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ROAD-MAP OF INDIGENIZATION OF NDE/ISI PROGRAMME OF NPP’S IN PAKISTAN (Tahir Nazir)
Dy. Chief Engineer NCNDT, PAEC
PRESENTATION OUTLINE
Introduction of NCNDT
Nuclear Power Plants (NPP,s) in Pakistan
PSI/ISI of Nuclear Power Plants (NPP,s) in Pakistan
ISI of Industrial Plants in Pakistan
Contribution of IAEA in Development of Human Resources and Inspection Facilities of NCNDT
Future Plans and Goal
2
INTRODUCTION OF NATIONAL CENTRE FOR NON-DESTRUCTIVE
(NCNDT)
3
The NCNDT is housed in 05-storeyed building having a
covered area of about 3300 square meters with
properly designed:
Laboratories
Lecture Halls
Offices
Meeting Rooms
150-Seat Auditorium
6
INTRODUCTION TO NCNDT
LABORATORIES
7
MT / VT Lab
Concrete Testing Lab ET Lab
UT Lab
MAJOR ACTIVITIES OF NCNDT
Inspection & Testing Services to PAEC and National Industry
Training and Qualification of Inspection Personnel
Equipment Calibration Services
Third Party Inspection Services
Mechanical and Metallographic Testing Services
Failure Analysis and Condition Assessment
Research and Development
Promotion of Pakistan Society for NDT (PASNT)
8
HISTORY Year Achievements
1971-95
• NDT Group Started at PINSTECH
• Lead Trainers got certified through IAEA
• Provision of Training & Inspection Services to PAEC & National Industry
1995-2000 • Establishment of NCNDT
• Developed Training Manuals for IAEA
2000-05 Started ISI in Conventional Island of NPPs
Hold National Conferences on NDT
2005-10 • Started ISI of different Piping System Welds in Nuclear Island of NPPs
2010-16
2016-17
• Started ISI of Components Welds
• RT of SG Nozzles Dissimilar Metal Welds
• ET of Steam Generator Tubes
• PSI of C-3/C-4
CAPABILITIES (HUMAN RESOURCE)
10
Engineers and Scientists 22
• PhD 3
• MS Engineering 14
• MSc Physics 1
• BS Engineering 4
Technical Staff 95
Administrative Staff 6
Total 123
11
28
40
27
8
13
5 5
8
15
20
14
11
16
8 8
5 4 3 3 2 2
0
5
10
15
20
25
30
35
40
45
RT UT PT MT ET VT LT
Level-1 Level-2 Level-3
126 92 27
* Some Persons have certificates in more than one NDT method
CAPABILITIES (HUMAN RESOURCE) Certified NDT Personnel at NCNDT
CAPABILITIES (EQUIPMENT) Ultrasonic Testing
– Ultrasonic Flaw Detectors (digital) › USM 36 SX › USM 35 SX › USM 58L › USM GO
– Ultrasonic Thickness Meters › Pocket Mike › DMS-2 › DM 4DL › WM2 › MMX-6L › TI-MVX
– Time of Flight Diffraction (TOFD)
– Phased Array Ultrasonic Testing (PAUT)
– Motorized WeldRover Scanner/Semi Automatic and Hand Scanners 12
CAPABILITIES (EQUIPMENT)
13
Analog Flaw Detectors Digital Flaw Detectors
OmniScan with Motorized WeldRover Scanner
Phased Array Equipment
CAPABILITIES (EQUIPMENT)
Radiographic Testing – X-Ray Machines
› Andrex Smart 225 kV › Andrex 300KV › YXLON International Andrex Smart 200 and 300 kV › Isovolt Titan-E GE Inspection Technologies 225 kV
– Gamma Ray Sources › Iridium-192 (Many sources)
› Cobalt-60
– Film Viewers
– Densitometers
14
CAPABILITIES (EQUIPMENT)
Radiographic Testing – Manual Film Processor
– Automatic Film Processor
– Film Dryer
– Reference Radiographs (ASTM and IIW)
– Equipment for Digital Industrial Radiography (DIR)
› X-Ray Film Digitizer
› Computed Radiography System (Durr CR-35)
› Fluoroscopic System Developed at NCNDT
15
CAPABILITIES (EQUIPMENT)
16
X-Ray Machine Ir-192 Source
Interpretation Room Exposure Room
CAPABILITIES (EQUIPMENT)
17
Film Digitizer Digital Fluoroscopy system
Imaging Plate Scanner Durr CR-35
CAPABILITIES (EQUIPMENT) Magnetic Particle Test Equipment
– Portable Magnetizing Units (Prod, Coil, Center Conductor)
– AC/DC Yokes & Permanent Magnets
– Magnetization Coil
– Residual Field Strength Meter
– UV Lights
– Demagnetizers
18
CAPABILITIES (EQUIPMENT)
Liquid Penetrant Testing – Penetrant Test Materials (Visible and Fluorescent)
– UV Lights
– Ultrasonic Cleaner
– UV light meters
– Thermometer (Digital/distance)
– Visible Light/Lux Meter
– Comparator blocks
19
CAPABILITIES (EQUIPMENT)
Visual Testing – Videoscope
(7.5m, 6mm dia, Stereo Measurement)
– Magnifiers/Mirrors
– Hand-held Microscope (100 X)
– Boroscope
20
CAPABILITIES (EQUIPMENT)
Eddy Current Testing – Eddy Current Flaw Detectors
› MS 5800 Multiscan, › MAD 8D, › Phasec 2D › Phasec 3D › EEC-39 RFT › ECT48 › EM-3300
– Eddy Current Conductivity Meter
– Coating thickness gauge
– Depth Gauge
21
CAPABILITIES (EQUIPMENT)
22
Calibration Tubes
EM 3300 MS 5800 Multi Scan and EFC 39 RFT
ECT 48 LB
CAPABILITIES (EQUIPMENT)
23
Infra-Red Thermographic Camera Wire Rope Testing Equipment
Strain Gauging System
INTERNATIONAL COLLABORATION
24
Collaboration between Pakistan and Sri Lanka in the field of NDT
MoU has been signed for exchanging know-how including NDT.
Chairman AEC Sri Lanka visited NCNDT in Nov. 2012
TRAINING MATERIAL DEVELOPED BY NCNDT AND REVIEWED AND FINALIZED BY IAEA
25
IAEA Document No. Title
TCS No. 03, 1992
TCS No. 09, 1999
TCS No. 10, 1999
TCS No. 11, 2000
Industrial Radiography
Industrial Management and
Quality Control Personnel
Ultrasonic Testing of Materials
Liquid Penetrant and
Magnetic Particle Testing
TRAINING MATERIAL DEVELOPED BY NCNDT AND REVIEWED AND FINALIZED BY IAEA
26
27
STATUS OF NUCLEAR POWER PLANTS (NPP’s) IN PAKISTAN
NUCLEAR POWER PLANTS (NPP’s) IN PAKISTAN
28
NUCLEAR POWER PLANTS (NPP’s) IN PAKISTAN Operating Reactors in Pakistan
Reactor Province Type MWe gross MWe net Construction start
Commercial operation
Karachi 1 Sindh PHWR 137 90 1966 December 1972
Chashma 1 Punjab PWR 325 300 1993 June 2000
Chashma 2 Punjab PWR 325 300 2005 May 2011
Chashma 3 Punjab PWR 340 330 May 2011 December 2016
Total (4) 1127 operating
29
NUCLEAR POWER PLANTS (NPP’s) IN PAKISTAN Nuclear Power Reactors Under Construction
Reactor Province Type MWe gross MWe net Construction start
Planned Commercial operation
Chashma 4 Punjab PWR 340 330 Dec 2011 May 2017
Kanupp- 2 Sindh PWR 1100 1100 Aug 2015 late 2021
Kanupp-3 Sindh PWR 1100 1100 May 2016 late 2022
Total (3) 2540
30
NUCLEAR POWER PLANTS (NPP’s) IN PAKISTAN Nuclear Power Reactors Planned for Construction in near Future
Reactor Province Type MWe gross.
Chashma 5 Punjab PWR 1000
Muzaffargarh-1 Punjab PWR 1000
Muzaffargarh-2 Punjab PWR 1000
Total (3)
3000
Government has set a target of 8,000 MWe. Electricity from Nuclear Power Plants by 2030.
31
32
IN-SERVICES INSPECTION (ISI) OF NUCLEAR POWER PLANTS
(NPP’s) IN PAKISTAN
ISI OF NUCLEAR POWER PLANTS
33
Activity Nuclear Power Plant
In-Service Inspection (ISI)
Chashma Nuclear Power Plant UNIT # 1 (C-1)
Chashma Nuclear Power Plant UNIT # 2 (C-2)
Karachi Nuclear Power Plant (KANUPP)
CHASHMA NUCLEAR POWER PLANTS UNIT-1 (C-1), UNIT-2 (C-2)
34
ISI OF C-1 AND C-2 Reference Codes
35
Nuclear Power Plant Reference Code Chashma Nuclear Power Plant UNIT # 1
ASME Section XI (Rules for In-service Inspection of Nuclear Power Plant Components 2007 (1989)
Chashma Nuclear Power Plant UNIT # 2
ASME Section XI (Rules for In-service Inspection of Nuclear Power Plant Components 2001
ISI OF C-1 AND C-2
Inspection Program
NOTE:
(1) If the first period completion percentage for any examination category exceed 34%, at least 16 % of the required examination shall be performed in the second period.
36
Inspection interval
Inspection period, calendar Years of
Plant Service Within the Interval
Minimum Examinations Competed, %
Maximum Examinations Credited, %
All 3 7
10
16 50 (1)
100
50 75
100
ISI OF C-1 AND C-2
The Regulatory Body:
In Pakistan, The Pakistan Nuclear Regulatory Authority (PNRA) is responsible for Licensing and Supervision, and Regulates the Safety and Security of all Civil Nuclear Materials and Facilities.
They also undertakes Audits and Periodic Reviews
NCNDT is the only Inspection Organization in Pakistan, authorized by PNRA to perform PSI/ISI of NPP,s.
37
38
ISI OF C-1 AND C-2
ISI OF C-1 AND C-2
Inspection Personnel's Qualification Documents
As an inspection organization, NCNDT performs the examination with qualified NDE system
(Equipment, Procedures and Personnel's)
The inspection personnel's qualified in accordance with SNT-TC-1A / CP-189 documents.
39
ISI OF C-1 AND C-2
ISI of C-1 was performed during Re-Fueling Outage (RFO-1) to RFO-10
ISI of C-2 during RFO-1 to RFO-4
RFO-11 of C-1 is in progress from 03 April, 2017.
Domains of ISI Activities:
ISI in Conventional Island (CI)
ISI in Nuclear Island (NI)
40
ISI OF C-1 AND C-2
Inspection Methods:
Visual Examination (VT-1, VT-2, VT-3).
Surface Examination (MT, PT)
Volumetric Examination (RT, UT, ET)
41
ISI OF C-1 AND C-2 ISI of Conventional Island
42
NDT METHOD COMPONENTS INSPECTED Visual Testing Ultrasonic Testing Ultrasonic Thickness Measurements
Emergency Diesel Generator’s Cylinders, Turbine
& Generator Parts
Piping System Welds, Turbine & Generator Parts
Piping System Welds
ISI OF C-1 AND C-2
ISI of Conventional Island
43
NDT METHOD COMPONENTS INSPECTED Penetrant Testing Radiographic Testing Magnetic Particle Testing Eddy Current Testing
Piping System Welds, Turbine & Generator Parts Piping System Welds Dearator Tank, Turbine & Generator Parts Low and High Pressure Heaters, Main Condensers, SCW Heat Exchangers, Lube Oil Coolers and Non-Essential Chillers
ISI OF C-1 AND C-2 ISI of Nuclear Island
44
NDT METHOD COMPONENTS INSPECTED Ultrasonic Testing
Piping System Welds of Residual Heat Removal System (SRH), Safety Injection System (SIS), Main Feed Water System (SMF), Chemical & Volume Control System (SCV) and Reactor Coolant System (SRC) Components Welds of Steam Generator and Pressurizer welds and Regenerative Heat Exchanger, Reactor Coolant Pump (RCP)
ISI OF C-1 AND C-2 ISI of Nuclear Island
45
NDT METHOD COMPONENTS INSPECTED Radiographic Testing
Piping System Welds of Residual Heat Removal System (SRH), Safety Injection System (SIS), Main Feed Water System (SMF), Chemical & Volume Control System (SCV) and Reactor Coolant System (SRC). Components Welds of Steam Generator Inlet Nozzle Dissimilar Metal Weld.
ISI OF C-1 AND C-2 ISI of Nuclear Island
46
NDT METHOD COMPONENTS INSPECTED Penetrant Testing
Piping System Welds of Residual Heat Removal System (SRH), Safety Injection System (SIS), Main Feed Water System (SMF), Chemical & Volume Control System (SCV) and Reactor Coolant System (SRC) Components Welds of Steam Generator and Pressurizer welds and Regenerative Heat Exchanger, Reactor Coolant Pump (RCP)
ISI OF C-1 AND C-2
ISI of Nuclear Island
47
NDT METHOD COMPONENTS INSPECTED Eddy Current Testing Hardness Testing Material Analysis Visual Testing
Steam Generators Tubes Turbine & Generator Parts High Pressure Turbine Steam Piping Closure nuts , impeller of RCP, Diffusion Assembly
PT of Diffuser Assembly of RCP of C-1 UT of Studs of RCP
Ultrasonic Weld Inspection and Thickness Measurement in Conventional Island
48
ISI OF C-1 AND C-2
ISI OF C-1 AND C-2
49
Ultrasonic Weld Inspection of Safety Injection System of CNPGS Unit # 1
50
ISI OF C-1 AND C-2
RT of Cross-Over Piping
51
Metallography during RFO-2
ISI OF C-1 AND C-2
ET of LP Heater RT during RFO-3
ISI OF TURBINE PARTS C-2
52
53
Positioning Tool Developed for Radiographic Testing of Steam Generator Nozzle Dissimilar Metal Weld
ISI OF C-1 AND C-2
ISI OF KANUPP
54
ISI OF KANUPP ISI of Nuclear Island
55
NDT METHOD COMPONENTS INSPECTED Ultrasonic Testing Ultrasonic Thickness Measurements Radiographic Testing
Piping System and Components Welds, Snout Jaws Intrados of Elbows of Feeder Piping System Redundant Emergency Injection Water System (RIJW) and Forced Emergency Injection Water System (FIJW) Piping Systems Welds, Snout Jaws
ISI OF KANUPP
ISI of Nuclear Island
56
NDT METHOD COMPONENTS INSPECTED
Eddy Current Penetrant Testing Hardness Testing
Tubes of Steam Turbine Condenser RIJW and FIJW Piping Systems Snout Jaws
57
PRE-SERVICES INSPECTION (PSI) OF NUCLEAR POWER PLANTS
(NPP,S) IN PAKISTAN
CHASHMA NUCLEAR POWER PLANTS UNIT-3 (C-3) AND UNIT 4 (C-4)
58
PSI OF C-3/C-4
NCNDT carried out first PSI of Safety Class 2 & 3 Piping System Welds/Supports of Chashma Nuclear Power Plant Unit # 3 in 2016. NCNDT performed this activity as sub-contractor of China Nuclear Power Operation Technology Corporation Limited (CNPO). After Through evaluation, CNPO has accepted NCNDT as potential supplier of non-destructive testing services for nuclear power plant.
59
PSI OF C-3/C-4
After successful completion of PSI of C-3, NCNDT carried out PSI of Safety Class 2 & 3 Piping System Welds/Supports of Chashma Nuclear Power Plant Unit # 4 in 2017.
60
PSI OF C-3/C-4 Reference Codes
61
Nuclear Power Plant Reference Code Chashma Nuclear Power Plant UNIT # 3
ASME Section XI (Rules for In-service Inspection of Nuclear Power Plant Components 2001
Chashma Nuclear Power Plant UNIT # 4
ASME Section XI (Rules for In-service Inspection of Nuclear Power Plant Components 2001
PSI OF C-3/C-4 PSI of Nuclear Island
62
NDT METHOD COMPONENTS INSPECTED Ultrasonic Testing Radiographic Testing
Piping System Welds of Residual Heat Removal System (SRH), Safety Injection System (SIS), Main Feed Water System (SMF) and Main Steam System (SMS). Piping System Welds of Residual Heat Removal System (SRH), Safety Injection System (SIS)
PSI OF C-3/C-4
PSI of Nuclear Island
63
NDT METHOD COMPONENTS INSPECTED Penetrant Testing Visual Testing
Piping System Welds of Residual Heat Removal System (SRH), Safety Injection System (SIS), Containment Spray System (SCS), Main Feed Water System (SMF) and Main Steam System (SMS). Piping Supportsof Residual Heat Removal System (SRH), Safety Injection System (SIS), Containment Spray System (SCS), Main Feed Water System (SMF) and Main Steam System (SMS).
64
Ultrasonic Testing of Piping Weld of Residual Heat Removal System (SRH) performed by NCNDT
PSI OF C-3/C-4
Liquid Penetrant Testing of Piping Weld of Main Steam System (SMS)
PSI OF K-2/K-3
Work on two Karachi Nuclear Power Projects Unit-2 (K-2) and Unit-3 (K-3) with capacity of 2200 megawatts of electricity is in progress. In near future, NCNDT will perform PSI and ISI of these plants. The inspection code for K2 / K3 is RSE-M
65
CONTROL POINT WITNESS OF C-1,C-2, C-3/C-4, K-2/K-3 DURING MANUFACTURING OF REACTOR
PRESSURE VESSEL, STEAM GENERATOR, PRESSURIZER
66
CONTROL POINT WITNESS OF C-1, C-2, C-3/C-4, K-2/K-3 COMPONENTS
NCNDT Engineers remained fully involved in Control Point Witness of C-1,C-2, C-3/C-4, K-2/K-3 during manufacturing of Reactor Pressure Vessel, Steam Generator, Pressurizer.
67
CONTROL POINT WITNESS OF C-1, C-2, C-3/C-4, K-2/K-3 COMPONENTS
Ultrasonic Testing witness on a Steam Generator Weld of K-2/K-3
68
CONTROL POINT WITNESS OF C-1, C-2, C-3/C-4, K-2/K-3 COMPONENTS
Magnetic Particle Testing witness on a Steam Generator Weld of K-2/K-3
69
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IN-SERVICES INSPECTION (ISI) OF CONVENTIONAL INDUSTRIAL
PLANTS IN PAKISTAN
71
National Power Industry
WAPDA (Water and Power Development Authority)
• Tarbela Power Station
• Mangla Power Station
• Warsak Power Station
• Jabban Hydel Power Plant, Dargai
UCH Power Plants
ROUSCH Power Plant, Khanewal
Korangi Thermal Power Station, Karachi
Kot Addu Power Company (KAPCO)
INSPECTION SERVICES
National Process Industry Oil and Gas Plants
Refineries
Fertilizers
72
Served more than 100 organizations nation-wide …
INSPECTION SERVICES
CONTRIBUTION OF IAEA
IN DEVELOPMENT OF HUMAN RESOURCES AND INSPECTION
FACILITIES OF NCNDT
73
COLLABORATION WITH IAEA
NCNDT has been receiving extensive support from IAEA through Technical Co-operation (TC) Projects, Regional Cooperative Agreement (RCA) Projects and Coordinated Research (CR) Projects :
74
Workshop on “Structural Integrity of RPV”
at NCNDT under IAEA, 27-30 May 2014
Workshop on “ISI of NPPs” at NCNDT under IAEA,
18-20 May 2016
IAEA TECHNICAL CO-OPERATION (TC) PROJECTS For Cycle 2016-17 (In progress)
“Development of Capabilities for PSI and ISI of RPV and Other Vital Components of NPPs”
Contribution through Fellowship, Scientific Visits, Expert Mission
Organized Workshop at NCNDT under IAEA, 18-20 May 2016
For the Cycle 2014-2015 –“Ensuring Integrity of System Structure and Components in
Nuclear Power Plants for Safe and Reliable Operation” .
Organized Workshop at NCNDT under IAEA, 27-30 May 2014
75
IAEA TECHNICAL CO-OPERATION (TC) PROJECTS
1. Development of Capabilities for Automated Ultrasonic Testing and Corrosion Monitoring for Integrity Assessment (PAK/4/046)
2. Development of In-Service Inspection (ISI) Facilities for Nuclear Power Plants (PAK/8/015)
3. Non-Destructive Evaluation of Pressurized Components and Concrete Structures (PAK/8/013)
4. NDT Equipment Calibration and Concrete Testing (PAK/8/011)
76
– Capacity Building in Applications of Advanced NDE Technologies for Enhancing Industrial Productivity – (in progress) (RAS/1/020)
– Supporting Advanced Non-Destructive Examination for Enhanced Industrial Safety, Product Quality and Productivity (RAS/1/013)
– Application of Digital Industrial Radiography (DIR) and Computer Tomography (CT) in Industry and Civil Structures (RAS/8/110)
– Development and Application of Advanced Industrial Radiography and Tomography Techniques (RAS/8/105)
– Non-Destructive Testing and Evaluation (RAS/8/085)
77
IAEA REGIONAL CO-OPERATIVE AGREEMENT (RCA) PROJECTS
Optimization of Digital Industrial Radiographic (DIR) Techniques for Special Applications and Development of Procedures and Protocols (2007-2010)
– Developed Low Cost Digital Fluoroscope at NCNDT
Corrosion and Deposit Determination in Large Diameter Pipes, with and without Insulation by Radiography Testing (2002-2005)
– Standard Protocols of Test: NDT Radiographic Examination For Determination of Corrosion and Deposits in Pipe Having Diameter Larger Than 150 mm
In Situ Applications of X-ray Fluorescence Techniques (2000-2003)
– Standardization of Non-destructive X-ray Fluorescence (XRF) Alloy Analyzer for In-service Inspection
78
IAEA COORDINATED RESEARCH (CR) PROJECTS
COLLABORATION WITH IAEA - SUMMARY Publications for IAEA (Training Course Guidelines) = 04
Expert Missions
NCNDT to IAEA = 17
IAEA to NCNDT = 19
IAEA Regional Courses held at NCNDT = 05
IAEA Scientific Visitors to NCNDT = 04
IAEA Trainees to NCNDT = 04
IAEA TC Projects = 06
IAEA RCA Projects = 05
IAEA CR Projects = 03
79
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FUTURE PLANS AND GOAL OF NCNDT
PRESENT CAPABILITIES At present, NCNDT is carrying out mostly manual inspection services in;
– Conventional Island (since 2000)
– Piping and Components Welds in Nuclear Island (since 2006)
Not yet performed mechanized inspection of Reactor Pressure Vessel (RPV) of NPPs
81
FUTURE PLAN
82
NDT METHOD COMPONENTS TO BE INSPECTED
Ultrasonic Testing
Inspection of Reactor Pressure Vessel (RPV), (Shell Welds, Head Welds, Shell to Flange Weld, Head to Flange Weld, Nozzle to Vessel Weld, Nozzle Inside Radius Section, Nozzle to Safe End Butt Weld, Closure Studs),
FUTURE PLAN
83
NDT METHOD COMPONENTS TO BE INSPECTED
Visual Testing Surface Methods
Inspection of Reactor Pressure Vessel (RPV), Head to Flange weld, Nozzle to Safe End Socket Weld, Closure Studs, Closure Washers, Vessel Interior, Interior attachments within beltline region, Core Support Structure, Bolts, Studs, Nuts Inspection of Reactor Pressure Vessel (RPV), Head to Flange Weld, Nozzle to Safe End Socket Weld, Welded Attachments.
FUTURE PLANS
Training of Manpower for Mechanized Inspection Systems for Reactor Pressure Vessel (RPV)
Procurement of Mechanized Inspection Systems for Reactor Pressure Vessel (RPV)
Fabrication of Mock ups
FUTURE PLANS
Local Fabrication of UT and ET Probes
Development of Qualification and Evaluation Facility:
ASME/PDI
ENIQ
FUTURE GOAL
Development of Capabilities for Indigenization of Pre-Service and In-Service Inspection of Reactor Pressure Vessel and other Vital Components of Nuclear Power Plants
Enhance International Cooperation including IAEA
CONCLUSION
› NCNDT is capable of performing manual inspection of Piping and Components Welds in Nuclear Island.
› NCNDT, PAEC allocated budget for Procurement of Mechanized Inspection System for RPV of NPPs.
› Training of Manpower to perform Mechanized Inspection System is in progress.
› Hopefully, NCNDT, PAEC will achieve these targets shortly.
88
THANK YOU
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