Capabilities of Ultrasonic Phased Arrays for Far-Side Examinations of Austenitic Stainless Steel Piping Welds

2006 ◽  
Author(s):  
Michael T. Anderson ◽  
Stephen E. Cumblidge ◽  
Steven R. Doctor
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Phased Array ◽  
Fatigue Cracks ◽  
Welding Parameters ◽  
Circumferential Welds ◽  
Array Technology ◽  
Asme Code ◽  
Ultrasonic Techniques ◽  
Performance Demonstration

A study was conducted to assess the ability of advanced ultrasonic techniques to detect and accurately determine the size of flaws from the far-side of wrought austenitic piping welds. Far-side inspections of nuclear system austenitic piping welds are currently performed on a “best effort” basis and do not conform to ASME Code Section XI Appendix VIII performance demonstration requirements for near side inspection. For this study, four circumferential welds in 610mm (24inch) diameter, 36mm (1.42inch) thick ASTM A-358, Grade 304 vintage austenitic stainless steel pipe were examined. The welds were fabricated with varied welding parameters; both horizontal and vertical pipe orientations were used, with air and water backing, to simulate field welding conditions. A series of saw cuts, electro-discharge machined (EDM) notches, and implanted fatigue cracks were placed into the heat affected zones of the welds. The saw cuts and notches ranged in depth from 7.5% to 28.4% through-wall. The implanted cracks ranged in depth from 5% through-wall to 64% through-wall. The welds were examined with phased array technology at 2.0 MHz, and compared to conventional ultrasonic techniques as a baseline. The examinations showed that phased-array methods were able to detect and accurately length-size, but not depth size, the notches and flaws through the welds. The ultrasonic results were insensitive to the different welding techniques used in each weld.

Ultrasonic Phased Array Evaluations of Implanted and In-Situ Grown Flaws in Cast Austenitic Stainless Steel Pressurizer Surge Line Piping

2011 ◽  
Author(s):  
Susan L. Crawford ◽  
Anthony D. Cinson ◽  
Traci L. Moran ◽  
Matthew S. Prowant ◽  
Aaron A. Diaz ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Phased Array ◽  
Fatigue Cracks ◽  
Base Material ◽  
Pacific Northwest National Laboratory ◽  
Asme Code ◽  
Ultrasonic Phased Array ◽  
Surge Line

A set of circumferentially oriented thermal fatigue cracks (TFCs) were implanted into three cast austenitic stainless steel (CASS) pressurizer (PZR) surge-line specimen welds (pipe-to-elbow configuration) that were salvaged from a U.S. commercial nuclear power plant that had not been operated. Thus, these welds were fabricated using vintage CASS materials that were formed in the 1970s. Additionally, in-situ grown TFCs were placed in the adjacent CASS base material of one of these specimens. Ultrasonic phased-array responses from both types of flaws (implanted and in-situ grown) were analyzed for detection and characterization based on sizing and signal-to-noise determination. Multiple probes were employed covering the 0.8 to 2.0 MHz frequency range. To further validate the Pacific Northwest National Laboratory (PNNL) findings, an independent in-service inspection (ISI) supplier evaluated the flaws with their American Society of Mechanical Engineers (ASME) Code, Section XI, Appendix VIII-qualified procedure. The results obtained by PNNL personnel compared favorably to the ISI supplier results. All examined flaws were detected and sized within the ASME Code-allowable limits.

An Ultrasonic Phased Array Evaluation of Cast Austenitic Stainless Steel Pressurizer Surge Line Piping Welds

2010 ◽  
Author(s):  
Aaron A. Diaz ◽  
Anthony D. Cinson ◽  
Susan L. Crawford ◽  
Traci L. Moran ◽  
Michael T. Anderson
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Ultrasonic Testing ◽  
Phased Array ◽  
Fatigue Cracks ◽  
Ultrasonic Beam ◽  
Custom Made ◽  
Ultrasonic Phased Array ◽  
Surge Line ◽  
Thermal Fatigue Cracks

A set of circumferentially oriented thermal fatigue cracks (TFCs) were implanted into three cast austenitic stainless steel (CASS) pressurizer (PZR) surge-line specimens (pipe-to-elbow welds) that were fabricated using vintage CASS materials formed in the 1970s, and flaw responses from these cracks were used to evaluate detection and sizing performance of the phased-array (PA) ultrasonic testing (UT) methods applied. Four different custom-made PA probes were employed in this study, operating nominally at 800 kHz, 1.0 MHz, 1.5 MHz, and 2.0 MHz center frequencies. The CASS PZR surge-line specimens were polished and chemically etched to bring out the microstructures of both pipe and elbow segments. Additional studies were conducted and documented to address baseline CASS material noise and observe possible ultrasonic beam redirection phenomena.

scholarly journals Evaluation of Microstructure and Impact Toughness of Shielded Metal Arc Dissimilar Weldments of High Strength Low Alloy Steel and Austenitic Stainless Steel

2020 ◽  
Vol 5 (2) ◽  
Author(s):  
Misbahu A Hayatu ◽  
Emmanuel T Dauda ◽  
Ola Aponbiede ◽  
Kamilu A Bello ◽  
Umma Abdullahi
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Impact Toughness ◽  
Impact Energy ◽  
High Strength ◽  
Impact Testing ◽  
Welding Parameters ◽  
Dissimilar Weld ◽  
Weld Joints ◽  
The Impact

There is a growing interest for novel materials of dissimilar metals due to higher requirements needed for some critical engineering applications. In this research, different dissimilar weld joints of high strength low alloy (HSLA) and 316 austenitic stainless steel grades were successfully produced using shielded metal arc welding (SMAW) process with 316L-16 and E7018 electrodes. Five variations of welding currents were employed within the specified range of each electrode. Other welding parameters such as heat inputs, welding speeds, weld sizes, arc voltages and time of welding were also varied. Specimens for different weld joint samples were subjected to microstructural studies using optical and scanning electron microscopes. The impact toughness test was also conducted on the samples using Izod impact testing machine. The analysis of the weld microstructures indicated the presence of type A and AF solidification patterns of austenitic stainless steels. The results further showed that the weld joints consolidated with E7018 electrode presented comparatively superior impact energy to the weldments fabricated by 316L-16 electrode. The optimum impact energy of E7018-weld joints (51J) was attained at higher welding heat inputs while that of 316L-16-weld joints (35J) was achieved at lower welding heat inputs, which are necessary requirements for the two electrodes used in the experiment. Hence, the dissimilar weld joints investigated could meet requirement for engineering application in offshore and other critical environments.Keywords—Dissimilar metal weld, heat input, impact toughness, microstructures

Production of Realistic Flaws and Their Meaning for Ultrasonic Testing

2019 ◽  
Vol 5 (3) ◽  
Author(s):  
Jiri Hodac ◽  
Pavel Mares ◽  
Jaromir Janousek ◽  
Martin Linhart
Keyword(s):  
Staff Training ◽  
Ultrasonic Testing ◽  
Phased Array ◽  
Fatigue Cracks ◽  
Ultrasonic Test ◽  
P 75 ◽  
Array Technology ◽  
Ultrasonic Echo ◽  
Ultrasonic Phased Array ◽  
Test Result

This work is designed to artificially create test specimens with flaws that behave the same way as real-function flaws when observed by nondestructive testing (NDT) technologies. Thus, the understanding of the detection limitations of NDT methods is needed. In this study, real, realistic, and artificial flaws were compared by ultrasonic phased array technology. Fatigue flaws, which belong to the most common structural issues (Ruzicka, M., Hanke, M., and Rost, M., 1987, Dynamicka Pevnost a Zivotnost, CVUT, Prague, Czech Republic, p. 75), are investigated. Measurements have revealed significant differences in the amplitude of ultrasonic echo from fatigue cracks in distinct phases of crack propagation. Studied specimens with realistic flaws have demonstrated their quality for calibration, staff training, and NDT system qualification. More realistic test specimens will increase ultrasonic test result reliability.

NDE Performance (POD) Curves for Fatigue Cracks in Piping Based on Industry Performance Demonstration Data

2002 ◽  
Author(s):  
S. R. Gosselin ◽  
F. A. Simonen ◽  
P. G. Heasler ◽  
S. R. Doctor ◽  
F. L. Becker
Keyword(s):  
Stainless Steel ◽  
Carbon Steel ◽  
Nuclear Energy ◽  
Crack Detection ◽  
Fatigue Cracks ◽  
Probability Of Detection ◽  
Performance Factors ◽  
Best Estimate ◽  
Industry Performance ◽  
Performance Demonstration

This paper evaluates non-destructive examination (NDE) detection capabilities of fatigue cracks in piping. Industry performance demonstration initiative (PDI) data for fatigue crack detection were used to develop a matrix of statistically based probability of detection (POD) curves that consider various NDE performance factors. Seven primary performance factors were identified — Material, Crack Geometry/Type, NDE Examination Access, NDE Procedure, Examiner Qualification, Pipe Diameter, and Pipe Wall Thickness. A database of 16,181 NDE performance observations, with 18 fields associated with each observation, was created and used to develop statistically based POD curves for 42 stainless steel and 14 carbon steel performance cases. Subsequent comparisons of the POD fits for each of the cases showed that excellent NDE performance for fatigue cracks can be expected for ferritic materials. Very little difference was observed between the POD curves for the 14 carbon steel performance cases considered in this study and NDE performance could therefore be represented by a single POD curve. For stainless steel, very good performance can also be expected for circumferential cracks located on the same side of the weld from which the NDE examination is made. POD depended primarily on component thickness. Three POD curves for stainless steel were prepared. Best estimate and the associated 95% confidence bounds POD verses through-wall depth logistic regression digital data are provided. Probabilistic fracture mechanics (PFM) calculations were performed to compare best estimate leak probabilities obtained from both the new performance-based POD curves and previous PFM models. This work was performed under joint funding by EPRI and the U.S. Department of Energy (DOE), Office of Nuclear Energy Science and Technology’s Nuclear Energy Plant Optimization (NEPO) program.

Technical Basis for Flaw Acceptance Criteria for Cast Austenitic Stainless Steel Piping

2020 ◽  
Vol 142 (2) ◽  
Author(s):  
Do Jun Shim ◽  
Nathanial Cofie ◽  
Dilipkumar Dedhia ◽  
Tim Griesbach ◽  
Kyle Amberge
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Evaluation Procedure ◽  
Correction Factors ◽  
Acceptance Criteria ◽  
Regulatory Guidance ◽  
Asme Code ◽  
Tensile Data ◽  
Equivalent Factor ◽  
Technical Basis

Abstract According to the current ASME Code Section XI, IWB-3640 and Appendix C flaw evaluation procedure, cast austenitic stainless steel (CASS) piping with ferrite content (FC) less than 20% is treated as wrought stainless steel. For CASS piping with FC equal or greater than 20%, there was no flaw evaluation procedure in the ASME Code prior to the 2019 Edition. In this paper, the technical basis for the recently approved Code change containing flaw acceptance criteria for CASS piping is presented. The procedure utilizes the current rules in ASME Code Section XI, IWB 3640/Appendix C and the existing elastic-plastic correction factors (i.e., Z-factors) for other materials in the Code. The appropriate Z-factor to use for the CASS piping is determined based on the FC (using Hull's equivalent factor). Experimentally measured fully saturated fracture toughness and tensile data of the three most common grades of CASS material in the U.S. (CF3, CF8, and CF8M) were used to determine the flaw acceptance criteria in the Appendix C Code method. As described here, the method is conservative since it utilizes the fully saturated condition of CASS materials. In addition, it is simple and consistent with the current regulatory guidance on aging management of CASS piping.

Low Frequency Phased Array Application for Crack Detection in Cast Austenitic Piping

2006 ◽  
Author(s):  
Michael T. Anderson ◽  
Stephen E. Cumblidge ◽  
Steven R. Doctor
Keyword(s):  
Stainless Steel ◽  
Crack Detection ◽  
Phased Array ◽  
Fatigue Cracks ◽  
Low Frequency ◽  
Pacific Northwest National Laboratory ◽  
The United States ◽  
Coarse Grained ◽  
Inspection Method ◽  
Centrifugally Cast

As part of a multi-year program funded by the United States Nuclear Regulatory Commission (US NRC) to address nondestructive examination (NDE) reliability of inservice inspection (ISI) programs, studies conducted at the Pacific Northwest National Laboratory (PNNL) in Richland, Washington, have focused on assessing novel NDE approaches for the inspection of coarse-grained, cast austenitic stainless steel reactor components. The primary objective of this work is to provide information to the US NRC on the utility, effectiveness and reliability of ultrasonic testing (UT) as related to the ISI of primary piping components in US commercial nuclear power plants. This paper describes progress, recent developments and results from an assessment of a portion of the work relating to the ultrasonic low frequency phased array inspection technique. Westinghouse Owner’s Group (WOG) cast stainless steel pipe segments with thermal and mechanical fatigue cracks, PNNL samples containing thermal fatigue cracks and several blank vintage specimens having very coarse grains that are representative of early centrifugally cast piping installed in PWRs, were used for assessing the inspection method. The phased array approach was implemented using an R/D Tech Tomoscan III system operating at 1.0 MHz and 500 kHz, providing composite volumetric images of the samples. Several dual, transmit-receive, custom designed low-frequency arrays were employed in laboratory trials. Results from laboratory studies for assessing detection and localization are discussed.

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