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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

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Page 1: Generation Nondestructive Evaluation (NDE) Research … · inaccessible locations (HRSGs) ... Model Piping Systems for Flow-Accelerated Corrosion 2006 –Application of NDE at Xcel

© 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

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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

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3© 2016 Electric Power Research Institute, Inc. All rights reserved.

Safety Moment

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4© 2016 Electric Power Research Institute, Inc. All rights reserved.

Do you know what you would do?

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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.

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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!

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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

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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

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9© 2016 Electric Power Research Institute, Inc. All rights reserved.

When Police Arrive

Don’t be

confused as

the bad guy

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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

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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

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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

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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

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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

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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

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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)

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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

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18© 2016 Electric Power Research Institute, Inc. All rights reserved.

Generation NDE Research Area

Table Top Display

At

Council Reception

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Generation Nondestructive Evaluation (NDE) Research

Program Manager: Stan Walker

704-595-2581 [email protected]

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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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30© 2016 Electric Power Research Institute, Inc. All rights reserved.

NDE Cockpit

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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44© 2016 Electric Power Research Institute, Inc. All rights reserved.

Generation Advanced NDE Development Supplemental

Program

Project Status

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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

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46© 2016 Electric Power Research Institute, Inc. All rights reserved.

Generation Advanced NDE Development Supplemental

Program

Proposed Projects

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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

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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

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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

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50© 2016 Electric Power Research Institute, Inc. All rights reserved.

Schematic of NoPig Specifications

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51© 2016 Electric Power Research Institute, Inc. All rights reserved.

Generation NDE Supplemental Projects

Project Status

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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

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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, [email protected],

(704) 595-2572

SPN Number: 1025490

Improve Industry NDE Capability by Proficiency Demonstrations

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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

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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%

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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

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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

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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

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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

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60© 2016 Electric Power Research Institute, Inc. All rights reserved.

The Setup

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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

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62© 2016 Electric Power Research Institute, Inc. All rights reserved.

Concept for Turbine Hall Inspection

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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

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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?

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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

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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

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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

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68© 2016 Electric Power Research Institute, Inc. All rights reserved.

Status of EPRI Technology Innovation Project

Project Status

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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

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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

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71© 2016 Electric Power Research Institute, Inc. All rights reserved.

Access Gained to Headers

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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

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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

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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

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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

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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

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77© 2016 Electric Power Research Institute, Inc. All rights reserved.

Potential Projects for Advanced NDE Supplemental Program

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78© 2016 Electric Power Research Institute, Inc. All rights reserved.

Together…Shaping the Future of Electricity