nsuf partner facility presentation: westinghouse electric ... gift - wec nsuf partner.pdf• for...

Westinghouse Non-Proprietary Class 3 © 2017 Westinghouse Electric Company LLC. All Rights Reserved.

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Frank Gift Product Manager, Chemistry, Materials and Qualification Services May 25, 2017

NSUF Partner Facility Presentation: Westinghouse Electric Company LLC

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Nuclear Science Users Facilities (NSUF): Westinghouse Involvement • Westinghouse became an “ATR-NSUF” Partner Facility late in 2013. • Post-Irradiation Examination (PIE) capabilities are what Westinghouse

offers to users of the NSUF, taking advantage of our multiple hot cells, radiological controlled areas (RCAs), and dedicated laboratory equipment for sample preparation, examination, and analysis.

• Westinghouse Churchill Site has the capabilities to ship, handle, prepare, test, characterize, and dispose of plant-relevant materials and reaction products.

• Experienced radiological shipping personnel, health physics staff, engineering and technician support can rapidly mobilize and provide customized research, testing, and forensic examination programs for the nuclear industry.

Excellent collaboration with National Laboratories, Universities, Nuclear Industry Groups and Utilities

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Nuclear Science Users Facilities (NSUF): Supporting the Charter Westinghouse has actively supported the U.S. Department of Energy (DOE) Funding Opportunity Announcement (FOA) for Consolidated Innovative Nuclear Research (CINR) for the 2015, 2016 and 2017 Fiscal Years.

• For FY2015, Westinghouse supported one letter of intent / pre-application, which

was submitted for consideration and screening and was identified for full application and subsequently submitted. No project award received.

• For FY2016, Westinghouse supported eleven (11) letters of intent / pre-application, of which ultimately six (6) were submitted for consideration and screening. Of those six applications, three (3) were identified for full application and subsequently submitted. One project was awarded supporting the Principal Investigator (Dr. Janelle Wharry, Purdue University). Paula Freyer is the Westinghouse lead and interface with Dr. Wharry on this contract.

• For FY2017, Westinghouse supported six (6) letters of intent / pre-application, of

which ultimately five (5) were submitted for consideration and screening. Of those five applications, two (2) were identified for full application and subsequently submitted.

Discussion later in the presentation related to observations and suggestions for the NSUF

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Facility Overview • Westinghouse completed a facility upgrade to its Churchill, PA facility in

2012-2013 to improve its testing capabilities for R&D, as well as operating plant services and new plant construction support.

• 36 different laboratory areas are present at the Churchill Site in the two primary buildings – Bldg 301 and Bldg 302/302A, supported by over 70 Westinghouse site employees.

Presentation Purpose: Provide an overview of this laboratory facility and capabilities, with

points of contact for follow up questions

Hallmark Facilities are the hot cells: 6 different hot cells 30,000 curie licensed facility Contaminated Controlled Areas

(CCAs) within the RCA boundary Extensive library of materials

irradiated in light water reactors

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Customers and Services •Westinghouse R&D and Product support for Product Lines,

Subsidiaries and Affiliates • US and International Utilities • US and International Universities • US and International Laboratories • EPRI • DOE and DOD • PWROG • International Organizations (e.g., International IASCC

Advisory Committee) •Other commercial organizations, manufacturers, etc.


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SELECT CAPABILITIES AND EXAMPLES OF PROJECT WORK

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“Mechanical” Property Testing / Specimen Fabrication • In-cell and out of cell capabilities to fabricate a wide range

of test specimens (including miniature size) with CNC capability and skilled machinists.

• Standardized specimens to generate design data and performance comparison data.

“Mechanical” Testing Capabilities include: – Hardness / micro-hardness testing – Charpy testing – Tensile testing – Compact-tension test – 3-point bend test – Bolt pull testing

Capability of performing tests at elevated temperatures and/or in autoclave environments to simulate reactor conditions. Environmental effects like stress corrosion cracking studied extensively at Westinghouse.

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Testing of Highly Activated Materials - Nuclear Power Plant Reactor Vessel Internals Baffle Bolt Materials

• Logistics for highly activated materials – several 1000 R/hr on contact

• Machining, fixturing, testing… • Load capacity to test to

50,000lbf in cell - full bolts to assess geometry factors

• Specimen machining capability – miniature specimens to assess material factors

• Development of tensile properties – Compare materials – Compare effect of fluence

levels – Identify hardening and residual

ductility

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Westinghouse Hot Cell Digital Image Correlation (DIC) and Advanced Video Extensometry (AVE)

Unique hot cell capability that provides strain behavior of irradiated materials

• Instron DIC/AVE System • Interfaces with hot cell Instron

screw driven tensile machine (Model 5985) equipped with Instron Bluehill 3 software

• Images captured during test…image processing performed post-test

• Measures the full-field strain over the entire material surface…useful color strain maps produced

• Virtual strain gauges and extensometers can be placed on the specimen after the test and replayed multiple times

Same irradiated specimen.

Strain maps at 50 ksi and at UTS of 95 ksi (EL = 41%).

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Westinghouse Hot Cell Testing of Miniature Irradiated Additively Manufactured (AM) Tensile Specimens

• Westinghouse internally funded R&D • Room temperature and elevated

temperature testing of ~150 miniature tensile specimens, unirradiated and irradiated

• Digital Image Correlation (DIC) and Advanced Video Extensometry (AVE)

• Developed custom miniature specimen fixture and DIC speckle marking approach for highly activated specimens

• Testing of irradiated AM 316L and a nickel base superalloy have been completed • Work completed on schedule and on budget • 316L results will be published at Aug 2017

Environmental Degradation Conference

• Testing of irradiated zirconium alloys will begin in late 2017 Unique hot cell capability utilizing fully

calibrated equipment and testing per ASTM specifications

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Westinghouse Hot Cell Complex Precision Specimen Machining

Unique hot cell specimen machining capability for a variety of specimen

geometries

• Example: contract for INL/Sebastien Teysseyre

• Highly irradiated EBR-II hex material (~35 dpa)

• Complex precision machining in-cell of 4 one-of-a-kind modified 1/4T CT specimens

• Crack propagation through known void swelling gradients

• Welding of 4 leads per CT specimen

• Plus 2 round tensiles and 4 thin plates for subsequent microscopy

• Work completed on schedule and on budget

• Believe test results for 2 specimens will be published by INL at Aug 2017 Environmental Degradation Conference

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Westinghouse Irradiated Material Laser Welding

Irradiated Hex-Block Material

(~50R/hr)

Specimen Block Sectioned into two pieces in hot cell

Specimen milled on both sides to simulate field machining activities of a repair strategy (pre-welding) at a nuclear plant

Westinghouse work sponsored by EPRI to assess low heat input weld feasibility on approximately 1ppm Helium content Type 304 stainless steel.

• Specimen preparation for the welding trials shown above. • Material used in the laboratory research is courtesy of Idaho National Laboratory’s

NSUF material library (specimens stored in the Westinghouse hot cell).

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Westinghouse Irradiated Material Laser Welding

CCD Camera

Cut section of wire being used (not on spool)

Customized pulsed-laser weld system set up in the Westinghouse hot cell to support EPRI and NSUF research programs evaluating welds made on highly irradiated materials.

3-pass welds made on a machined block; different weld parameters utilized in different regions.

• Good weld fusion, with no hot cracking observed in welds.

• Detailed microstructural characterization work yet to be performed.

(Approximately 35R/hr)

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Failed Bolts – SEM Fractography

Intergranular Cracking Transgranular Cracking

Significant interest in the nuclear industry on baffle bolt degradation;

Westinghouse leads efforts to evaluate with almost 50 bolts received over the last year for

examination and testing. Baffle Bolts reading > 4,000 R/hr on contact.

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Westinghouse Focused Ion Beam (FIB)/Transmission Electron Microscopy (TEM) of Highly Irradiated Materials

Advanced FIB and TEM capabilities for highly irradiated materials

• Contract for CANDU Owners Group (COG)

• 4 samples of highly irradiated nickel base superalloy (~70 dpa)

• Dose rates up to 32 R/hr

• Extremely compressed schedule

• Site-specific FIB specimen preparation followed by detailed quantitative TEM microstructural characterization of matrix and grain boundary features

• Work completed on schedule and on budget

• Results will be published at Aug 2017 Environmental Degradation Conference

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Feedback to the NSUF

• Great opportunity to connect world-class researchers and facilities with funding to support industry needs for nuclear technology development.

• Research needed to determine definitive cause of

irradiation damage effects, to improve materials selection and performance in nuclear applications, and most importantly to provide technology solutions that reduce costs of operation and maintenance of operating fleet.

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Feedback to the NSUF

• NSUF funding and document submittal processes: – Consider putting budgetary estimate earlier in schedule

or coincident with scope definition; will avoid cases where work program exceeds budget expectation.

– Adherence to FOA process, schedule, funding limits • Radiological shipping & disposal:

– Education on shipping, receiving, storage of specimens will help researchers and avoid pitfalls defining work plan

• FOA process: – Checklist for Principal Investigators that simplify activities,

dates, and communication plan required for applications

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Westinghouse Electric Company LLC NSUF Access – Points of contact

For questions or to discuss how we can meet your laboratory needs, please contact:

Ms. Paula Freyer Fellow Engineer Westinghouse Electric Company LLC Materials Center of Excellence 1332 Beulah Road, Building 302 – Office 201C Pittsburgh, PA 15235 Phone (Office): 1-412-256-1771 Phone (Mobile): 1-724-513-9458 Email: [email protected]

Dr. Michael Burke Consulting Engineer Westinghouse Electric Company LLC Materials Center of Excellence 1332 Beulah Road, Building 302 – Office 201D Pittsburgh, PA 15235 Phone (Office): 1-412-256-1277 Phone (Mobile): 1-724-584-8909 Email: [email protected]

Mr. Edward Blanciak Radiation Safety Officer Westinghouse Electric Company LLC Environmental Health and Safety 1322 Beulah Road, Building 302 – Office 209 Pittsburgh, PA 15235 Phone (Office): 1-412-342-1746 Phone (Mobile): 1-412-290-2147 Email: [email protected]

Mr. Frank Gift Product Manager Westinghouse Electric Company LLC PWR Engineering Products 1332 Beulah Road, Building 301 – Office 106A Pittsburgh, PA 15235 Phone (Office): 1-412-342-1910 Phone (Mobile): 1-724-316-8024 Email: [email protected]

http://www.westinghousenuclear.com/Operating-Plants/Engineering/NSSS-System-Component-Analysis











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QUESTIONS

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SEM and Focused Ion Beam (FIB) Tescan LYRA-3 GMU FIB/SEM – for characterization of radioactive and clean specimens • Dual beam FIB, with a 3rd generation Tescan Mira electron column

and an Orsay Physics Canion FIB column and mono-gas (Pt) injection

• E-T and high resolution In-Lens SE detectors, retractable BSD detector, and low vacuum secondary electron detector

• Equipped with Oxford Instruments Xmax-N 80 SDD XEDS detector for very high count rates and fast mapping aquisition, Oxford-HKL fast EBSD detector, SmarAct in situ FIB lamella sample manipulator and XEi Zephyr in-chamber plasma cleaner

• Variable pressure capability for characterization of insulating materials

Insitu observation

– Standard planar surface – Cross-section View through “trench”

Section Lift out capability – Low activity specimen preparation

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FEI CM-300 FEG-TEM – for characterization of radioactive and clean specimens • High resolution FEG with twin objective lens

and compu-stage control • Scanning unit (STEM) with bright field and

dark field detectors • Oxford Instruments Si(Li) XEDS detector • Gatan Orius SC1000B 11 MP fast CCD

detector, well-suited for imaging as well as diffraction pattern acquisition

• Image acquisition and feature analysis capabilities

Under focused BF TEM image

Binary image with cavities shown in red overlaying the under focused BF TEM image

Binary black and white image

Conventional feature imaging plus nano-feature sizing and counting

Transmission Electron Microscope (TEM)

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X-ray Diffraction for Precise Identification of Phases

PANalytical X’Pert Pro MPD X-ray Diffractometer – for characterization of radioactive and clean specimens • Equipped with a high resolution, large dynamic range PIXcel

silicon strip detector for very high count rates and acquisition speeds, a graphite monochromator to remove Cu Kβ lines and fluorescent signal from ferrous materials

• Equipped with numerous sample stages and a 15-position sample changer

• Equipped with a monocapillary lens and optical microscope for microdiffraction work with spot size of 500 µm, and polycapillary lens well suited for stress measurements

Calc'd from SAD CrFe2O4

4.77645 4.84 1 1 12.900754 2.96 2 2 0

2.4739766 2.53 3 1 12.0534884 2.09 4 0 01.6397098 1.61 3 3 31.4838111 1.48 4 4 0

d-spacing (Å)

hkl

Application to Fuel Crud

Application to Corrosion Film in PWR Structural Element

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Optical and Scanning Electron Microscope (SEM) Standard Optical Metallographic Capabilities • In cell and outside of cell

Tescan Vega-3 XMU SEM – for characterization of extremely radioactive specimens • Attached to SEM Hot Cell for completely remote

sample loading(refer to Hot Cell section) • E-T SE detector and retractable BSE detector

Zeiss SUPRA-40 FE-SEM – for characterization of radiologically clean species • Gemini column for high resolution imaging of

materials at very low accelerating voltages • E-T and high resolution In-Lens SE detectors,

and retractable four-quadrant BSE detector • Equipped with an Oxford Instruments Xmax 80

SDD XEDS detector for very high count rates for elemental identification and mapping


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Building 302/302A Hot Cells

302-208A - Clean Hot Cell • 55” x 65” x 82”h • Steel shot 16” wall • Clean Irradiations • Single Window w/Remote

Manipulators • Designed for ~ 1kCi


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302A-105 – High Level Hot Cell • 5’ x 24’ x 12’h • Concrete wall with Iron shot

and Magnetite, 27” • Sectioning and machining of

irradiated metal • 4 Windows w/Remote

Manipulators • Designed for ~38 kCi


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302A-105 – Low Level Hot Cell • 6’ x 17.5’ x 10’h • Concrete wall 24” • Physical Testing • 3 Windows w/Remote

Manipulators


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302A-105A – Cell “A” • 6’ x 6’ x 11.5’h • Steel wall, 10” • Hydrogen Analysis • 1 Window w/Remote

Manipulators


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302A-105A – Cell “M” • 6’ x 6’ x 11.5’h • Steel wall, 10” • Metallography • 1 Window w/Remote

Manipulators


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Building 302/302A Hot Cells 302A-211F – SEM • 40” x 40” x 84”h • Steel wall, 8” • Shielded SEM • 1 Window w/Remote

Manipulators

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