22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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Qualification of VVER Steam Qualification of VVER Steam Generator Tubes InspectionGenerator Tubes Inspection
J. Guerra, C. Costilla, C. Salvador, Tecnatom S.A.
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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INTRODUCTIONINTRODUCTION
Inspection of steam generator tubes is an essential part of the component integrity assessment and greatly contributes to safe and reliable operation of the plantInspection performance shall be first demonstrated and later ensured through a QA programInspection performance is demonstrated on a qualification processThis paper presents Tecnatom approach to qualify its VVER steam generator tube inspection system
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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QUALIFICATION STRATEGYQUALIFICATION STRATEGY
Follow general rules of ENIQ TJ requirementsSeparate QUALIFICATION of inspection system components
Mechanical devicesET instrumentAnalysis softwareProbes and inspection techniquesInspection ProcedurePersonnel
Final “assembly” of documentation on TJ document
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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TECHNICAL JUSTIFICATION (TJ)TECHNICAL JUSTIFICATION (TJ)COMPONENT DETAILS
Engineering dataInspection area ConstructionOperation
Defect descriptionsINSPECTION OBJECTIVESNDE METHOD AND TECHNIQUE SELECTIONINSPECTION SYSTEM AND TECHNIQUESEXPERIMENTAL EVIDENCESESSENTIAL VARIABLES VERIFICATION
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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COMPONENT DETAILS (I)COMPONENT DETAILS (I)Horizontal position of tube bundleAustenitic steel tubes 08XH18N10T (SS 321)
WWER 440: 5,500 tubes aroundWWER 1000: 11,000 tubes around
Tube supports of stainless steel stripesRelatively low flow velocity in the tube bundleHydrazine ammonia water chemistryCollectors material
Austenitic stainless steel 08XH18N10T (SS 321) (WWER 440)Low alloy steel (carbon steel) 10GN2MFA (WWER 1000)
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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COMPONENT DETAILS (II)COMPONENT DETAILS (II)
WWER 440
WWER 1000
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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DEFECT DESCRIPTIONDEFECT DESCRIPTION
Type of defects:Tubes
ODSCCPittingWear
CollectorCracking of collector material
90% of defects located at tube support plate intersections in hot leg
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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ODSCC CHARACTERISTICSODSCC CHARACTERISTICS
Initiated directly on the outer surface or in the bottom part of corrosion pitsPreferentially oriented in the axial directionMain mechanism of crack propagation is IGASCC, but also some cases of transgranular SCC observedDistribution of indications does not follow general rules, each SG has it own particular flaw distributionMost indications located in the middle of tube Support plate intersection
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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EXAMPLES OF TUBE DEFECTSEXAMPLES OF TUBE DEFECTS
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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COLLECTOR DEFECTS (I)COLLECTOR DEFECTS (I)Three (3) types of collector ligament cracks can be defined according destructive examination performed on replaced SG collectors
Satellite cracks (micro-dimension)width: up to 0.1 mm, length: up to 1 mmPlanetary cracks (between two adjacent holes)width: 0.2 to 0.5 mm, length: up to full thickness of ligament, depth: up to 30 mmArterial cracks (through several holes)width: more than 0.5 mm, length: up to 1000 mm, depth: up to 171 mm (wall thickness including cladding)
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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COLLECTOR DEFECTS (II)COLLECTOR DEFECTS (II)
Satellite cracksPlanetary
crack
Arterial cracks
Collector secondary side
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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INSPECTION SYSTEM INSPECTION SYSTEM COMPONENTSCOMPONENTS
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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MECHANICAL DEVICES MECHANICAL DEVICES QUALIFICATIONQUALIFICATION
Input documents : specification and design documentsTest protocol developed to meet specification requirementsTest protocol applied and verifiedFunctional testBlank test
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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ACQUISITION SCREENACQUISITION SCREEN
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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ET INSTRUMENT QUALIFICATIONET INSTRUMENT QUALIFICATIONInternal qualification
According to Tecnatom development and manufacturing proceduresVersion and configuration control
External qualificationEPRI qualified: Rev 5 SG GuidelinesAs part of inspection system : Forsmark(Sweden),KKL&KKM (Switzerland) , Tsuruga(Japan), GE (USA),Kozloduy (Bulgaria), Loviisa (Finland),CNEA (Argentina), Maanshan (Taiwan)….
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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ANALYSIS SOFTWARE QUALIFICATIONANALYSIS SOFTWARE QUALIFICATIONInternal qualification
Specification and design documentsVerification and configuration control documentsFinal acceptance documentsUser manual and qualified software as final product
Versioning and verification documentation updated External qualification
EPRI qualified: Rev 5 SG Guidelines, Rev 6 in progress
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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EXPERIMENTAL EVIDENCE (I)EXPERIMENTAL EVIDENCE (I)COLLECTOR INSPECTION
Defect libraryRealistic flaws on collector and tube materialEDM notchesMagnetic variation signals
100% of library defects detectedAchieved inspection objectives
Detection of EDM notch of 1 mm depth, 3 mm length, 0.1 mm width on collector edgeDiscrimination of false indications from magnetic variations
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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EXPERIMENTAL EVIDENCE (II)EXPERIMENTAL EVIDENCE (II)
COLLECTOR CRACK
OD TUBE CRACK
MAGNETIC VARIATION
QUALIFICATION BLOCK
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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EXPERIMENTAL EVIDENCE (IV)EXPERIMENTAL EVIDENCE (IV)
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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EXPERIMENTAL EVIDENCE (V)EXPERIMENTAL EVIDENCE (V)
Tube defect libraryManufactured by NRISimulated PittingRealistic ODSCCEDM notchesAt different tube locations: bend, straight area, support plate intersections, expansion
Open Practical Demonstration of Inspection Procedures
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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EXPERIMENTAL EVIDENCE (VI)EXPERIMENTAL EVIDENCE (VI)
Most results based on NRI manufactured tube library
Very limited availability of pulled tube data
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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EXAMPLES OF SIGNALSEXAMPLES OF SIGNALSRealistic SCCOD, 30% TW, 10mm L : 38% Bobbin
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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EXAMPLES OF SIGNALSEXAMPLES OF SIGNALSSimulated Pitting, 50% TW, 1mm L : 46% Bobbin
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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EXAMPLES OF SIGNALSEXAMPLES OF SIGNALSRealistic SCCOD at U bend, 50%TW, 10mm L: 21% Bobbin
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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EXAMPLES OF FIELD SIGNALSEXAMPLES OF FIELD SIGNALS
PITTING
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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EXAMPLES OF FIELD SIGNALSEXAMPLES OF FIELD SIGNALS
ODSCC
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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PERSONNEL QUALIFICATIONPERSONNEL QUALIFICATIONTecnatom personnel certified according to European (EN-473) and American (ASME, EPRI) rulesEN-473 requirements
Training can be internal or externalExternal agency responsible for certification
ASME: SNT-TC-1A, CP-189Company responsible for certification implementationInternal training and certification written program
EPRI Guidelines requirements for analysts (QDA certification)
22 22 –– 2424 MarchMarch 2004,2004, PodolskPodolsk,, Russian Federation Russian Federation
THE 6THE 6--thth INTERNATIONAL SEMINAR ON INTERNATIONAL SEMINAR ON HORIZONTAL STEAM GENERATORSHORIZONTAL STEAM GENERATORS
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CONCLUSIONSCONCLUSIONS
Qualification of Inspection techniques is a complex taskENIQ TJ helps to organize and compile all qualification documentationQualification should be kept updated to current system configurationAvailability of pulled tube data will improve knowledge of POD on “real conditions”Personnel qualification and training is an essential part on the performance of the inspection
