Component Asset Management with Ultra-High Pressure Cavitation Peening

Transcription

1 Component Asset Management with Ultra-High Pressure Cavitation Peening Darren H. WOOD, P.E. Global Product Development Manager Lyon, France 23 October 2017 Darren H. WOOD p.1

2 Agenda Why UHP Cavitation Peening? Process Selection and Development Tooling / Capabilities Planning / Return on Experience Regulatory Acceptance Summary and Conclusions Darren H. WOOD p.2

3 What is Ultra High Pressure (UHP) Cavitation Peening? High Velocity Jet Creates pressure below that of vapor pressure in water Cavitation Vapor bubbles form in water Shock Waves Occur from bubble collapse at surface generating high pressures on the material Compressive Stresses In the surface layer of material results UHP Cavitation Peening is a Well Understood, Proven Process for Surface Stress Mitigation and Improving Fatigue Life Darren H. WOOD p.3

4 Why discuss UHP Cavitation Peening? PWSCC of primary components can lead to Increased inspection frequency Greater outage scope Component repairs Schedule extension Component replacements Increased costs Tensile Stress Susceptible Material Corrosive Environment UHP Cavitation Peening is an Asset and Risk Management Tool Darren H. WOOD p.4

5 Agenda Why UHP Cavitation Peening? Process Selection and Development Tooling / Capabilities Planning / Return on Experience Regulatory Acceptance Summary and Conclusions Darren H. WOOD p.5

6 Surface Mitigation Process Selection 2009: 99 mitigation techniques identified 2010: 10 techniques selected based on technical / economics 2011: 3 techniques selected for additional testing Cavitation Peening Laser Shot Peening Roto Peening 2012 / 2013: Several R&D projects for: Corrosion testing on Alloy 182 samples Tooling development and qualification for UHP Cavitation Peening of BMN nozzles (ID & OD) 2014 / 2015: UHP Cavitation Peening process and tooling development RV Head Primary Nozzle Darren H. WOOD p.6

7 Internal Testing Summary Similar to MRP-267 Corrosion Testing Cavitation Peening induced a compressive stress state on the surface of all samples The surface remained in compression through all corrosion testing Cracks did not initiate on fresh samples treated with Cavitation Peening Shallow existing cracks on pre-aged samples did not propagate after treatment with Cavitation Peening No crack initiation or growth after an additional.4% strain was applied for 1000 hours UHP Cavitation Peening Prevents PWSCC Darren H. WOOD p.7

8 Unique Technologies Cavitation peening (Patent) Hyperbaric testing Controlled depth abrasive jet milling High speed ceramic machining Selective coating removal Precision 5-axis machining Downhole energy tooling Nuclear cleaning & decommissioning tooling Customers US Navy, Air Force, Army Missile defense agency NASA National Science Foundation Pratt and Whitney Rocketdyne Rolls-Royce General Electric Energy/Aircraft Engines AREVA Lockheed Raytheon ATK Boeing Baker-Hughs Sikorsky W.L. Gore General Atomic CoorsTek Our partner Ormond has the pedigree nuclear power requires Darren H. WOOD p.8

9 UHP Cavitation Peening Surface Finish Before Peening Non-peened with PT Indications Peened No PT Indications After Peening Darren H. WOOD p.9

10 Why AREVA Selected UHP Cavitation Peening? Safe for both personnel and component when operated within the controlled boundaries Very robust process with a large saturation zone No risk of equipment damage or material removal No foreign material concerns Smooth transition zones with no abrupt edge between peened and unpeened regions Compressive stress depths meet or exceed EPRI MRP requirements Very adaptable and tolerant to surface conditions and complex geometries J-grooves CRDM thermal sleeve annulus BMI nozzle inside diameter Does not require complicated tooling compared to laser or waterjet UHP Cavitation Peening Scored Highest with Evaluation Criteria : Safety, Results, and Ease of Implementation Darren H. WOOD p.10

11 UHP Cavitation Peening Qualification The peening process effectiveness was demonstrated on full scale representative mockups at the nominal, max and min ranges of essential variables used for site implementation Full scale nozzle mockups include material and geometry constraints X-ray diffraction was used to determine the residual stress on peened full scale representative mockups Confirm the desired peening coverage and depth of compression has been achieved A qualification report is provided to the utility that documents how all requirements are met Topical Report / Relief Request / ASME Code Same Essential Variable Range for Qualification Mockups and Site Implementation Darren H. WOOD p.11

12 Process Control and Verification Essential variables are controlled/monitored in-process to ensure acceptable results are achieved The operator has a real-time display of all essential variables If an essential variable gets outside of the qualified limits the operator is immediately alerted The tooling control system records the value of each essential variable The electronic data may be reviewed/verified post-process Process Quality is Ensured and May be Verified Darren H. WOOD p.12

13 Agenda Why UHP Cavitation Peening? Process Selection and Development Tooling / Capabilities Planning / Return on Experience Regulatory Acceptance Summary and Conclusions Darren H. WOOD p.13

14 Where is UHP Cavitation Peening Applicable? Reactor Vessel Closure Head Penetrations Alloy600 base metal Primary RPV Nozzle Dissimilar Metal Weld and Safe-End Alloy600 weld Bottom Mounted Instrumentation Nozzle Penetrations Reactor Vessel Safety Injection Nozzle Dissimilar Metal Weld and Safe- End Darren H. WOOD p.14

15 Bottom Mounted Instrumentation Nozzle UHP Cavitation Peening BMN OD Surfaces Alloy 600 (nozzle): 1 to 1.5 mm depth of compressive stress Alloy 82/182 (j-groove weld): 1 mm depth of compressive stress BMN ID Surfaces Alloy 600 (nozzle): 0.5 mm depth of compressive stress Lightweight tooling easily managed from the refueling bridge Darren H. WOOD p.15

16 RV Closure Head UHP Cavitation Peening CRDM OD Surfaces Alloy 600 (nozzle): from 1 mm at the minimal parameter boundary to 1.5 mm depth of compressive stress at nominal dimensions Alloy 82/182 (j-groove weld): 1 mm depth of compressive stress CRDM ID Surfaces with or without Thermal Sleeve Alloy 600 (nozzle): Greater than.25 mm depth of compressive stress on all PWSCC susceptible CRDM ID surfaces The only process that can peen the annulus without removing or modifying the thermal sleeves Vent Nozzle Surfaces Alloy 600 (nozzle): 0.5 mm depth of compressive stress Alloy 82/182 (j-groove weld): 1 mm depth of compressive stress UHP Cavitation Peening is the Most Adaptive Process for these Geometries Darren H. WOOD p.16

17 Mega SUMO Under-Head Manipulator NDE Synergies with Peening Realized benefit of common manipulator Integrating and streamlining all pre-deployment activities Delivers all peening, contingency repair, and inspection tooling for RVCH penetrations Simultaneous use of 2 manipulators for increased production rates Only one head lift necessary Beginning of inspection Critical path savings by installing false floor for water reclamation before head is set, not after inspection NDE Performance AREVA started performing Exelon head inspections with award of peening contract Fastest full scope inspection at Braidwood: 69 hour duration (23.2 hours ahead of schedule for 2R19) Flexible, Robust Delivery System Darren H. WOOD p.17

18 Primary RPV Nozzle Dissimilar Metal Weld UHP Cavitation Peening Nozzle DMW ID (Weld + Heat Affected Zone) 1 mm depth of compressive stress Tool can swim NO supplemental support structures UHP Cavitation Peening Performed from Inside the RPV, Lower Dose vs OD Darren H. WOOD p.18

19 Basics of the Process Critical peening tooling (and essential variables) are the same for all applications Pumps Piping / Hoses Orifice Observed differences are in the delivery mechanism Crawler Submarine Manually Delivered Darren H. WOOD p.19

20 Agenda Why UHP Cavitation Peening? Process Selection and Development Tooling / Capabilities Planning / Return on Experience Regulatory Acceptance Summary and Conclusions Darren H. WOOD p.20

21 Peening Implementation Byron and Braidwood RVCH <30 day outages 78 CRDM type nozzles (5 CETs, 18 open penetrations, 55 CRDM nozzles with thermal sleeves) and 1 vent line Byron 2 Completed May 2016 Braidwood 1 Completed October 2016 Byron 1 Completed March 2017 Braidwood 2 Completed May 2017 Proven process on most challenging configuration First of a kind risks have been mitigated Extensive lessons learned to benefit next interventions Customer headstand modifications were implemented seamlessly and did not affect critical path UHP Cavitation Peening is a PROVEN Technology that will Maintain Your Asset for the Life of Your Plant Darren H. WOOD p.21

22 Site Preparation & Implementation Equipment Setup : Two (2) UHP water jet pumps + spare and chiller 460VAC Operator control station in a low dose area inside or outside containment building Two (2) sets of each tool head Darren H. WOOD p.22

23 Plant Configuration and Basic Logistics for UHP Cavitation Peening RV Head BMN Primary Nozzles All Work with Component on Head Stand Establish minimum height for tooling Experience operating two tools in parallel Lower Internals Removed from Vessel / Flooded Cavity Workers locate equipment from refuel bridge Logically plan with a 10 year RPV ISI Plan with two tools in parallel Average schedule dependent on plant size / configuration and to be optimized with the operator Average dose depending on plant-specific conditions Hot Leg Only: Fuel Offloaded / Flooded Cavity Hot Leg + Cold Leg: Lower Internals Removed from Vessel / Flooded Cavity Workers monitor from refuel bridge Crane required to introduce tool, then released Logically plan Cold Leg mitigation with a 10 year RPV ISI Plan with two tools in parallel Darren H. WOOD p.23

24 Basic Activity Planning Pre-Outage Tasks Establish parameters based on as-built configuration Implementation documentation Customer-specific qualifications and readiness demonstrations Safety Justification Inspection Relief Request (as applicable) must be submitted before the next required inspection and can be planned after implementation Outage Scope (N-1 Walkdown Recommended) Inspection Contingency Repair UHP Cavitation Peening Darren H. WOOD p.24

25 Agenda Why UHP Cavitation Peening? Process Selection and Development Tooling / Capabilities Planning / Return on Experience Regulatory Acceptance Summary and Conclusions Darren H. WOOD p.25

26 ASME Code and Safety Authority Criteria AREVA worked with EPRI, ASME, and the NRC to lead the way for Regulatory Acceptance of cavitation peening in the USA. Code Case N is approved by ASME Provides inspection relief for primary nozzles mitigated by peening Code Case N is approved by ASME Provides inspection relief for RV heads mitigated by peening MRP-335, Rev. 3 Topical Report for Primary Water Stress Corrosion Cracking Mitigation by Surface Stress Improvement: Provides technical basis for inspection relief after peening for both RV heads and primary nozzles NRC safety evaluation released with conditions in August 2016 RV heads with pre-existing flaws must inspect the next 2 refuel outages after peening before returning to a 10 year inspection frequency MRP-335, Rev. 3-A : amendment to include the NRC Safety Evaluation Conditions (November 2016) ASME Code and US Safety Authority Requirements are Established and the Benefits of Peening are Confirmed Darren H. WOOD p.26

27 US Precedent UHP Cavitation Peening Was implemented in accordance with current 10 CFR regulatory process The NRC review of Byron Unit noted it supported the conclusions with no concerns Was controlled as a 10 CFR 50 Appendix B Criterion IX special process Post-Peening In-service Inspection Relief Changes in the volumetric inspection frequency specified in 10 CFR 50.55(a) requires NRC approval via the relief request process Basis provide by MRP-335, Rev. 3-A Typically several years before the NRC will endorse the ASME Code Cases Exelon submitted fall of 2016 for Byron 2 and received approval September 2017 Darren H. WOOD p.27

28 Agenda Why UHP Cavitation Peening? Process Selection and Development Tooling / Capabilities Planning / Return on Experience Regulatory Acceptance Summary and Conclusions Darren H. WOOD p.28

29 UHP Cavitation Peening Advantages Demonstrated mitigation technology offers less complexity, more flexibility, easier and safer delivery, and higher confidence for success AREVA s under-head experience is greatest in the industry with regard to RV head inspections and number of nozzles repaired (predictable performance) AREVA offers both mitigation, inspection, and repair solutions from a common platform (RV head) The technology is the most adaptable process to complex geometries We are the only vendor that can peen the CRDM ID with the thermal sleeves in place, requiring no modifications (4 loop configuration) The technology is less complex / more forgiving than laser technologies No risk of equipment damage or material removal AREVA worked closely with US NRC for peening implementation Depth of compression meets or exceeds EPRI MRP requirements Partnering with AREVA provides access to a full scope solutions portfolio to support your unique LTO strategy NDE, engineering, contingency repair (specialized welding and machining processes), mitigation, and even replacement components AREVA has a proven track record in the industry of fulfilling our commitments Darren H. WOOD p.29

30 UHP Cavitation Peening Summary of Results Surface Depth of Compression AREVA EPRI / MRP CRDM Nozzle OD Alloy mm mm 1 mm CRDM J-Groove Weld OD Alloy 82/182 1 mm 1 mm CRDM Nozzle ID Annulus w/ thermal sleeve Alloy mm -.50 mm.25 mm CRDM Nozzle ID (Open) Alloy mm.25 mm Vent Nozzle J-Groove Weld OD Alloy 82/182 1 mm 1 mm Vent Nozzle ID Alloy 600/82/ mm.25 mm BMN Nozzle OD Alloy mm mm 1 mm BMN J-Groove/Repair Weld OD Alloy 82/182 1 mm 1 mm BMN Nozzle ID Alloy mm.50 mm Primary Nozzle DMW Alloy 82/182 1 mm 1 mm UHP Cavitation Peening reliably meets or exceeds EPRI MRP mitigation criteria Darren H. WOOD p.30

31 UHP Cavitation Peening Concluding Thoughts Proven Technology : demonstrated in safety conscious nuclear and aerospace industries for Asset Management : can mitigate PWSCC susceptible components, extending their useful lifetime (depending on local accounting laws, perhaps capitalize the investment) Risk Management : planning certainty to avoid component repairs and replacements due to PWSCC which lead to increased outage cost, schedule, and dose Schedule Optimization : reduce inspection frequency of renewed components Our Vision: High-performing people and technologies for safe and competitive nuclear plants worldwide Darren H. WOOD p.31

32 Any reproduction, alteration, transmission to any third party or publication in whole or in part of this document and/or its content is prohibited unless AREVA NP has provided its prior and written consent. This document and any information it contains shall not be used for any other purpose than the one for which they were provided. Legal action may be taken against any infringer and/or any person breaching the aforementioned obligations. Darren H. WOOD p.32