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© Hitachi, Ltd. 2009. All rights reserved.Energy and Environmental Systems Laboratory
Hitachi, Ltd., Energy & Environmental Systems Laboratory
E-Journal of Advanced Maintenance (EJAM)
Hitachi Inspection Technologyfor Nuclear Power Plant
Masahiro Tooma 1
Yoshiaki Nagashima
Yutaka KometaniMasayoshi Sonobe
Masahiro KoikeKojiro Kodaira
Hitachi-GE nuclear energy, Ltd.
© Hitachi, Ltd. 2009. All rights reserved.Energy and Environmental Systems Laboratory
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Contents
Underwater vehicleUnderwater vehicle4
Introduction (Overview)Introduction (Overview)
Phased array UT Phased array UT
Eddy current testing (ECT)Eddy current testing (ECT)
5 ConclusionConclusion
Japan Society of Maintenology EJAM Occasional Topics (OT) 8
EJAM OT8
© Hitachi, Ltd. 2009. All rights reserved.Energy and Environmental Systems Laboratory
3
Piping CorrosionInspection
PipingInspection
Overview of Hitachi Inspection Technology for NPP
Turbine Inspection
Nuclear RadiationMonitoring
Eddy Current Testing (ECT)Ultrasonic Testing (UT)Underwater Vehicle (ROV)Guided Wave InspectionRadiation Monitoring
Core Internals, Bottom MountedInstruments (BMI)Inspection
Inspection/Monitoring Technology
© Hitachi, Ltd. 2009. All rights reserved.Energy and Environmental Systems Laboratory
4 Objectives of Bottom Head Inspection
CRDH: Control Rod Driving HousingICMH: Incore Monitoring Housing
Integrity Evaluation ofComponents at Bottom HeadIntegrity Evaluation ofComponents at Bottom Head
BWR Bottom Head Region
H9
H11
ICMH
CRDH
RPV
PlateShroudSupport
- Welded to the Reactor Pressure Vessel (RPV)
- Nickel Alloy (SCC)
Nondestructive Testing (NDT)Nondestructive Testing (NDT)
- Detection of StressCorrosion Crack (SCC)
- Length and DepthSizing Measurement
EJAM OT8EJAM OT8
© Hitachi, Ltd. 2009. All rights reserved.Energy and Environmental Systems Laboratory
5
1 2 3
Contents
Underwater vehicleUnderwater vehicle4
Introduction (Overview)Introduction (Overview)
Phased array UT Phased array UT
Eddy current testing (ECT)Eddy current testing (ECT)
5 ConclusionConclusion
© Hitachi, Ltd. 2009. All rights reserved.Energy and Environmental Systems Laboratory
6
Shroud
Shroud support
CRD stub
RPV
Expanding inspection area to BHDPurposePurpose
Conventional ECTConventional ECTSingle ECT sensor :High sensitivity for SCC,
but difficulty to apply tothe complicated area
�Rapid inspection: Multi coils�Complicated area inspection:
Flexible sensor�Noise reduction:
Phase mapping method
IdeaIdea
180mm Curveture
20mm
Purpose of flexible Multi ECT Inspection
EJAM OT8EJAM OT8
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�Multi coil (51 coils: Length 60mmOptimization by the eddy current simulation.
Eddy current sensor
ImpedancePlane
Real-time C-scope
Strip Chart
ECT software display
Bend the probe
Radius of Curvature(20mm)
ECT detector
Flexible plate
Flexible Multi-coil ECT System
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8
Result of IdentificationResult of Identification
180mm
60m
m
Min
Max
SCC SCC
Conventional: Signal Amplitude
Mockup Mockup
Visual Testing
PenetrantTesting
10mm
800mm
We have developed an automatic crack signal identification system.
SCC SCC
Developed: Identification by Phase Map
SCC Identification
EJAM OT8EJAM OT8
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9
AccuracyAccuracy
0Actual length (mm)
EDM slit
SCCWeld crack
Accuracy < 3mm
60
60+3mm
-3mm
C scope
200
SUS Crack 20m
m40
40m
m
ECT Penetration testing
25m
m Cracklength
Mea
sure
d le
ngth
(mm
)
0
Out
put(
V)
-12dBVp-p
Estimated length of a crack
Position
Method of Crack Length SizingMethod of Crack Length Sizing
Curved Surface MockupCurved Surface Mockup
Crack length sizing method was authorized by JAPEIC.Crack length sizing method was authorized by JAPEIC.
JAPEIC: Japan Power Engineering and Inspection Corporation
Crack Length Sizing
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10
6-axes robot arm
ECT scanner
Flexible sensor
Fig. C scope image obtained by robot ar
(a) Location image (b) C-scope image Fig. An example of ECT results
(a) Location image (b) C-scope image Fig. An example of ECT results
Access tools
EJAM OT8EJAM OT8
© Hitachi, Ltd. 2009. All rights reserved.Energy and Environmental Systems Laboratory
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Contents
Underwater vehicleUnderwater vehicle4
Introduction (Overview)Introduction (Overview)
Phased array UT Phased array UT
Eddy current testing (ECT)Eddy current testing (ECT)
5 ConclusionConclusion
© Hitachi, Ltd. 2009. All rights reserved.Energy and Environmental Systems Laboratory
12
H9
Plate RPV
CladdingWeld
Thickness:150mm
RPV
Array Sensor
0
200
300
400
500
100
0 10 1 Amp.0
200
300
400
500
100150
Amp.
Aperture of SensorSmall Large
Sharp
Optimization by UT SimulationOptimization by UT Simulation
Dep
th (m
m)
Dep
th (m
m)
Array Sensor
Focal Beam
Y
Z
200x200mm
Y
Z
Array Sensors for OD Side of RPV
EJAM OT8EJAM OT8
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Array Sensor
Control Unit Data Acquisition Unit
48Aperture
1-10MHz100 – 300 v
48 (Max. 144)Specification
Voltage
Elements
Frequency
Items
Electric Scanning of Ultrasonic Beam: Controlled by Phased Array System
Phased Array UT System (ES-3100: Hitachi Engineering & Service co,. Ltd.)
Sectorial Scanning- Range: +/- 60 deg.- Pitch: 0.5 deg- 2MHz Longitudinal Wave
Array Sensor
Equipment (2): Phased Array System
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14
ISI GuideRail
Scanner
Scanner
ISI GuideRail
RPV RPV
Array Sensor
Array Sensor
H9 Shroud SupportH9 Shroud Support H11 Shroud SupportH11 Shroud SupportSupport
Plate
Array Sensor: Scanned on the OD Surface of RPVby Automated Scanner mounted on the Guide Rail
Equipment (1): Automated Scanners
EJAM OT8EJAM OT8
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15
Close upClose upTip of Notch
Weld
Array Sensor
Horizontal Notch
UltrasonicBeam
Cladding
Depth
Signal of Tip(Tip Echo)
100 300 500
100
50
0
Propagation Length (mm)
Bottom Surface
Am
plitu
de
Horizontal NotchHorizontal Notch
RPV
SN Ratio of Tip Echo:More than 6dB
Results: H9(1) Horizontal Notch
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16
Sizing accuracy for horizontal and vertical notches is Sizing accuracy for horizontal and vertical notches is less than 3mm (< ASME Code 0.125 inch)less than 3mm (< ASME Code 0.125 inch)
0
10
20
30
40
50
60
0 10 20 30 40 50 60Actual Depth (mm)
Horizontal NotchVertical Notch
SD: 2.6mmError Av. : -1.2mmRMS Error: 2.7mm
SD: 2.6mmError Av. : -1.2mmRMS Error: 2.7mm
SD: Standard DeviationRMS: Root Mean Square
Mea
sure
d D
epth
(mm
)
Results of Depth Sizing (Notches)
EJAM OT8EJAM OT8
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17
Outputs
Electrical Volumetric Scans(Faster than 2D)
Fast InspectionsPoint-Focused Beam
High Resolution
Electrical Planar Scans
(Faster than 1D)Focused Beam
Unable to Scan Electrically
Light and Inexpensive
Features
PhasedArray
Methods
SingleElementMethod
3D3D Focus-UT
2DConventional
1DConventional
Ultrasonic Scanning Methods
3D Image
2D ImageLinearArray Probe
Monolithic Probe
Waveform (1D)
Features of 3D Phased Array UT Features of 3D Phased Array UT
Matrix Array Probe
VolumetricScan
PlanarScan
One Direction
Point-Focus
Focus
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18
Fast data acquisitions by 256 simultaneously active elementsFast data acquisitions by 256 simultaneously active elements
Pulser / Receiver
Matrix Array Probe(256 elements: 16×16)Matrix Array Probe
(256 elements: 16×16)
511mm 400mm
480m
m
Data Acquisitions for 3D ScansData Acquisitions for 3D Scans
3D Scanning
Transmit or receiveultrasoundsby 256 elements simultaneously
Photo of 3D Focus-UT
EJAM OT8EJAM OT8
© Hitachi, Ltd. 2009. All rights reserved.Energy and Environmental Systems Laboratory
19 Applications / FBHs in Metal Test Piece
With CAD of Test Piece
100 mm
20
RotationalSectorialScan
FBH
φ1mm FBH
φ2mm FBH
ScanningRegion
3D Image of FBH3D Image of FBHMatrix Array256 elementsLongitudinal 2MHz
Metal Test PieceMetal Test Piece10
0 m
m50
mm
FBH: Flat Bottom Hole
FBH Echoesφ1mm
FBH Echoesφ2mm
Bottom Echo
• Scanned results can be evaluated at one time in a 3D view. • Scanned results can be evaluated at one time in a 3D view. • Echoes can be easily related to the reflection sources
with the help of CAD data.• Echoes can be easily related to the reflection sources
with the help of CAD data.
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20
EDM Slit: depth of 3.2mm
Rotational SectorialScan
Bolt
Applications / Bolt InspectionsApplications / Bolt Inspections
Bolts (φ24)Bolts (φ24) 3D Image of Thread and Slit 3D Image of Thread and Slit
• Bolt inspections can be performed without any mechanical motions.
• Bolt inspections can be performed without any mechanical motions.
Matrix Array256 elementsLongitudinal2MHz
One of the Sectors(Conventional Image)
Thread Echo
Slit Echo
EJAM OT8EJAM OT8
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Contents
Underwater vehicleUnderwater vehicle4
Introduction (Overview)Introduction (Overview)
Phased array UT Phased array UT
Eddy current testing (ECT)Eddy current testing (ECT)
5 ConclusionConclusion
© Hitachi, Ltd. 2009. All rights reserved.Energy and Environmental Systems Laboratory
22 ROVs Lineup
EJAM OT8EJAM OT8
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23
CABLE Bottom head ROV
Dep
th o
f the
wat
er a
bout
30m
CameraUnit
Thruster
ThrusterThruster
352m
m
120mm250mm
Movement image
(10/17)
CRD housing
(1) Detail of the C-type ROV
SizeW120mm H352mm L250mmFunction The thrusters in back are for cruising forward and backwardThe camera pans 360 degrees and tilt 90 degreesRadiation ToleranceDepth of the water about 30m
360
90
C-type ROV
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24 Inspection ROV : Specifications
165mm
60mm
Pitch control mechanism
Specifications
CCD Camera (Wide view)
High brightness LED
CameraSystem
Driving thrustercircling screw
Pitch control mechanism
Actuators
60 165mm
Underwater weight 0g(Weight in air 450g)
Housing
Main Specifications
Driving thruster
CCD Camera High brightness LED
EJAM OT8EJAM OT8
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25
forward
right
upward
Up and down thruster
The examples of motion
Horizontal thruster
right
circling
forward
up down
Generate any motion by allocating thrust force to five thruster
The vector control using multiple thruster
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26
Water flow
Hovering controlExperimental setup Experimental result
The hovering area: about 0.04m
-0.10
-0.05
0
0.05
0.10
0 10 20 30 40Time [s]
Distance of the initial position [m
]
Control on Control off
Moving by water flow
ObjectMoving by
disturbance
0.2m/s (right)0.1m/s (right)0.2m/s (backward)0.1m/s (backward)
The experimental result of the hovering control
ROV Object
Appearance of the experiment
Water flow
EJAM OT8EJAM OT8
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27 Conclusion
To carry out efficient inspection for core internal, shroud support and bottom mounted instrument of reactor pressure vessel, we have developed
the flexible multi-coil ECT system for novel identification and length sizing of surface breaking crack,the phased array UT system for depth sizing
of sub-surface breaking crack in thick-wall structure, the remotely operated vehicles with these
sensors.
EJAM OT8EJAM OT8