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© 2016 Electric Power Research Institute, Inc. All rights reserved.
Stan Walker & Jay Richardson
EPRI
Generation Sector Program Advisory Meeting
- Orlando
September 12, 2016
Generation Nondestructive
Evaluation (NDE) Research
Area Meeting
2© 2016 Electric Power Research Institute, Inc. All rights reserved.
Agenda
TIME TOPIC PRESENTER
12:00 p.m. Lunch – Kingston Hall
1:00 p.m. Welcome and Introductions Stan Walker
1:10 p.m. Safety Moment Stan Walker
1:20 p.m. Generation NDE Research Area
1:45 p.m.Generation Advanced NDE Development Supplemental Program
StatusStan Walker/Jay Richardson
2:00 p.m.Generation Advanced NDE Development Supplemental Program
Proposed ProjectsStan Walker/Jay Richardson
2:30 p.m. Afternoon Break
3:00 p.m. Supplemental Project Status Stan Walker/Jay Richardson
3:30 p.m. TI Project Status Stan Walker/Jay Richardson
4:00 p.m. 2016 NDE Deliverables Stan Walker
4:15 p.m.Identify Potential Projects for Advanced NDE Development
Supplemental ProgramAll
5:00 p.m. Adjourn
3© 2016 Electric Power Research Institute, Inc. All rights reserved.
Safety Moment
4© 2016 Electric Power Research Institute, Inc. All rights reserved.
Do you know what you would do?
5© 2016 Electric Power Research Institute, Inc. All rights reserved.
Safety Moment
PROFILE OF AN ACTIVE SHOOTER
An Active Shooter is an individual actively engaged in killing or attempting to kill people in a confined and populated area; in most cases, active shooters use firearms and there is no pattern or method to their selection of victims.
Active shooter situations are unpredictable and evolve quickly. Typically, the immediate deployment of law enforcement is required to stop the shooting and mitigate harm to victims.
Because active shooter situations are often over within 10 to 15 minutes, before law enforcement arrives on the scene, individuals must be prepared both mentally and physically to deal with an active shooter situation.
6© 2016 Electric Power Research Institute, Inc. All rights reserved.
What to do in Active Shooter Situation
Good practices for coping with an active shooter situation
Be aware of your environment and any possible dangers
Take note of the two nearest exits in any facility you visit
If you are in an office, stay there and secure the door
If you are in a hallway, get into a room and secure the door
As a last resort, attempt to take the active shooter down. When
the shooter is at close range and you cannot flee, your chance of
survival is much greater if you try to incapacitate him/her.
CALL 911
WHEN IT IS SAFE TO DO SO!
7© 2016 Electric Power Research Institute, Inc. All rights reserved.
How To Respond When An Active Shooter Is In Your Vicinity
Quickly determine the most reasonable way to protect your own life
1. EvacuateIf there is an accessible escape path, attempt to evacuate the premises
2. Hide outIf evacuation is not possible, find a place to hide where the active shooter is less likely to find you
3. Take action against the active shooterAs a last resort, and only when your life is in imminent danger, attempt to disrupt and/or incapacitate the active shooter by:
• Acting as aggressively as possible against him/her
• Throwing items and improvising weapons
• Yelling
• Committing to your actions
8© 2016 Electric Power Research Institute, Inc. All rights reserved.
Commitment
If you’ve disrupted
the shooter or, better,
gotten the weapon
out of his hands,
inflict damage on him
until he is dead or
has stopped moving
Tough, I’ll admit, but
these are tough
times; commit to your
actions
9© 2016 Electric Power Research Institute, Inc. All rights reserved.
When Police Arrive
Don’t be
confused as
the bad guy
10© 2016 Electric Power Research Institute, Inc. All rights reserved.
Antitrust Guidelines for EPRI Meetings and Conferences
The antitrust laws and other business laws apply to EPRI, its Members, participants, funders, and advisers; violations can
lead to civil and criminal liability. EPRI is committed to both full compliance and maintaining the highest ethical standards in
all of our operations and activities.
These guidelines apply to all occasions: before, during, and after EPRI meetings, including in the hallways, over lunch,
during breaks and at dinner.
…is to conduct research and development relating to the
generation, delivery and use of electricity for the benefit
of the public. EPRI advisory meetings are conducted to
further that purpose.
…is to follow the meeting agenda and provide advice on
EPRI’s R&D program and how to make EPRI results
most useful. Consult with your company counsel if at any
time you believe discussions are touching on sensitive
antitrust subjects such as pricing, bids, allocation of
customers or territories, boycotts, tying arrangements
and the like.
EPRI’S PRIMARY PURPOSE
YOUR ROLE AT EPRI
ADVISORY MEETINGS
11© 2016 Electric Power Research Institute, Inc. All rights reserved.
Antitrust Guidelines for EPRI Meetings and Conferences (continued)
…pricing, production capacity, or cost information which
is not publicly available; confidential market strategies or
business plans; or other competitively sensitive
information. Do not disparage suppliers and/or
competitors of EPRI, technology providers and/or EPRI
Members and participants.
…the use of particular vendors, contractors or
consultants for non-EPRI projects. EPRI will not promote
or endorse commercial products or services of third
parties. You must draw your own conclusions and make
your own choices independently.
…in any discussions of goods and services offered in
the market by others, including your competitors,
suppliers, and customers.
DO NOT DISCUSS
EPRI DOES NOT
RECOMMEND
BE ACCURATE, OBJECTIVE,
AND FACTUAL
12© 2016 Electric Power Research Institute, Inc. All rights reserved.
Antitrust Guidelines for EPRI Meetings and Conferences (continued)
…to discriminate against or refuse to deal with (i.e.,
“boycott”) a supplier; or to do business only on certain
terms and conditions; or to set price, divide markets, or
allocate customers.
…or advise others on their business decisions, and do
not discuss yours (except to the extent that they are
already public).
…for advice from your own legal department, if you have
questions about any aspect of these guidelines or about
a particular situation or activity at EPRI; or ask the
responsible EPRI manager to contact EPRI’s Legal
Department.
DO NOT AGREE WITH
OTHERS
DO NOT TRY TO
INFLUENCE
ASK
13© 2016 Electric Power Research Institute, Inc. All rights reserved.
Accessing Meeting Materials
1. EPRI Events Meeting App
Download from app store
Access at https://event.crowdcompass.com/gen-adv-council
• Code - genf16 Login using Registration confirmation
1. Member Center Program Cockpit
Log into member center http://membercenter.epri.com
14© 2015 Electric Power Research Institute, Inc. All rights reserved.
Generation Meeting App Features
• Find the time and place for your meetings
• Access
• Meeting Agendas
• Meeting presentations and materials
• Speaker biographies
• EPRI documents
• Hotel maps
• List of nearby restaurants
• Link to site for things to do and see in Orlando
15© 2015 Electric Power Research Institute, Inc. All rights reserved.
Smart Device App Home Page
Welcome:
• General meeting information
• EPRI Antitrust Guidelines
• Future advisory meetings through
2017
Access Materials:
Click on the three lines at the top to
log into the app
• See welcome letter for
registration ID or visit the
Registration Desk
• Some programs and Council
materials are restricted to
members ONLY
Schedule:
• Meeting times and places
• Agendas
• Presentations and other materials
16© 2015 Electric Power Research Institute, Inc. All rights reserved.
Schedule Page
Full Week Schedule of Events
All Program Agendas
• Meeting times and places
• Agendas
• Presentations and other
materials
(Research Areas)
17© 2015 Electric Power Research Institute, Inc. All rights reserved.
Event Extras Page
My personal schedule
Login for access to
meeting materials
Confirmation code is in
welcome email or at
registration desk
18© 2016 Electric Power Research Institute, Inc. All rights reserved.
Generation NDE Research Area
Table Top Display
At
Council Reception
Generation Nondestructive Evaluation (NDE) Research
Program Manager: Stan Walker
704-595-2581 swalker@epri.com
Program Chair: Kevin McCarthy Xcel Energy
•Strategic 5-year plan outlines gaps, key
issues & collaborative R&D needed
•NDE technologies & support to shorten
plant outages
•Technical analysis of NDE diagnostic
capabilities during extended plant
operation
• Implementation support for NDE & evaluation
guidelines through EPRI & industry materials
analysis programs
•Proficiency demonstration process for NDE
•Technical guidance that improves NDE
Maximizing safety & reliability of power plant components;
determining optimal timing for repair or replacement through
accurate and timely detection and measurement of service-
generated damage
Increasing accuracy of information about material conditions
20© 2016 Electric Power Research Institute, Inc. All rights reserved.
Research Areas of Focus – Nondestructive Evaluation
Boiler Components
Steam Turbines
Combustion Turbines
Heat Recovery Steam Generators
Balance of Plant Components
Materials and Chemistry
21© 2016 Electric Power Research Institute, Inc. All rights reserved.
Key Project -- Technology Innovation
Development of Header Inspection Tool
Probe Travels Full Length of Tubes (~70 Ft) to Provide Thorough Inspection
Need to inspect headers and tubes in
inaccessible locations (HRSGs)
• Tightly clustered tubes and headers prevent access for
conventional NDE
• Providing opening to HRSG casing and removing
header endcap permits insertion of internal inspection
tool
• Robot moves through header and inserts probe in
each tube
• Completed one field trial; second trial with
improvements scheduled for Sept. 19, 2016
22© 2016 Electric Power Research Institute, Inc. All rights reserved.
Key Project – Supplemental (P65)
Digital Radiography for Crack Detection in Last-Stage Turbine
Rotor Blade Attachments
Reduced Radiation Exclusion Zone Via Shielding
Detect cracking in pin finger attachments of
L-0 stage without de-blading rotor
• Supplemental Project with 10 utilities
• Evaluate use of real-time digital radiography
• Technologies to reduce radiation exclusion
zone for other work activities
• Optimize process in laboratory
• Conduct field trial to verify functionality in plant
23© 2016 Electric Power Research Institute, Inc. All rights reserved.
Key Project – P79
Rotor Life Management: Compressor End Dovetail Slot Cracking
Improve Remaining Life Assessment via Enhanced Detection and Sizing
GE 7F/9F gas turbine compressor wheel dovetail slot radius HCF cracking (TIL-1971 and TIL-1972)
• At risk - thin design attachment rim accumulating 1000-1500 starts. Cracking reported on disks 12 through 17
• OEM recommends visual & liquid penetrant examinations requiring shipping offsite for disassembly
• Current in-situ ultrasonic techniques limited
• Available scanning surface not optimal
• Crack propagation direction challenging for tip-diffraction response
• Optimizing detection and sizing through simulation & experimentation on retired wheels
24© 2016 Electric Power Research Institute, Inc. All rights reserved.
Success Stories - Recent Member Applications of EPRI Results
Members Expanding Uses of EPRI NDE Technology
2016 – TVA Applies Encoded Phased Array UT to
Ammonia Storage Tanks
2016 – Luminant Uses New Flaw Acceptance Criteria
2016 – CEZ Detects and Measures Magnetite
Exfoliation Blockage
2015 – Southern Company Shows Value of Flexible
Eddy Current Array Probe
2014 –TVA Demonstrates Pulsed Eddy Current for
Inspecting Insulated Piping Systems
2013 - NB Power Demonstrates Potential of Digital
Radiography for Detection of Cracking in Turbine
Blades
2012 - GenOn Energy Demonstrates New
Technology in Detection of Magnetite Exfoliation
25© 2016 Electric Power Research Institute, Inc. All rights reserved.
Success Stories - Earlier Member Applications of EPRI Results
Early Applications of EPRI NDE Technology in Generation Sector
2010 – E.ON U.S. Shows Potential of Digital
Radiography for Detection of Boiler Corrosion Fatigue
Cracking
2010 – Dynegy Tests Snake Robot Technology for
Inspection of HRSG Tubes
2009 – AEP Hosts Field Testing of Digital Radiography
2008 – New Brunswick Power Uses CHECUPweb™ to
Model Piping Systems for Flow-Accelerated Corrosion
2006 – Application of NDE at Xcel Energy
2005 - MsS Helps CPS Examine 3 Miles of Insulated
Piping in 2 Days
2000 – NYPA Saves With INCOTEST Through-Insulation
Inspection for Flow-Accelerated Corrosion
26© 2016 Electric Power Research Institute, Inc. All rights reserved.
Success Story
Encoded Phased Array to Inspect Ammonia Storage Tanks
Finding New Applications of Existing Technology Reduces Costs
TVA team used EPRI reports to adapt technology to
inspect ammonia storage tanks for weld damage
• Project team devised methodology, qualification test plate, and
work scope to examine welds for surface-initiated IGSCC from
the exterior surface without removal of tank contents
• Examined exterior of tank walls & avoided unit outage &
cost/time to empty tank for inspection of interior surfaces
• Adaptation of encoded phased array technology reduced the
time needed to inspect each tank to 1 day and reduced the cost
to ~ $10K per tank
• 10 ammonia storage tanks inspected by Feb 2016 with
substantial savings
27© 2016 Electric Power Research Institute, Inc. All rights reserved.
Success Story
Luminant Uses New Flaw Acceptance Criteria to Reduce
Unnecessary Repairs
Flaw Size Boundaries Provide Useful Life Prediction, Avoid Unnecessary Repairs
In 2015, Luminant used EPRI criteria to evaluate
integrity of small-diameter boiler tube butt welds
• Criteria use phased array ultrasonic technology exam & are based
on fitness-for-service analysis
• Increased consistency of flaw evaluation, improved examination
confidence, & reduced number of unneeded repairs
• Reduced number of new welds requiring repair by more than 20%
• Using risk-based variable fracture margin also allows prioritization of
tube weld repairs to fit future outage schedules
28© 2016 Electric Power Research Institute, Inc. All rights reserved.
Success Story
Flexible Eddy Current Array Probe for Detecting Cracks in
HRSG Welds
NDE Sensor Development is Vital in Advancing Inspection Technology Automation
Southern Company hosted demonstrations of new
wearable, flexible-eddy current array probe
• Effective detecting cracks in tube-to-header welds of HRSGs &
other complex structures
• Demonstrations at Southern Power’s Plant Rowan & Plant Harris
gave firsthand experience with probe, documented performance
• Participants confirmed probe was significant improvement
• Also demonstrated on NG turbine buckets, valve seat & gate
• Southern personnel also used probe to examine buckets of
combustion turbine, several compressor blades & portions of NG
turbine rotor
29© 2016 Electric Power Research Institute, Inc. All rights reserved.
Generation NDE Cockpit
Not in same Member Center
location as Program Cockpits
In Member Center, go to
Generation Sector
NDE Research Area is in lower
left hand list
30© 2016 Electric Power Research Institute, Inc. All rights reserved.
NDE Cockpit
31© 2016 Electric Power Research Institute, Inc. All rights reserved.
Project Status Updates (PSU)
Information on current program research
Located on Project Status Updates tab on Program Cockpit
Issued Quarterly
32© 2016 Electric Power Research Institute, Inc. All rights reserved.
Research Support
Added tab for Research Support
Contains hot links to Success Stories
Can add newsletters and other
informative documents
33© 2016 Electric Power Research Institute, Inc. All rights reserved.
2016 Generation NDE Five-Year Plan (Working)
2016 2017 2018 2019 2020
Continue To Expand Proficiency Demonstration Project To Additional Components & Technologies
Continue Increasing
Availability Of NDE
Technologies Operating
Through Insulation
Expand NDE Projects Within Generation Sector
Develop NDE For Material Properties
Evaluation
Define Acceptance
Standards For High-
Sensitivity NDE
Expand Lab Equipment & Facility
Generation Advanced NDE Development Supplemental Program
EPRI NDE
Conference/Technology Fair
EPRI NDE
Conference/Technology Fair
International NDE
ConferenceInternational NDE
Conference
International
NDE Conference
Add NDE Project
Manager
34© 2016 Electric Power Research Institute, Inc. All rights reserved.
Expand Proficiency Demonstration Project To Additional Components &
Technologies
Original concept of NDE proficiency demonstration project was to 1st address
components & damage mechanisms identified by members as most urgent &
then gradually expand to other components & damage mechanisms as
warranted
Demonstrations for boiler tubes, high energy piping & headers currently
implemented – plans to allow for expansion to other components
2016 2017 2018 2019 2020
Turbine Blade
Attachments
Boiler Tube
Practice Samples
Piping Practice Samples
Other Components
Offer Proficiency Demonstrations To International members
Equip Dedicated Lab
For Demonstrations
Continue To Expand Proficiency Demonstration Project To
Additional Components & Technologies
35© 2016 Electric Power Research Institute, Inc. All rights reserved.
Expand NDE Projects Within Generation Sector
NDE should address all components within the sector, including boilers, high
energy piping, turbines, generators, wind turbines, wind blades, combustion
turbines, material issues & joint activities with chemistry such as FAC
2016 2017 2018 2019 2020
Start By Expanding Into
P79
Expand To P65 & Other Programs
Expand NDE Projects Within The Generation Sector
Assist Maintenance Applications Center and Balance of Plant with NDE
36© 2016 Electric Power Research Institute, Inc. All rights reserved.
Continue Increasing Availability Of NDE Technologies Operating Through
Insulation
Utilities have great expense in removal & re-installation of insulation
Ability to have more NDE technology that does not require insulation removal will be good cost saver
2016 2017 2018 2019 2020
Pulsed Eddy Current
Continue Increasing Availability Of NDE
Technologies Operating Through Insulation
Digital Radiography Of
Piping For FAC
Electromagnetic NDE Techniques
37© 2016 Electric Power Research Institute, Inc. All rights reserved.
Develop NDE For Material Properties Evaluation
NDE is needed that can identify damage at an earlier stage & be able to
assess material properties
2016 2017 2018 2019 2020
Develop NDE For Material Properties
Evaluation
38© 2016 Electric Power Research Institute, Inc. All rights reserved.
Define Acceptance Standards For High-Sensitivity NDE
As NDE becomes more and more sensitive, smaller defects being identified
Members have requested EPRI work to define acceptance standards that would be appropriate for smaller defects that are now being detected
Old criteria of rejecting every defect detected is no longer valid & efforts underway to prepare appropriate criteria
2016 2017 2018 2019 2020
Define Acceptance Standards For
High-Sensitivity NDE
39© 2016 Electric Power Research Institute, Inc. All rights reserved.
Acquire NDE Technical Staff To Conduct NDE Experiments
To meet desire by upper management to do more internal projects, it will be necessary to acquire additional NDE staff to conduct NDE R&D and develop new technologies for various applications
Currently, EPRI defines scope of NDE projects & directs contractors in what might be best approach, but contractors are becoming known as the NDE experts rather than EPRI staff
2016 2017 2018 2019 2020
Increase NDE Technical Expertise Within Generation
Such That We Conduct In-House R&D Activities
Acquire Additional NDE Staff
Expand NDE Staff
40© 2016 Electric Power Research Institute, Inc. All rights reserved.
Expand Lab Equipment & Facility
In order to accommodate additional staff & to allow EPRI to actually perform
R&D, additional NDE laboratory equipment & facilities will be needed
2016 2017 2018 2019 2020
Enhance NDE Lab To Include NDE
Simulation Capabilities
Expand Lab Equipment & Facility
Expand NDE Laboratory Facility
Obtain Modern NDE Hardware
41© 2016 Electric Power Research Institute, Inc. All rights reserved.
Generation Advanced NDE Development Supplemental Program
Started Jan 2013 & Will Continue Through The 5 Years
Line Items Should Address Member Issues On The Table & Jump Start New Projects For Component Programs
2016 2017 2018 2019 2020
Generation Advanced NDE Development Supplemental Program
Advanced NDE
Conference
Evaluate Pulsed Eddy
Current for Finned Tube
Sampling Phased Array
42© 2016 Electric Power Research Institute, Inc. All rights reserved.
International NDE Conference
Occur every 18 months throughout the 5 years
1 week event
2016 2017 2018 2019 2020
International NDE
Conference
International NDE
Conference
International NDE
Conference
43© 2016 Electric Power Research Institute, Inc. All rights reserved.
EPRI NDE Conference/Technology Fair
Occur 2017 & then every 2 years (as needed) for 1 week
2016 2017 2018 2019 2020
EPRI NDE
Conference/Technology
Fair
EPRI NDE
Conference/Technology
Fair
44© 2016 Electric Power Research Institute, Inc. All rights reserved.
Generation Advanced NDE Development Supplemental
Program
Project Status
45© 2016 Electric Power Research Institute, Inc. All rights reserved.
2016 Projects
NDE Webinars
– Prepare series of 1 hour webinars
Geared towards utility engineers
Not intended to create NDE practitioners
Provide high level overviews
– Generic NDE Methods and standard applications
– Phased Array
– TOFD
– Others as needed and cost permits
46© 2016 Electric Power Research Institute, Inc. All rights reserved.
Generation Advanced NDE Development Supplemental
Program
Proposed Projects
47© 2016 Electric Power Research Institute, Inc. All rights reserved.
Detection of Damage in Boiler Tubes from the Tube Interior
Outside surface of majority of tubes between mud drum and steam drum are difficult to access, making conventional NDE techniques difficult to use for inspection
Use of guided waves capable of covering inaccessible areas from a remote sensor location is proposed as a possible solution to this inspection issue
For steam boilers, the guided wave probe can be inserted in tubes through open end of tube in mud drum or steam drum
It is expected that end-to-end NDE of the full length of the tube can be accomplished using a probe inserted at only one end of a tube
Applicable to corrosion damage and cracking
48© 2016 Electric Power Research Institute, Inc. All rights reserved.
Objectives
Develop guided wave approach that can detect corrosion
damage and cracking in boiler tubes when access is only
available from interior at mud or steam drum
Two types of MsT probes to be investigated
– MsT probe using mechanical coupling
– EMAT MsT probe using electromagnetic coupling
49© 2016 Electric Power Research Institute, Inc. All rights reserved.
NDE of Buried Piping
EPRI asked to look into NoPig NDE technology for buried piping
Nondestructive testing method for unpiggable pipelines using above ground measurements for detecting wall thickness anomalies like corrosion
An applied current between two points on pipeline up to 0.6 miles (1 km) apart
Contains several harmonic components at distinct frequencies
Resultant magnetic field is measured above ground along the pipe– Measurement data are processed to determine magnetic field
shape
– For local pipe wall thinning, a frequency-dependent deviation of the magnetic field shape from the circular form occurs
– Skin effect and magnetic stray flux evoke this deviation in case of wall defects caused by corrosion
50© 2016 Electric Power Research Institute, Inc. All rights reserved.
Schematic of NoPig Specifications
51© 2016 Electric Power Research Institute, Inc. All rights reserved.
Generation NDE Supplemental Projects
Project Status
52© 2016 Electric Power Research Institute, Inc. All rights reserved.
Review Supplemental Project Status
NDE Proficiency Demonstrations
Digital Radiography for Turbine Pinned Finger
Blade Attachments
HRSG Inspection Technology Demonstration
53© 2016 Electric Power Research Institute, Inc. All rights reserved.
Conducting Generation NDE Proficiency Demonstration & Annual Updates
Objectives & Scope
Ensure proficiency of individual NDE practitioners when applying advanced NDE techniques
Develop protocol & design new samples
Expand to international members
Value
Improve industry NDE capability by demonstrations
Expand / enhance applications of advanced NDE technologies
Details and Contact
Price: $100k Total (7 Members @ $15k Each)
Qualifies For Tailored Collaboration Or SDF
Project Manager
Jay Richardson, jrichardson@epri.com,
(704) 595-2572
SPN Number: 1025490
Improve Industry NDE Capability by Proficiency Demonstrations
54© 2016 Electric Power Research Institute, Inc. All rights reserved.
NDE Proficiency Demonstrations
Review 2015 Status
51 Demonstration sessions conducted through December 2015
Success rate
For 1 demo: 40%
2nd Attempt candidates: 22%
3rd Attempt candidates: 100%
Demonstration results show need for
Defined NDE vendor training
– Technicians don’t understand damage modes
Understanding of the probe/procedure limits
Familiarization with equipment
Confidence
55© 2016 Electric Power Research Institute, Inc. All rights reserved.
NDE Proficiency Demonstration Update
Demonstrations Show Improve Performance
Year 1st
Initial Attempt Successful Unsuccessful Total Success Rate
2011 4 1 4 5 20.00%
2012 80 31 61 92 33.70%
2013 13 13 15 28 46.40%
2014 50 35 30 65 53.80%
2015 27 11 25 36 30.60%
Total 180 94 142 236 39.80%
56© 2016 Electric Power Research Institute, Inc. All rights reserved.
Proficiency Demonstration Conducted 2015
Component Successful Unsuccessful Total Success Rate
Boiler Tube 2 10 12 16.67%
Girth Weld 4 21 25 16.0%*
Seam Weld 9 5 14 64.29%
2015 Proficiency Demonstration Conducted
* Decrease in the success rate of 23% compared to 2014
Reason for decrease in the success rate for girth welds
– NDE technicians not following procedure
– Phased array procedure not clear on transducer capabilities
– Technicians not properly prepared
– #1 flaw missed for unsuccessful demonstrations was Cracks
57© 2016 Electric Power Research Institute, Inc. All rights reserved.
Proficiency Demonstration Protocol
NDE Proficiency Demonstration Protocol
Protocol updated during 2015– Defined essential variables for phased array equipment
Procedures should define probe limitations and component thickness range
Procedure should define minimum digitizing requirements for encoded scans
– Address waiting period for re-attempt of unsuccessful demonstrations
– Address training requirements for unsuccessful demonstrations
Revisions for 2016– Add re-demonstration duration
– Add detection of weld push through (excessive root)
– Address changes in procedure and/or equipment that requires repeat demonstration
58© 2016 Electric Power Research Institute, Inc. All rights reserved.
Supplemental Project
Digital Radiography for Crack Detection in Last-Stage Turbine
Rotor Blade Attachments
Reduced Radiation Exclusion Zone Via Shielding
Detect cracking in pin finger attachments of
L-0 stage without de-blading rotor
• Supplemental Project with 10 utilities
• Evaluate use of real-time digital radiography
• Technologies to reduce radiation exclusion
zone for other work activities
• Optimize process in laboratory
• Conduct field trial to verify functionality in plant
59© 2016 Electric Power Research Institute, Inc. All rights reserved.
Current Status
Developed procedure with mockups
Laboratory blind test detected 29/30 small flaws
– The 1 flaw not identified was 1 of 4 radial flaws emanating from one of the
pin holes - 0.2 x 0.22 inch (5 x 5.6 mm) but appeared in subsequent image
Performed first field trial January 2016
– Verified setup and RT procedure
– Identified radiation exclusion zone
Behind Betatron 24.6 ft (7.5 m)
Front of Betatron 47.6 ft (14.5 m)
Side of Betatron ~ 26.2 ft (8 m)
Had issues with radiation detector plate
Planning final field trial to complete project
60© 2016 Electric Power Research Institute, Inc. All rights reserved.
The Setup
61© 2016 Electric Power Research Institute, Inc. All rights reserved.
Next Steps
Design and build a system to facilitate deployment in Turbine Hall or Central Workshop without need for large temporary shielding– Betatron will be placed in steel & lead shielded outer containment
– Deployment gantry capable of attaching to “strong points” remaining after top half shell removed
62© 2016 Electric Power Research Institute, Inc. All rights reserved.
Concept for Turbine Hall Inspection
63© 2016 Electric Power Research Institute, Inc. All rights reserved.
Future Applications of DRT to L-1 Pinned Finger Attachments?
Consistent feedback from EPRI advisors indicate that L-1 crack detection is a more urgent industry issue
– GE TIL 1886
– Increased risk of SCC
– High consequence failures
– Traditional inspection with buckets removed is very difficult and time-consuming
– High risk of turbine damage due to stuck pins
Can we apply the learnings from L-0 DRT to the L-1 row?
– Yes, to some extent, but major technical hurdle exists due to required “stand-off” distance of source to disk rim
– Need to solve this issue first…
Despite challenges, this may be the best approach for an in-situ L-1 inspection
64© 2016 Electric Power Research Institute, Inc. All rights reserved.
Potential Concept for L-1 Pin Finger Blade Attachment DRT Application
Challenges…..
Difficulty in fabricating
guide tube for right angle
Retaining sufficient
energy to penetrate 4 ½
inches (115 mm) of steel
or more
Adequate imaging
capability with this setup
Key unknown… can an x-ray guide
be constructed and will there be
sufficient energy delivered to rotor?
65© 2016 Electric Power Research Institute, Inc. All rights reserved.
Proposed 2017 Base-Funded Project
Project Title:“Application of Radiography Inspection to L-1 Pinned Finger Bucket Attachment: Feasibility Assessment”
Objectives:Demonstrate feasibility of x-ray guide concept, and assessment of source strength
Overall Approach:
1. Laboratory demonstration proving x-ray guide concept
2. Use modeling software to evaluate required source strength and image quality
3. Start with simple experiments on stacked plates to determine image quality
4. If successful, prepare mockups and develop RT procedure
5. Verify procedure via blind testing
6. Field trial and final reportProposed 2017
Base project
66© 2016 Electric Power Research Institute, Inc. All rights reserved.
HRSG Inspection Technology Demonstrations
SPN 3002003916
Cancelled due to inability to obtain critical mass of
participants
Most of the technologies have progressed and are either
commercially available or have been thoroughly documented
through EPRI projects
67© 2016 Electric Power Research Institute, Inc. All rights reserved.
Potential Technologies To Be Demonstrated
1. TesTex’ LFET
2. ApplusRTD’s INCOTEST
3. SwRI’s Flexible Eddy Current Array Probe
4. Carnegie Mellon University’s Snake Robot
5. TesTex’ C-Clamp Device
6. United Dynamics Corp (UDC) Radio Controlled Helicopters
7. TesTex’ Inside Header Inspection Tool
8. SwRI’s Eddy Current Mechanized Scanner for HRSG Tube-to-Header Weld Inspection
68© 2016 Electric Power Research Institute, Inc. All rights reserved.
Status of EPRI Technology Innovation Project
Project Status
69© 2016 Electric Power Research Institute, Inc. All rights reserved.
Tool would be inserted from end of header
Update on the Development of HRSG Inspection Tool
70© 2016 Electric Power Research Institute, Inc. All rights reserved.
Status Update On HRSG Internal Access Tool
• Main Delivery Unit completed first quarter of 2015
• Designed for insertion in 8” (203mm) headers and larger
• Final Probe design completed first quarter of 2015
• Can be pushed up tube 80 feet (25m)
• Cable Reel Unit completed second quarter of 2015
• Electronics and integration of system completed third quarter of 2015
• Field trials
• First field trial conducted September 2015
• Second field trial scheduled week of September 19, 2016
71© 2016 Electric Power Research Institute, Inc. All rights reserved.
Access Gained to Headers
72© 2016 Electric Power Research Institute, Inc. All rights reserved.
Main Delivery
Unit inserted in
HRSG Header to
push probe up
tubes
Delivery Unit in HRSG Header
73© 2016 Electric Power Research Institute, Inc. All rights reserved.
Controlling Equipment External To HRSG
Picture shows
computers,
external
electronics,
Xbox gamepad
controller, and
cable reel that
were positioned
on ground next
to header
74© 2016 Electric Power Research Institute, Inc. All rights reserved.
Modifications Made After September 2015 Field Trial
Installed large power supply for the probe feed module
The probe pusher feed module can now push the probe up entire 51 feet (15.5 m) of
mockup
Installed new color camera with faster capture rate on probe tip
Switch poly on probe to a stiffer poly
75© 2016 Electric Power Research Institute, Inc. All rights reserved.
Recent Efforts In Development Of Internal Access Tool
Redesign cover plate for probe feed module
Add an option to install mini-sawblades for drive wheels
Install additional lighting to crawler
76© 2016 Electric Power Research Institute, Inc. All rights reserved.
2016 NDE Deliverables
63Nondestructive Evaluation (NDE) for Damage Detection and Sizing in Clamshell Header Tee's
63Assessment of Eddy Current Arrays for Detection of Hidden Seam and Girth Welds
63Nondestructive Evaluation (NDE): Flexible and Curved Arrays for Detection of Boiler Tube Cracking and/or Hydrogen Damage
63 Use of Acoustic Emission Monitoring for Damaged Header
63 Nondestructive Evaluation (NDE) for Detection of Axially Oriented Blasting Damage in Boilers
63 Use of Ultrasonic Guided Waves for Detection of Wall Loss and Cracking in Boiler Membrane Waterwall Tubes
NDE Supplemental Program NDE Webinars
NDE Supplemental Program
NDE Supplemental Program
63 Supplemental Evaluation of Digital Radiography for Detection of Flow Accelerated Corrosion in Insulated Piping
63 Supplemental Annual Update Report on NDE Proficiency Demonstration Activities
TI Internal Access Header Inspection Tool
65 Supplemental Digital Radiography for Turbine Pin Finger Blade Attachment Cracking Detection
79In-Situ Phased Array Evaluation of GE Compressor Dovetail Slot Cracking
88 C-Clamp Device for Remote Examination of HRSG Tube-to-Header Welds
77© 2016 Electric Power Research Institute, Inc. All rights reserved.
Potential Projects for Advanced NDE Supplemental Program
78© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
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