall thickness (AWT) estimate, and the PEC evaluated Defect Algorithm are compared in this study.

Case Studies of Pulsed Eddy Current to Measure Wall Loss in Feedwater Piping and Heater Shells

2008 ◽  
Author(s):  
Marvin J. Cohn ◽  
Jordan W. Norton
Keyword(s):  
Eddy Current ◽  
Power Plants ◽  
Cost Effective ◽  
Nuclear Industry ◽  
Accelerated Corrosion ◽  
Pulsed Eddy Current ◽  
Catastrophic Failures ◽  
Recent Developments ◽  
Wall Loss ◽  
Flow Accelerated Corrosion

There have been several feedwater piping and heater shell failures in power plants caused by flow-accelerated corrosion (FAC). This failure mechanism may be one of the most important types of damage to find proactively because FAC damage has occasionally resulted in catastrophic failures and human fatalities. Predicting, detecting, and resolving significant FAC damage can significantly reduce future forced outages and increase personnel safety. This paper describes the implementation of recent developments to perform cost-effective FAC examinations. These advances include the use of specialized pulsed eddy current (PEC) hardware and software to scan for wall thinning without removing insulation. Recent results are based on the current version, MK II, of this equipment. The authors have performed more than 200 power plant projects with this PEC equipment, examining numerous pipes and shells. This work consists of more than 70 projects of wall loss examinations for the nuclear industry, including examinations of feedwater heater shells inside the condenser. Results of wall loss measurements regarding PEC average wall thickness (AWT) measurements, ultrasonic thickness examinations (UTTH), and the PEC evaluated Defect Algorithm are compared in this study.

Effects of Flow Accelerated Corrosion on Piping Steady-State Vibration Evaluations

2003 ◽  
Author(s):  
Brian J. Voll
Keyword(s):  
Steady State ◽  
Nuclear Power ◽  
Power Plants ◽  
Pipe Wall ◽  
Vibration Monitoring ◽  
Accelerated Corrosion ◽  
Monitoring Programs ◽  
Wall Thinning ◽  
Piping Systems ◽  
Flow Accelerated Corrosion

Piping steady-state vibration monitoring programs were implemented during preoperational testing and initial plant startup at most nuclear power plants. Evaluations of piping steady-state vibrations are also performed as piping and component failures attributable to excessive vibration are detected or other potential vibration problems are detected during plant operation. Additionally, as a result of increased flow rates in some piping systems due to extended power uprate (EPU) programs at several plants, new piping steady-state vibration monitoring programs are in various stages of implementation. As plants have aged, pipe wall thinning resulting from flow accelerated corrosion (FAC) has become a recognized industry problem and programs have been established to detect, evaluate and monitor pipe wall thinning. Typically, the piping vibration monitoring and FAC programs have existed separately without interaction. Thus, the potential impact of wall thinning due to FAC on piping vibration evaluations may not be recognized. The potential effects of wall thinning due to FAC on piping vibration evaluations are reviewed. Piping susceptible to FAC and piping susceptible to significant steady-state vibrations, based on industry experience, are identified and compared. Possible methods for establishing links between the FAC and vibration monitoring programs and for accounting for the effects of FAC on both historical and future piping vibration evaluations are discussed.

A Procedure for Determining the Safe Operation Time of Equipment and Pipelines Based on Nondestructive Testing Results

Vestnik MEI ◽  
2020 ◽  
Vol 6 (6) ◽  
pp. 11-17
Author(s):  
Dmitriy A. Kuz'min ◽  
◽  
Aleksandr Yu. Kuz'michevskiy ◽  
Artem E. Gusarov ◽  
◽  
...  
Keyword(s):  
High Pressure ◽  
Wall Thickness ◽  
Nuclear Power ◽  
Power Plants ◽  
Nuclear Power Plants ◽  
Operation Time ◽  
Safe Operation ◽  
Accelerated Corrosion ◽  
Equipment And Pipelines ◽  
Flow Accelerated Corrosion

The reliability of nuclear power plants (NPPs) has an influence on power generation safety and stability. The reliability of NPP equipment and pipelines (E&P), and the frequency of in-service inspections are directly linked with damage mechanisms and their development rates. Flow accelerated corrosion (FAC) is one of significant factors causing damages to E&P because these components experience the influence of high pressure, temperature, and high flow velocity of the inner medium. The majority of feed and steam path components made of pearlitic steels are prone to this kind of wear. The tube elements used in the coils of high pressure heaters (HPH) operating in the secondary coolant circuit of nuclear power plants equipped with a VVER-1000 reactor plant were taken as the subject of the study. The time dependences of changes in the wall thickness in HPH tube elements are studied proceeding from an analysis of statistical data of in-service nondestructive tests. A method for determining the initial state of the E&P metal wall thickness before the commencement of operation is proposed. The article presents a procedure for predicting the distribution of examined objects' wall thicknesses at different times of operation with determining the occurrence probability of damages caused by flow accelerated corrosion to calculate the time of safe operation until reaching a critical state. A function that determines the boundary of permissible values of the HPH wall thickness distributions is obtained, and it is shown that the intervals of in-service inspections can be increased from 6 years (the actual frequency of inspections) to 9 years, and the next in-service inspection is recommended to be carried out after 7.5 years of operation. A method for determining the existence of FAC-induced local thinning in the examined object has been developed. The developed approaches and obtained study results can be adapted for any pipelines prone to wall thinning to determine the frequency of in-service inspections (including an express analysis based on the results of a single nondestructive in-service test), the safe operation time, and quantitative assessment of the critical value reaching probability.

Flow Accelerated Corrosion Program in the Belgian Nuclear Power Plants

2009 ◽  
Author(s):  
Anne-Sophie Bogaert ◽  
Michel Desmet ◽  
Arnaud Gendebien
Keyword(s):  
Nuclear Power ◽  
Power Plants ◽  
Nuclear Power Plants ◽  
Ultrasonic Inspection ◽  
Accelerated Corrosion ◽  
Balance Of Plant ◽  
Nuclear Plants ◽  
Set Up ◽  
Predictive Software ◽  
Flow Accelerated Corrosion

Since the Surry-accident of 1986, Electrabel and Tractebel Engineering have performed extensive ultrasonic inspection campaigns to detect pipe wall thinning due to Flow Accelerated Corrosion (FAC) in the Balance-of-Plant systems of the seven Belgian nuclear power plants. Since 2000 EPRI’s predictive software CHECWORKS is used as a means to focus future inspections on the most susceptible components. In 2005, Tractebel Engineering participated in a benchmark set-up by the Framatome Owners Group (FROG) that compared the different FAC predictive models used by the FROG members. In 2006, Electrabel and Tractebel Engineering decided to perform an assessment of the way in which the follow-up of Flow Accelerated Corrosion (FAC) is done in the Belgian nuclear plants. This paper summarizes the Flow Accelerated Corrosion program in the Belgian nuclear plants as well as some of the main aspects of the Flow Accelerated Corrosion management, including the use of a predictive software, the method of inspections and the actions taken to keep the FAC program up to date.

Thickness reconstruction of nuclear power plant pipes with flow-accelerated corrosion damage using laser ultrasonic wavenumber imaging

2017 ◽  
Vol 17 (2) ◽  
pp. 255-265 ◽  
Author(s):  
Thanh Chung Truong ◽  
Jung-Ryul Lee
Keyword(s):  
Nuclear Power ◽  
Inverse Method ◽  
Power Plants ◽  
Corrosion Damage ◽  
Longitudinal Direction ◽  
Accelerated Corrosion ◽  
High Pressure High Temperature ◽  
Flow Changes ◽  
Flow Accelerated Corrosion ◽  
Structural Base

The pipeline is an essential part of nuclear and other power plants. Designed to operate for decades, the pipeline is susceptible to multiple types of damage due to working in a high pressure, high temperature, and highly corrosive environment. Therefore, it requires regular inspection. The issue of many current nondestructive testing systems for pipelines is the use of a one-dimensional scan mechanism along the longitudinal direction of the pipe, which is incompatible with the two-dimensional curvature of elbow pipes, yet it is at these places in which the flow changes directions inside the elbow pipes that a common type of damage occurs: flow-accelerated corrosion damage. In this article, flow-accelerated corrosion damage is visualized using the Ultrasonic Wavenumber Imaging algorithm, which maps the dominant local spectroscopic wavenumber of the wavefield at a particular mode and a particular frequency. In previous studies, the mode and frequency were chosen empirically. In this article, a novel theoretical study is presented to optimize the two input parameters of Ultrasonic Wavenumber Imaging based on a sensitivity analysis of the spectroscopic wavenumber with respect to the change in thickness of the structural base. Additionally, an inverse method is proposed to estimate the thickness of the structure based on the Ultrasonic Wavenumber Imaging map.

Wall-Thinning Analysis of the Pipelines in the Secondary Section of NPP

2013 ◽  
Author(s):  
Na Ma ◽  
Li Wang ◽  
Jinguang Qin
Keyword(s):  
Carbon Steel ◽  
Nuclear Power ◽  
Power Plants ◽  
Xrd Analysis ◽  
Operating Conditions ◽  
Chemical Compositions ◽  
Accelerated Corrosion ◽  
Wall Thinning ◽  
Erosion Corrosion ◽  
Flow Accelerated Corrosion

Wall-thinning investigation of three carbon steel pipe samples from secondary section of nuclear power plants has been carried out in this paper. The operating conditions of the three pipe samples are quite different, which leads to the different wall-thinning reasons and characteristics of the pipes. The chemical compositions of the steel materials, the stereomicroscope examinations, SEM examinations, as well as the XRD analysis are performed. The results show that: The wall-thinning of No.1 elbow was caused by erosion corrosion; the wall-thinning of No.2 elbow was caused by flow accelerated corrosion; the wall-thinning and crevasse of No.3 orifice plate was caused by cavitations. Measures to solve the wall-thinning problems of different pipes are also given in this paper.

Tackling Erosion in Nuclear Piping Systems

2007 ◽  
Author(s):  
Harold M. Crockett ◽  
Jeffrey S. Horowitz
Keyword(s):  
Nuclear Power ◽  
Power Plants ◽  
Training Module ◽  
Droplet Impingement ◽  
Damage Mechanisms ◽  
Accelerated Corrosion ◽  
Computerized Training ◽  
Piping Systems ◽  
Research Plan ◽  
Flow Accelerated Corrosion

Various mechanisms degrade power piping in nuclear power plants. The most important mechanism has been flow-accelerated corrosion (FAC). FAC has caused ruptures and leaks and has led to numerous piping replacements. U.S. utilities are using a combination of EPRI software and aggressive inspection programs to deal with FAC. However, current technology does not deal with erosive forms of attack including, cavitation erosion, flashing erosion, droplet impingement, and solid particle erosion. These forms of degradation have caused shutdowns and leaks have become a maintenance issue. To deal with these problems EPRI has begun a series of projects in this area. The first of these was a comprehensive report on erosion in piping systems. This work was followed with a computerized training module designed to educate utility engineers about erosive attack. Further steps are planned to deal with these forms of degradation. The first will be a meeting with knowledgeable EPRI and utility engineers to prioritize the damage mechanisms. From this meeting a research plan will be developed. This paper will present a description of erosive damage mechanisms and describe the planned R&D to deal with these mechanisms.

Hydrazine-Dependency of Low-Alloy Steel Flow-Accelerated Corrosion in a Deoxygenated Solution at 250°C

2007 ◽  
Vol 26-28 ◽  
pp. 1133-1136
Author(s):  
Ki Woung Sung ◽  
Hyun Il Seo ◽  
Uh Chul Kim ◽  
Wan Young Maeng
Keyword(s):  
Nuclear Power ◽  
Power Plants ◽  
Low Alloy Steels ◽  
Accelerated Corrosion ◽  
Test Loop ◽  
Concentration Dependency ◽  
Alloy Steels ◽  
Steel Flow ◽  
Flow Accelerated Corrosion ◽  
Experimental Weight Loss

In the nuclear power plants (NPPs), wall thinning of the piping materials is generally caused by a flow-accelerated corrosion (FAC) and leads to a rupture with no warning unless it is detected and repaired in a timely manner. To reduce the FAC, it is better to use low-alloy steels, such as 1Cr-½Mo and 2¼Cr-1Mo, having higher FAC-resistance than carbon steel. Meanwhile, in the secondary water chemistry at the NPPs in Korea, hydrazine concentration is maintained within the range of 100~150 ppb. For applying these low-alloys to a piping material, we investigated the influence of hydrazine concentration on their FAC. An experiment was carried out at pH25°C of 9 controlled with ammonia in a deoxygenated aqueous solution containing 0~250 ppb-hydrazine by using a FAC test loop at 250°C for 300 hours. Experimental weight loss showed a hydrazine concentration dependency of the FAC in this concentration range, giving minimum at 150 ppb.

Development of an On-Line Ultrasonic System to Monitor Flow-Accelerated Corrosion of Piping in Nuclear Power Plants

2004 ◽  
Vol 270-273 ◽  
pp. 2232-2238 ◽  
Author(s):  
Na Young Lee ◽  
Chi Bum Bahn ◽  
Sang Geun Lee ◽  
Ji Hyun Kim ◽  
Il Soon Hwang ◽  
...  
Keyword(s):  
Nuclear Power ◽  
Power Plants ◽  
Nuclear Power Plants ◽  
Accelerated Corrosion ◽  
On Line ◽  
Flow Accelerated Corrosion
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