RCC-M-2009-Nuclear PALENGAT ATTI Nucleare iBV6

NUCLEAR PRESSURE EQUIPMENT RCC-M Code

R. Palengat

Milan June 17th, 2009

Content

3Bureau Veritas Presentation _ Date

Content

1 Generals

2 RCC M structure

3 Section I

4 Section II materials

5 Section III examination methods

6 Section IV welding

7 Quality assurance

8 Conclusions

1 Generals


1 Which requirements for a NPP ?

►

A construction code is a part of several requirements applicable

to manufacture a Nuclear Power Plant

Construction code and associated standards (European, ASTM, national standards )

Regulatory requirements

Equipment specification


1 RCC M frame

RCC M Code is dedicated to the manufacturing of PWR mechanical components located in the nuclear islands

Steam

generator

Reactor

Primary

pump

Pressurizer


1 Why a construction code ?

►

To take into account :

Pressure risks

Safety concerns

►

For a economical interest

►

To integrate feed-back experience


1 Historical recall

►

First French 900 MW and 1300 MW were manufactured under Westinghouse licence

Design based on ASME III Code

Construction based EDF specifications

Issuing of the 1974 Order on Main Primary Systems

•

Safety margins defined so as to be globally compatible with ASME

III provisions

Technical specifications issued with adaptations and FRA + EDF approval needed

►

In 1978

30 nuclear plants in operation or under construction

Practices well

established

and technical

performances knownDecision

to write

the rules

corresponding

to these

practices


1 Which code for a New Nuclear Power Plant ?

►

Example of EPR for Finland, France

and China

ASMESect. III

NC RCC-MSubs. C

KTA 3211

Class 1: Highest level or guarantees Specific "Break Preclusion" Equipments

Class 2: Nuclear risk governs→ Nuclear standards

Class 3: Pressure risk governs→ Industrial standards

Sect. VIII

Annex ZCompliance

to PED

Harmonized Standards

PED 97/23 EC

EPRGlobal

Application

RCC-M Sect. ISubsection B

National Industrial Standards


1 Which code for a New Nuclear Power Plant ?

ASMESect. III

NC RCC-MSubs. C

KTA 3211

Sect. VIII

Annex ZCompliance

to PED

Harmonized Standards

PED 97/23 EC

EPRGlobal

Application

RCC-M Sect. ISubsection B

National Industrial Standards

ASME IIINB +

ASME IIINC +

ASME IIIND +

ASME VIII Div 1 +

Class 1

Class 2

Class 3

NC Harmonized standard : EN 13445, EN 13480National industrial standards : ASME VII, AD-M, CODAP …..


1 Regulatory requirements

►

In addition to the RCC-M Code regulatory requirements providing from the country where the nuclear equipments are installated

(if existing)

In Finland YVL are mandatory

In France ESPN is now mandatory for new NPP (ESPN Order 2005)

•

ESPN is based on European PED (to take account the pressure risk)

•

ESPN complete PED to take into account the radiological risk


1 Regulatory requirements

►

RCC M edition 2007 integrates

Standards updating : more and more European Standards are now referenced in the last edition

Regulatory evolutions coming from PED and ESPN Order : for example for the procurement of materials

Addition of 2 appendices to integrate PED and ESPN

•

Appendix ZU for PED

•

Appendix ZT for ESPN


1 Integration of PED (section I, subsection Z, appendix ZU)

►

ZU 200: hazard analysis

►

ZU 300: actions by Notified Bodies and Recognized Third Party Organizations

►

ZU 400: service instruction

►

ZU 500: identification of equipment items

►

ZU 600: equipment items and assemblies

►

ZU 700: materials

►

ZU 800: small components


1 Integration of ESPN (section I, subsection Z, appendix ZT)

►

ZT 200: hazard analysis

►

ZT 300: actions by Notified Bodies, Accepted Bodies, Accepted Organizations and Recognized Third Party Organizations

►

ZT 400: service instruction

►

ZT 500: identification of equipment items

►

ZT 600: equipment items and assemblies

►

ZT 700: materials

►

ZT 800: small components

►

ZT 900: radiological protection

2 Structure of RCC M Code


2 RCC M structure

RCC-M Code

ASME Code

Section 1: Nuclear Island Section III Components

Section 2:

Materials Section II

Section 3:

Examination Section V methods

Section 4:

Welding Section IX

Section 5: Fabrication Various

parts of Section III

Section 1 is the key to enter in the RCC-M

3 Section I


3 RCC M section 1: structure

RCC-M Code

ASME CodeSubSection

A: General requirements NCA

SubSection

B: Class 1 components NB

SubSection

C: Class 2 components NC

SubSection

D: Class 3 components ND

SubSection

E: Small components None

Subsection

G: Reactor internals NG

Subsection

H: Supports NF

Subsection

J: Storage tanks NC/ND 3800-3900

Subsection

Z: Technical appendices Appendices

Subsection A is the key to enter in RCC-M Section 1


3 Classification of components : safety requirements

►

General approach

Three barriers

•

Fuel enveloppe

•

Integrity of the cooling system

•

containment

Defense-in-depth approach

•

Prevention : quality of design and manufacturing

•

Protection :

•

Mitigation of postulated accident

Safety classification depending on equipment importance for the following three objectives

•

Core reactivity control

•

Evacuation of produced energy

•

Limitation of radioactive wastes


3 Classification of components

Safety

report

Class 1 Class 2 Class 3

Section 1 and various

subsections


3 RCC M section 1 subsection related to component classification


3 Damages risks taken into account by RCC M Code

►

Mechanical damages

Excessive deformation

Plastic instability

Elastic or elastic plastic instability

Progressive deformation

Fatigue

Fast fracture

►

Other damages

Corrosion : generalized, localized, stress corrosion, corrosion erosion

Release of the primary circuit in link with Cobalt content


3 RCC M section 1 subsection A

►

A 1000 chapters dedicated to standards editions applicable

►

A 2000 chapters are general provisions

Definition of responsibilities

Handling of non conformances

►

A 3000 chapters dedicated to documents

►

A 4000 chapters concerns RCC M classes of equipments

►

A 5000 chapters for Quality Assurance


3 RCC M section 1 subsection B

►

A 1000 ►

Relation between

Subsections

of Section 1 and the other

RCC-M Sections

Example

of Subsection

B

Other

subsections:►

Subsection

E: small

components►

Subsection

G: Core

supports structure►

Subsection

H: Standard supports

Chapter B.1000 Introduction

Documents

Chapter B.1000 Identification

Chapter B.3000 Design

Chapter B.4000 Fabrication

Examination

Chapter B.5000 Pressure tests

Section 1 A subsection

Section 2 Materials

Section 1 Z appendices

Section 3 Examination

Section 5 Fabrication

Chapter B.2000 Materials

Chapter B.6000 Overpressure

protection

Section 4 Welding

4 Section II Materials


4 RCC M section 2 (materials) : structure

►

RCC M technical requirements (at the procurement stage) allow to prevent any risk of degradation during :

Manufacturing

Operating

►

Structure of section 2

M 000 : general provisions

M 1000 : carbon steels

M 2000 : low alloy steels

M 3000 : stainless steels

M 4000 : special alloys as Inconel alloys

M 5000 : miscellaneous

M 6000 : iron castings


4 RCC M section 2 (materials) : peculiarities

►

RCC M contains a Technical Procurement Specification for a lot of class 1, class 2 and class 3 parts

TPS are applicable to issue procurement specifications

►

RCC M requires 3 kinds of qualifications

Product and shop qualification (chapter M 140)

Prototype parts dedicated to castings (chapter M 160)

Prototype series of heat exchanger tubes (chapter M 170)


4 RCC M section 2 : Technical Procurement Specification

►

Example of TPS for the reactor vessel

M 2…

low

alloy

steels

M 3…

stainless

steels

M 4…

inconel alloys


4 RCC M section 2 : product and shop qualifications

►

Product qualification is mandatory for all the parts listed in the chapter M 140

The qualification part is performed to check that a product, manufactured in accordance with a specified technical manufacturing program, will respond satisfactorily to fabrication operations and service operations. The homogeneity and the singularities identified have to be mainly studied in detail

Qualification process:

•

Description of the manufacturing program with identification of the major parameters

•

Description of the testing program for approval

•

Manufacturing of the part

•

Qualification report and approval


4 RCC M section 2 : product and shop qualifications

►

Shop qualification is also required by chapter M 140

The purpose of this qualification is to check that a supplier is capable of successfully, manufacturing a satisfactory product within an adequate margin, whilst meeting the requirements of the equipment specification and the criteria of the acceptance tests

The qualification report contains:

•

The description of facilities

•

Information about the personnel and management

•

The description of industrial experience


4 RCC M section 2 : prototype casting parts

►

Purpose

Test the manufacturing method choosen for the production of a series of castings for a given design

►

NDT and eventually DT are performed to test 100% of the volume

►

Surface examinations are performed as required by the Technical Procurement Specification


4 RCC M section 2 : prototype serie of heat exchangers tubes

►

Production of this prototype series of tubes allows

To specify real manufacturing conditions and parameters, establish NDE methods required in the prototype series and observe any encountered difficulties

To evaluate the type of defects that are specifically due to the manufacturing procedure, the nature of the material or the dimensionnal characteristics of the product ,with a view to starting a defect catalogue

To establish the final manufacturing programme for the insdustrial series of tubes


4 Intergranular corrosion risks of stainless steels

►

RCC M defines very clear and detailed rules to avoid this type of damage on austenitic stainless steels

GROUP 1

•

WELDING

•

FORMING

•

HT at θ

> 450 °C

•

Austenitic very low carbonC < 0,030 % or C < 0,035 % controlled Nitrogen

•

Austeno-ferritic

cast partsC < 0,040 %Ferrite 12 % -

25 %•

Austenitic stabilized Nb

and Ti

GROUP

1 bis

WELDING Same grades, plus :

•

Austenitic low carbon

C < 0,060 %

After Quality Heat Treatment (QHT)

of material thickness < 3 mm after QHT

GROUP

2

Same grades, plus :

•

Austenitic Stainless Steels

C > 0,08 %

No WELDING after QHT

5 Section III Examination methods


5 RCC M : Non Destructive Testings

►

NDT are described in various sections of RCC M

Methods are described in section 3

Methods to be used, extent of examination, time of examination and acceptance criteria are defined on

•

Section 2 for the procurement of base materials

•

Section 4 for the production welds

Personnel performing NDT has to be qualified and certified in accordance with European standard (EN 473)

6 Section IV Welding

http://www.maxicours.com/img/1/3/5/0/135007.jpg


6 RCC M section 4 : welding

►

Structure of this section

S 2000 acceptance of filler materials

S 3000 welding procedure qualification

S 4000 qualification of welders and operators

S 5000 qualification of filler materials

S 6000 technical qualification of production workshops

S 7000 production welds

S 8000 weld deposit hardfacings

Peculiarities


6 RCC M section 4 : welding procedure qualification

►

Several cases are taken into account

General cases as butt welding

Simulated repairs by welding

Steel cast parts repairs by welding

Special welds

•

Butt welding of dissimilar materials

•

Socket welds

•

Friction welding

Weld overlay cladding of stainless steel on carbon steel and low alloy steels

Weld overlay cladding of Ni base alloy on carbon steel and low alloy steels

Tube to heat exchanger tube plate welds



►

General cases as butt welding

The welding procedure test shall be performed in conformance with all the requirements of standard EN ISO 15614 -1 + RCC M provisions which explain or complete those in the standard

http://images.google.fr/imgres?imgurl=http://www.cewac.be/Destructifs/images/macro.jpg&imgrefurl=http://www.cewac.be/index.php%3Fpage%3Ddmacro&usg=__n756wEE_DJh4RnnorN6AHpMGD7g=&h=338&w=450&sz=135&hl=fr&start=31&tbnid=KLxsfsFEw09HyM:&tbnh=95&tbnw=127&prev=/images%3Fq%3Dmacrographie%2Bsoudure%26gbv%3D2%26ndsp%3D21%26hl%3Dfr%26safe%3Dactive%26sa%3DN%26start%3D21



►

Weld overlay cladding of stainless steel on carbon steel and low

alloy steels

In the RCC M code paragraph S 3600 gives detailed information allowing to perform qualifications

Therefore some peculiarities can be underlined

•

The range of validity concerning the chemical composition is not

in relation with the thickness of the cladding but with the number of layers

•

The risk of reheat cracking is taken into account for high energy processes

•

There are specific requests concerning the simulation of cladding repairs

•

The combination of various welding procedures is taken into account (for example SAW and SMAW processes)



►

Weld overlay cladding of Ni base alloy on carbon steel and low alloy steels

In the RCC M code paragraph S 3700 gives detailed information allowing to perform qualifications

The structure of this paragraph is quite similar to the structure of stainless cladding. Therefore, there is a sub chapter dedicated to simulated tube to tube plate welds


6 RCC M section 4 : welders and operators qualifications

►

For general cases welders have to be qualified in accordance with

EN 287-1 for steels

EN ISO 9606-4 for base nickel alloys

►

There are specific requirements for special processes

Cladding and buttering of stainless steel and Nickel base alloys

Welding of tubes on tube plates

Socket welds friction welds


6 RCC M section 4 : filler material qualification

►

Chapter S 5000 describes the frame and the process for filler material qualifications

►

S 5000 concerns :

Fluxes associated with wire or strip electrodes

Flux cored wires

Covered electrodes

►

Requirements have to be fulfilled by :

The supplier of filler materials

•

Tests on weld metal deposited

•

Qualification data sheet

The manufacturer

•

Tests on standard test coupon (in accordance with S 3000)


6 Prerequisites to perform welding procedure qualifications and production welds

Welding

data package

Filler material

qualification

Filler materials

acceptanceWelding

Procedure

Qualification

Workshop qualification

Welders

and operators

qualification

Production welds


6 RCC M section 4 : technical qualification of the production workshop

►

Chapter S 6000 describes

The qualifications conditions

•

Facilities about welding, heat treatments and NDT

•

Personnel and supervision

•

Experience

Qualification report

Workshop qualification period


6 RCC M section 4 : production tests coupons

►

Chapter S 7800 gives details concerning

The rules for numbering the test coupons

•

General cases

•

Special cases : tubes to heat exchangers tube plate welds, pipe welds and claddings

Welding, examinations and tests

Special cases

•

Stainless steel cladding

•

Nickel base alloy cladding

7 Quality assurance


7 RCC M section 1 : quality assurance

Products corresponding to his requirements

The proof, a posteriori, of the quality obtained

COMPANY

The confidence a prioriin the capacity of the supplier

to get the required quality



The codes and the standards Assurance Qualitycomplete the codes and the standards Products

The codes and the standards Productspresent the characteristics

and the performances to be satisfied

Objective of "nuclear" codes standards

safety of nuclear installation

Objectiveof ISO 9000 standards

satisfaction of the customer



►

Quality assurance requirements

Quality system implementation in accordance with ISO 2001

•

Introduction

•

Scope

•

Normative references

•

Terms and definitions

•

Quality management system

•

Management responsibilities

•

Resources management

•

Product realization

•

Measures, analysis and improvement



►

Quality assurance requirements

Additional RCC M requirements

•

Design verification

•

Documents and data verification

•

Purchasing data

•

Product identification and tracability

•

Inspection and testing

•

Control of non conforming product

8 CONCLUSIONS


Conclusions

►

RCC M code is dedicated to the manufacturing of mechanical nuclear equipments

►

Last version integrates a lot of European standards, PED and ESPN requirements (for NPP in France)

►

There is a slight difference with ASME code concerning design

►

For other domains, RCC M code is more detailed and it’s the reason why relevant equipment specifications are “light”

►

This construction code requires very specific qualifications

Qualification parts including castings and tubes for heat exchangers

Filler material

Production workshop

►

Production tests coupons are necessary
