Long Term Operations Technical Advisory Committee ... · As of October 2015: 250 NPPs > 30 years of...
Transcript of Long Term Operations Technical Advisory Committee ... · As of October 2015: 250 NPPs > 30 years of...
© 2016 Electric Power Research Institute, Inc. All rights reserved.
Mike Gallagher
Exelon, VP License Renewal
Sherry Bernhoft
EPRI, Senior Program Manager
Nuclear Power CouncilTuesday, August 30, 2016
Long Term Operations Technical
Advisory Committee
Introduction and Program
Summary
August 25, 2016 R.2
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
Meeting Purpose
EPRI LTO program created in 2010 to accelerate and coordinate
cross-sector research for safe, reliable and economic long-term
operations
Three major roles:
– Technical basis for aging management
– Opportunities for modernization and efficiency enhancements
– Provide technology transfer
US – participation in NEI tasks force and working groups, and
lead plant demonstration
International – participation with the IAEA and workshops at
host sites
LTO Technical Advisory Committee
Provides a review of the technical projects to ensure alignment
with industry needs
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Long-Term Operations – Global Need
In the U.S.
License renewal – 40 to 60 years
Second license renewal – 60 to 80 years
As of October 2015:
250 NPPs > 30 years of operations
68 NPPs > 40 years of operations
Without SLR the U.S. will lose 30,000 MWs between 2029 and 2035.
Total Number of Reactors: 438Number of Reactors
Num
be
r o
f R
ea
cto
rs
35
30
25
20
15
10
5
0
If all existing nuclear
plants operate for 60
years.
If all existing nuclear
plants operate for 80
years.
Source: Capacity – Energy Information Administration; License Expiration –
Nuclear Regulatory Commission
Projected U.S. Nuclear Power Capacity(Megawatts)
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Agenda
Welcome & Introductions
Program Highlights and Projects Plans for 2017 – 2019
US DOE –LWRS Program Update
LTO Research at the Materials Ageing Institute (MAI)
License Renewal for Angra-1
Materials Issue Programs Report
Concrete Research Projects for LTO
Cable Research for LTO
Control Upgrades and Modernization Project
Integrated Life Cycle Management Update
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Member Resources:
LTO Program on EPRI.com
– LTO cockpit page
– Monthly updates
– Project Status Updates (PSUs)
– Project Overview Forms (POFs)
– Publications
Joint DOE-LWRS EPRI-LTO R&D Plan
– Updated annually
– INL LWRS website or LTO cockpit
LTO Program Roadmaps
– Updated every 6 months
– Link to Sector Roadmaps at bottom right of LTO Cockpit Home Page
Opens at LTO Roadmaps but includes all for Nuclear Sector
LTO Contacts:
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Topics
Strategic Research Focus Areas (RFAs)
– Results of members feedback
Key accomplishments for 2016
Project plans for 2017 and 2018
– Two year project look ahead
Member Satisfaction Survey
High Priority:
1. Reactor pressure vessel
2. Primary system metals, welds and piping
3. Electrical cables
4. Concrete and containment structures
Aging Impacts:
– Increased thermal exposure
– Increased radiation exposure
– Stress corrosion cracking
– Fatigue usage
– Wear
– Etc…..
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Research Focus Areas (RFAs)
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Prioritization Process
EPRI:
– Provided a written description of strategic focus areas sent out in May 2016
– Included a description of the types (examples) of projects
– Ranking sheet for completion by IC and TAC advisors
– Additional details provided in the LTO Program Plan (on the LTO Cockpit)
Advisors:
– Had fours weeks to review and provide comments
– Feedback was in the form of 1,2, or 3 ranking (1-highest) and any written
comments
Goal - Have the portfolio for 2 years out finalized in September
2017 – 2018 portfolio finalized in August 2016
Reviewed by TAC & IC at the August NPC
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Strategic Focus Areas (1 – High, 3 – Low)
Strategic Focus
Area
Ranking 2015 Ranking 2016 Comments - Summary
Aging management
for RCS metals,
RPV
1 1.22 Critical area for interface with MRP, BWRVIP and
reactor pressure vessel integrated surveillance
programs
Aging management
for concrete and
structures
1 1.22 Support for concrete aging management
programs, ASR and irradiation impacts
Aging management
for electrical cables
1 1.67 Need to understand synergistic effects testing and
impacts on cable qualifications (EQ)
Opportunities for
modernization and
efficiency
improvements
2.75 2.78 Needed to ensure cost effective LTO
Support for
industry and lead
plant activities
1.5 2 EPRI needs to stay engaged in industry activities
and provide support on technical issues
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EPRI LTO R&D Projects - 2009 through 2014
Aging Management Research
– RCS primary system metals
Advanced welding for highly irradiated materials - repair strategy
Advanced radiation resistant materials - future replacement strategy
– Reactor pressure vessel embrittlement
– Concrete and concrete structures
– Electrical cable systems
Opportunity for Modernization
– Centralized on-line monitoring
– Advanced I&C
– Enhanced safety and risk analysis
Enabling Technologies
– Integrated Life Cycle Management
– Plant Demonstration Projects
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EPRI LTO R&D Projects – 2015 through 2019
Aging Management Research
– RCS primary system metals
Advanced welding for highly irradiated materials - repair strategy
Advanced radiation resistant materials - future replacement
strategy
– Reactor pressure vessel embrittlement
– Concrete and concrete structures
– Electrical cable systems
Opportunity for Modernization
– Centralized on-line monitoring – Transitioned to Fleet-Wide Health Monitoring
– Advanced I&C
– Enhanced safety and risk analysis – Advanced PRA (Phoenix) Risks & Safety Management
Enabling Technologies
– Integrated Life Cycle Management – Transitioned to Plant Engineering
– Plant Demonstration Projects
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Key Accomplishments for 2016
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Industry Support
Technical reviews, comments and public meetings on NRC draft subsequent license renewal (SLR) GALL
Research ‘deep dive’ meetings with NRC and DOE-LWRS
Update the Advisory Committee on Reactor Safeguards (ACRS) on research status for SLR
NEI Task Force and Working Group meetings
IAEA IGALL, revision 3 – technical experts are participating on the steering committee, mechanical, electrical and structural working groups
IAEA SALTO lessons learned workshop
International member workshops on LTO
COG R&D Strategic workshop
Will be updating the IGALL EPRI product mapping
Research
Operating Experience
Inspection Results
Living research programs –
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Cable Aging Management
Updated joint EPRI-DOE-NRC cable aging research roadmap
IAEA IGALL working group on cable aging management
Workshops with UNESA (Spain) and CEZ on cable inspection and condition monitoring programs
Harvested cables from Crystal River for testing by NRC Research, DOE at PNNL, and EPRI
Submerged cable condition monitoring (EPRI technical report under review by NRC)
Temperature and radiation data capture (data loggers) continuing at Palo Verde
Starting update of License Renewal Tools Report for Electrical Equipment
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
Concrete Aging Management
Updated joint EPRI-DOE-NRC concrete aging research roadmap
IAEA IGALL working group on containment structures
Alkali Silica Reactions (ASR)
– Developed roadmap with technical report milestones
– First report on structural implications in draft
– Will be supporting lead plant structural monitoring program walk downs
Irradiation and gamma heating degradation of concrete support structures
– Published report on structural implications on BWR cavity and support structures
– Completed modeling and will be publishing a report on the impacts on the PWR biological shield wall
– Completing assessment on the impacts of gamma heating
Spent fuel pool leakage and boric acid corrosion
– Report with results from a three year study on the impacts of boric acid on SFP concrete
Working with Spain on harvesting irradiated concrete cores from Zorita
Progress is being made on NDE techniques for concrete
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RCS Metals and Reactor Pressure Vessel
Completed the roadmap to update technical reports for SLR
– Approval from the Materials program executives and funding to perform the work
– Presented to the NRC
Working closely with two lead US plants (PWR & BWR) to develop programs that will be the template for future SLRAs
– Includes approach for BWR integrated surveillance monitoring program for 60 to 80 years
– PWR supplemental surveillance program
Working with ORNL (DOE-LWRS) completed installation of welding cubicle in the hot cell and irradiating additional specimens for welding demonstrations
IAEA Working Group on materials aging management
International workshops on use of EPRI reports to support technical basis for LR
Starting work on updating the LR Mechanical Tools Report
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
Opportunities for Modernization
Completed feasibility study and literature
survey with INL (LWRS-DOE) for
development of a Structural Heath
Monitoring program
Supporting INL (DOE-LWRS) on control
room modernization project at APS
Collaboration with INL (DOE- LWRS) on
advanced risks informed safety margins
analysis
Application of risk informed safety margins to
evaluate life cycle management (Xcel pilot)
Integrated Life Cycle Management (ILCM)
completed turnover to Plant Engineering
– Pilot plant studies underway
– Interest group being formed
ISSUE DEFINITION
MANAGEMENT
ANALYSIS
STEP
S O
F TH
E R
ISM
C M
ETH
OD
Decision maker characterizes the issue(s) and analysis
scope
Determine risk-based scenarios
Safety case used to support decisions and Risk-Informed
Margins ManagementManage uncharacterized risks
Safety margin and uncertainty
quantification
Represent plant operation
probabilistically
Augment the plant model with issue specific knowledge
1 2
3 4
Represent plant physics
mechanistically
5 6
87
Coupling and Interactions
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LTO Project Plans for 2017 & 2018
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LTO Funded Projects for 2017 & 2018
Metals Materials Aging Management
– Advanced welding project for repair and replacements
– BWR Integrated Surveillance Program development
Concrete Aging Management
– ASR Aging Management studies
– Structural assessment of irradiated concrete
– Harvesting and testing irradiated concrete cores from Zorita
Cable Aging Management
– Cable vulnerability studies based on temperature and radiation data collection
– Cable harvesting and testing
– Advances in condition monitoring technology
Modernization and Efficiently Improvements
– Structural monitoring program
– Interface with INL on control room upgrades
– Risk Informed Safety Margin Characterization
Industry Support
– Subject matter experts
– Lead plant support
– Joint roadmaps and coordination with research partners
– IAEA IGALL participation
– International workshops
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Aging Management Roadmap
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Enhancement and Modernization Technology Roadmap
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
Member Satisfaction Survey
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
Member Satisfaction - Background
EPRI has captured member satisfaction
feedback in various forms for many years
Current member satisfaction survey
adopted by Board in 2006
Results reviewed regularly with Board
– one of Corporate Performance Indices (CPIs)
Member feedback used to drive
continuous improvement across EPRI
Helps prioritize efforts
– focus on areas with greatest impact on
satisfaction
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
Nuclear Member Satisfaction Survey Results
Overall Performance
Ease of Doing Business
Technical Program Value
Overall Satisfaction
2015 Results
2010-2015 Trend
92.3%
Overall
PerformanceEase of Doing
BusinessTechnical
Program Value
86.1%
93.2%
92.4%
75%
80%
85%
90%
95%
100%
2010 2011 2012 2013 2014 2015
• Impact of research on improving my business
• The program's strategic priorities and directions
• Quality of research results
• Relevance of research carried out by the program
• Technical staff expertise
Top ranked aspects of EPRI Experience
Who completed the Survey
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Category Initiative Timeframe
Research and
Development
• Research Focus Areas
• Project Overview Forms
• Quality Management ProgramImplemented 2016
Tech Transfer
• Executive Summary
• Onsite EPRI updates/regional meetings
• International workshops
• International NPC
• Digital Strategy (ongoing)
Implemented 2016
Simplification
• On-line Pricing
• Invoice Review
• New Pricing Model
Implemented 2016
Website• New Search Engine
• Member Center ImprovementsImplemented 2016
Improvement Initiatives
Listening and Responding to the Feedback of our Members
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
Digital Delivery Enhancements
Becomes
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
Becomes
Digital Delivery Enhancements
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
New Search Engine
The search engine gets smarter over
time based on use.
It tracks what people search and where
they go with the results.
The more the search engine is used, the
faster it learns.
As it learns, features such as relevance
and search term recognition will
dramatically improve, and as a result
improve your search experience.
You make the search engine better by
using it!
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
LTO Program Improvement Initiatives
Based on survey feedback:
Complete the process to identify and
scheduled the updates to the technical
reports for M-AMPs out to 80 years
Clear timeline for concrete and cable aging
management work
Ensure relevance and support for the
international members
Actions:
Review completed, resources allocated and
plan endorsed by Materials Executives
advisors – focus is support for lead plants
Developed – joint EPRI-DOE LWRS- NRC
Research roadmaps have been developed
for:
– Cable aging management
– Irradiated concrete aging management
– ASR aging management
IGALL support and international workshop
– IGALL working groups
– Workshops on LTO, cables and materials
– Looking to support ETN
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
Survey instrument
Key components …
1. Who you arewithout a name and organization, we can’t
count your input!
2. Number of years you have been an Advisor
3. How we’re doing
4. How you assess EPRI value
5. Key improvement in ease of doing business
6. Value you have received from this Program
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
Survey instrument
Key components
7. Rate each statement based on how
satisfied you are
8. Rank the top 5 statements as
indicated in the instructions
9. Would you recommend EPRI
10.If you are not satisfied with us in any
area, please tell us why
9
10
7
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Backup Slide on 2015 Results
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
2015 Nuclear Member Satisfaction Scores, By Area≤86% 87%-90% ≥91%
Program AreaSurveyed
Co's% Response
Overall
Performance
Technical
Program Value
Ease of Doing
Business
Overall
SatisfactionTotal
Nuclear Sector Council 19/39 48.7% 94.4% 96.6% 81.1% 93.3% 91.3%
Materials Degradation / Aging 18/40 45.0% 91.5% 92.1% 84.2% 92.1% 90.0%
Fuel Reliability 15/40 37.5% 89.5% 91.4% 89.5% 89.5% 90.0%
Used Fuel and High-Level Waste Management 16/40 40.0% 96.8% 96.0% 90.5% 97.8% 95.3%
Nondestructive Evaluation 13/40 32.5% 90.0% 92.7% 81.8% 90.0% 88.6%
Equipment Reliability 30/40 75.0% 91.0% 91.2% 83.8% 90.7% 89.2%
Risk and Safety Management 16/40 40.0% 92.2% 94.4% 91.1% 91.1% 92.2%
Strategic Initiatives (ANT and LTO) 20/40 50.0% 95.0% 95.7% 90.7% 95.7% 94.2%
Chemistry, Low-Level Waste and Radiation
Management15/40 37.5% 94.4% 94.4% 88.8% 95.8% 93.3%
Total 92.3% 93.2% 86.1% 92.4% 91.0%
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© 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
US Department of Energy Light Water Reactor
Sustainability Program Update
EPRI LTO TAC Meeting
New Orleans, Louisiana
August 30, 2016
Kathryn A. McCarthy
Director, LWRS Technical Integration Office
Idaho National Laboratory
Presentation Outline
Program Highlights
– Materials Aging and Degradation
• Reactor Pressure Vessel
• Cables
• Advanced Weld Repair
• Concrete NDE
• Service-aged materials from Zion
– Risk Informed Safety Margin Characterization
• Industry Application #2: External Events
– Advanced Instrumentation, Information, and Control Systems Technologies
• Control Room Modernization
• Computer-Based Procedures
• Business Case Example: Advanced Outage Management
– Reactor Safety Technologies
• Fukushima Daiichi Forensics Planning
FY-17 Look-Ahead
2
US Department of Energy Light Water
Sustainability Program Goals and
Scope
Goals– Develop the fundamental scientific basis to
understand, predict, and measure changes in materials and systems, structures and components (SSCs) as they age in environments
– Apply this knowledge to develop and demonstrate methods and technologies that support safe and economical long-term operation of existing reactors
– Research new technologies that enhance plant performance, economics, and safety
Scope– Materials Aging and Degradation
– Risk-Informed Safety Margin Characterization
– Advanced Instrumentation, Information, and Control Systems Technologies
– Reactor Safety Technologies
3
Materials Aging and
Degradation Pathway
Develop the scientific basis for
understanding and predicting long-term
environmental degradation behavior of
materials in nuclear power plants
Provide data and methods to assess the
performance of systems, structures, and
components essential to safe and
sustained nuclear plant operations
Develop means to detect and characterize
aging degradation processes
4
Pathway Lead: Keith Leonard,
ORNL
Areas of materials R&D
– Metals
– Concrete
– Cables
– Mitigation Technologies
Data from RPV Materials Irradiated in the INL
Advanced Test Reactor Provide Important
Information on RPV Aging
Significant progress in FY16 evaluating
mechanical properties (tensile, shear
punch, microhardness) and
microstructure (TEM, APT, SANS, SAXS)
at University of California Santa Barbara,
ONRL and INL
Work continues in FY17 collecting further
experimental data to formulate the
transition temperature model for RPV
steels over varying compositions and
fluences
5
Model for Transition Temperature Shift in RPV Steels in 2018
Progress in Cable Aging
Activities
BIW Control Rod Cable– Harvested from Callaway plant after in vessel
service for 30 years
– Hypalon (CSPE) jacket & EPR insulation
– Remaining Useful LIfe estimated compatible with SLR
Rockbestos Firewall III (RB FIII) power cable
– Harvested from San Onofre storage facility in 2014
– CSPE jacket & XLPE insulation
Radiation aging in Co-60 source at 25°C Rockbestos Firewall III & BIW cable
compared to multiple SCRAPS data– Hyp-04: Anaconda Flameguard
– Hyp-05: RB FIII
– Hyp-06: Eaton Dekoron
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EAB for BIW Hypalon & Rockbestos CSPE
compared to multiple Hypalon conductors
from EPRI / SCRAPS data base
EAB for BIW Hypalon/EPR at
120°C compared to Hyp-08
Model for Cable
Degradation in
2019
FY-17 Plans for Developing Cable
Aging Model
Additional testing of service-aged and laboratory-aged material
Characterize material changes with aging and compare behavior with existing
data with regards to current aging models; will include comparative analysis of
harvested materials with predictions based on Arrhenius model
Continue investigation of microstructural changes in materials with aging to
further understand fundamental aging mechanisms
Investigation of dose rate and inverse temperature effects in simultaneously
aged XLPE to ascertain the relative dominance of thermal versus radiation
aging
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Discussions with EPRI are underway regarding potential modeling activity
to support dose estimate of cable underway with Palo Verde
Advanced Welding R&D: Providing
Options for Welding Irradiated Material
Jointly funded by DOE and EPRI
Repair highly irradiated reactor internals without helium-induced cracking
Modeling and experiments to investigate long-term performance and cracking resistance
Installed the integrated welding hot cell
– State-of-the-art facility at ORNL for welding R&D to repair irradiated
– Demonstrated the baseline performance of friction stir weld subsystem
– Laser subsystem installation mid-August
8
Technology will be transferred to industry in 2018
Welding Task: Plans for FY17
Test laser welding subsystem
Demonstrate friction stir weld on irradiated samples
Examine irradiated friction stir weld material via optical,
microhardness and electron microscopyperform analysis on weld
cross-sections
Two rounds of irradiations in the High Flux Isotope Reactor (HFIR) to
prepare irradiated material for subsequent welding in the cubicle
– Material is pre-fabricated B-doped material supplied by EPRI
Access to Service-Aged Materials
Such as the Zion RPV are Essential
to Understanding Aging Behavior
RPV panels removed in 2015, test specimens
fabrication through 2017.
Sections contain belt-line weld (Linde 80, WF-
70 weld)
Peak fluence = 0.75x1019 n/cm2 (>1MeV),
anticipated temperature transition shift is
145°F.
High interest in:
– Evaluation of radiation damage models
– Attenuation studies, through wall variation in base
and weld metal.
– Mitigation techniques - annealing / re-irradiation
studies.
Axial Weld
WF-70, Belt-line
Weld
Risk Informed Safety Margin
Characterization Pathway
Develop and demonstrate a risk-assessment method coupled to safety margin
quantification that can be used by nuclear plant decision makers as part of their
margin management strategies
Create advanced “RISMC toolkit” that enables more accurate representation of
nuclear plant safety margin
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RISMC methods understood
Now applying RISMC methods to make it useful
for decision makers
Currently refining some of the technical aspects of
the methods
RISMC Toolkit
Domain Knowledge (failure models,
operational data, etc.)
RAVEN
(Controller and Scenarios)
RELAP-7
(T-H)
Grizzly
(Aging Effects)
Peacock(Graphical Interface)
Moose
(Solver Framework)
. . .
MOOSE (Solver Framework)
Pathway Lead:
Curtis Smith, INL
RISMC Activities: Balanced Focus
On Methods / Tools / Data
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Verification,
Validation, &
Uncertainty
MAaD R&D Pathway
Adv. IIC Sys. Technology R&D Pathway
RST R&D Pathway
Plant
Owners/
Operators/
Vendors
Integrated Tools
Modern Framework
TOOLSDATA
METHODS
DOE LWRS
Program
Industry
Stakeholders
RISMC Activities
RISMC
Pathway
RISMC Industry
Applications (IA)
IA 3
Reactor
Containment
Analysis
EPRI
LTOIA 2
Enhanced
Seismic/
External Hazard
Analysis
IA 1
Integrated
Cladding / ECCS
Performance
Analysis
RISMC R&D Pathway
RISMC Toolkit Development Risk-Informed Margin Management (RIMM) Applications
Componen
t
Subsyste
m
Syste
m
Facilit
y
Region
al
Type of information and
data
IA 4
Long Term
Coping
Studies -
FLEX
Risk-Informed Safety
Analysis Methods
Development
IA Safety Analysis Guidelines
FY15 start
Modeling of external events
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Seismic
Flood
Winds
…
Recent accomplishments in
Seismic Modeling
MASTODON code development (MOOSE based
seismic soil-structure analysis and structural
dynamics)
– Implemented nonlinear soil constitutive model
Performing a rigorous verification effort for
structural dynamic calculation capabilities including
– Linear and nonlinear seismic wave propagation
– Gapping and sliding activities
– Size of nonlinear seismic analysis finite element domain
Planning for large scale geotechnical laminar box
test (September 2016)
– Used for benchmarking and validation of 1D site response
14
INL
Beta Version of Seismic PRA Model Will be Released in 2017
Advanced SPRA Results: Conditional probabilities
of failure – nonlinear soil structure interaction can
result in significant reductions in system risk
15
Pump Battery
Switch
gearDistribution
panel
Block
wall
Advanced Instrumentation, Information, and Control Systems Technologies Pathway
Address long-term aging and reliability
concerns of existing II&C technologies:
– Establish a strategy to implement long-term
modernization of II&C systems.
– Develop, test, and deploy advanced technologies.
– Promulgate technologies, lessons learned, and foster
industry standardization.
– Develop advanced condition monitoring technologies
to monitor, detect, and characterize aging and
degradation processes.
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Pathway Lead:
Bruce Hallbert, INL
Control Room Modernization
Project begun with Arizona Public Services’ Palo Verde Nuclear Generating Station to
develop an end state for long term control room modernization informed by the plant’s
strategic modernization plan
Addresses feasibility and benefits of adopting a longer term outcome as a part of strategic
modernization
Employing best available technology optimized for safe and efficient operator use through
widespread inclusion of human factors principles
Design options are tested with Palo Verde staff in the INL’s Human System Simulation
Laboratory
17
Transformed Control Room (conceptual)Graphic of Current Control Room
Integral Human Factors Engineering
18
3-D Model of the Palo Verde conceptual design control room – 95th percentile male and 5th percentile female figures are used to check ergonomic aspects for anthropometric aspects of conceptual design using automated software tool
Control Room Modernization FY-
17 Plans
Develop an end-state design concept for the panels and systems involved in
the second phase
Develop a human factors engineering (HFE) plan to support the main control
room modernization effort at Palo Verde
Palo Verde phase 2 modernization and operator study report
Methodology and results of the Control Room Benefits experimental study
conducted with Palo Verde
Define performance measures for use in nuclear power plant simulator studies
based on Control Room Benefits studies conducted in FY 17
Develop an industry business case framework for control room modernization
Conduct Operator study to evaluate the design concept
Develop the Computerized Operator Support System to support Phase 2 of the
control room modernization
Conduct an industry peer review of the business case framework
19
Computer-Based Procedures
20
Field-based CBPs are one of the top enablers of improved efficiency and
human performance for NPPs, as well as a key foundation for future
technologiesError-Prone Situations Solutions
Omitting steps
Doing steps out-of-sequence
Making poor field decisions (failure to
adhere to procedure)
Manipulating wrong equipment
Relying on operator memory and experience
Automated Place-Keeping
Dynamic Context Sensitivity
Simplified Step Logic
Automatic Verifications
Dynamic cues to highlight important information
Access to supplemental materials
Automated aids Four Field Tests
– Catawba
– Palo Verde
– Diablo Canyon
– Vogtle 1 & 2
The CBP design requirements have been evaluated and validated
and will be published through NITSL and NEWPER in a Procedure
Professionals Association standard for dynamic smart documents
(CBPs), and a Design Guide for CBPs will be published
Business Case Example – Advanced
Outage Management
Completed the Advanced Outage Management Business
Case in March, working with ScottMadden and Duke
Energy
This business case was built on top of the Mobile Work
Packages business case to leverage mobile technology.
The result is an annual savings of >$7.7M, with a present
value >$48M over 15 years
Improvements are in better work
coordination, schedule analytics
remote job oversight, networked
meetings, and avoided errors
21
Operations$798
Maintenance$3,390
Work Management
$244
Radiation Protection
$289
Chemistry & Environmental
$185
Engineering$584
Training$3
CAP$390
Security$23
MWP and AOM Combined Harvestable Annual Labor Savings ($000s)
$3,277
$2,629
$179
$1,703
$0
$2,000
$4,000
$6,000
$8,000
MWP Benefits Incremental AOMBenefits
Business Case Annual O&M Benefits ($000s)
Labor Savings Non-Labor Savings
Total CombinedBenefit for MWP and
AOM
$ 7,788
Reactor Safety Technologies
Pathway
Evolved from coordinated global effort to
assist in analysis of the Fukushima accident
progression and accident response
Focus: Scientific/technical insights, data,
analyses and methods that can support
industry efforts to enhance nuclear reactor
safety during beyond design basis events
– Accident Tolerant Components
– Severe Accident Analyses
– Fukushima Forensics and Examination Plans
22
Pathway Lead: Mike
Corradini, University of
Wisconsin
Graphics Courtesy of TEPCO
RST Support to Forensics Planning
Forensics effort provides US access to
unique full-scale, prototypic, information for:
– Improved understanding of events that occurred in
each unit at Daiichi
– Reduced uncertainties in predicting severe accident
progression phenomena and equipment
performance
– Confirming/improving guidance for severe accident
prevention, mitigation, and emergency planning
– International effort under NEA appropriate means
for longer-term cooperation
Forensics Effort provides Japan:
– Consensus US input related to high priority
examination information needs
– Access to US expertise in severe accident
modeling, testing, and defueling & cleanup
Look-Ahead: FY-17 LWRS
Program Budget
Congress isn’t likely to pass a budget before October 1, 2016;
Continuing Resolution is likely
Three budgets
– President’s Request: $35.26M
– Senate: $35.26M
– House: $40M
Our budget has been steadily increasing ($25M in FY-12, $40M in FY-
16)
24
The LWRS Program Website Provides a
Range of Program Information
(www.inl.gov/lwrs)
25
Helping to Sustain National Assets
26
© 2016 – Materials Ageing Institute 1
LTO RESEARCH AT THE
MATERIALS AGEING
INSTITUTE
Regis Nhili
EDF R&D, MAI
August 2016
© 2016 – Materials Ageing Institute 2
LONG TERM OPERATION
CONTEXT
© 2016 – Materials Ageing Institute 3
EDF NUCLEAR GENERATION CAPACITY
IN FRANCEKey figures in FRANCE
58 reactors in operation on 19 sites
63 GWe installed nuclear capacity
1 reactor under construction
PWR technology only
Target : 50 to 60 years
© 2016 – Materials Ageing Institute 4
OPERATING LIFETIME CHALLENGES
Large-scale construction in the 1980s and
90s:
Phase the renewal of the generating capacity
operate power plants beyond 40 years
Halt at 40
years:
a major
investment in
new nuclear
power plants
© 2016 – Materials Ageing Institute 5
OBJECTIVES FOR THE PLANT OPERATING TIME
Safety improvements
•Ten-year inspection
revaluationSafety inspection every ten years
One file per reactor submitted by EDF
• 40-year key stage:
enhance the safety with
the objectives of new
reactorsREDUCE the consequences of a core
meltdown
REDUCE the probability of a core
meltdown occurring
Meet WENRA* requirements as closely as
possible
•Coexistence of GEN 2 and GEN 3(EPR)
Ageing management
• Replaceable components:
Define the best compromise
between routine
maintenance/preventive
replacement
• Non-replaceable components
Vessel: Demonstration of
endurance until 60 years
Containment: Repairs
*Western European Nuclear Regulators Association
© 2016 – Materials Ageing Institute 6
Mechanistic understanding of ageingprocesses and NDT assessment
• Operation feedback• Experiments• Modelling
R&D MISSION FOR UTILITIES
Predictive capability for
• Operation and Maintenance Optimisation• Inspection and Monitoring• Component Replacement
Plant Operators
R&D« Understand »
« Reproduce »
« Anticipate »
« Assess »
LTO objective
Availability
Radioprotection
Environment
°CGy.h-
1
© 2016 – Materials Ageing Institute 7
MAI OBJECTIVES AND
STRUCTURES
© 2016 – Materials Ageing Institute 8
MAI OBJECTIVES
1. Safe operation of NPPsknowledge-based management of materials
and components
2. Centralize and coordinate R&Dfeedback from NPPs, data, methods and models
3. Training & EducationTrain our next generation: courses, workshops
and seminars in the field of material ageing
4. Improve fundamental knowledgestudy ageing mechanisms with the help of state-
of-the art experimental tools and capabilities
© 2016 – Materials Ageing Institute 9
EXPERIMENTAL CAPABILITIES
Access to many experimental facilities
© 2016 – Materials Ageing Institute 10
MAI MEMBERSHIP
© 2016 – Materials Ageing Institute 11
MAI MEMBERS AND PARTNERS
Universities (Michigan, MIT, Tohoku, Manchester, Imperial, Oxford, Bristol, Rouen, Lille, Paris…), ParisTech (Mines, Ponts, Chimie,
Arts & Métiers), INP-Grenoble, INSA Lyon…
Founding Members
REA
© 2016 – Materials Ageing Institute 12
EDUCATION, TRAINING &
WORKSHOPS
© 2016 – Materials Ageing Institute 13
1st Benchmark Vercors mock-up (EDF Engineering div.)
MAI (Moret-sur-Loing): 7-9 March 2016 unrestricted
International ChemWorks Workshop (EPRI)
MAI (Moret-sur-Loing): 29-31 March 2016, open to MAI
members
Uncertainty Management in Computational Materials
Science
MAI (Moret-sur-Loing): 5-7 April 2016, unrestricted
Conference on Flow Accelerated Corrosion (EDF
Engineering div.)
Lille (France) : 24-27 May 2016, unrestricted
Master Materials for Nuclear Energy
INP-Grenoble/MAI, September 2016-January 2017
Materials Degradation Course for Engineers in the Nuclear
Industry in the US
EPRI-Charlotte Conference Center, 26-30 June 2017
2016 Programme
EDUCATION AND TRAINING
© 2016 – Materials Ageing Institute 14
Maintenance activities and
strategies, human factors,
organisation, operations
preparation and sequences,
industrial strategy,
components, maintenance
feedback, …
CAPITALIZING & SHARING KNOWLEDGE
Degradation observed in
LWRs Photographs, detailed
schematics, concise
analyses, precise
measurements and
recommendations
© 2016 – Materials Ageing Institute
MAI R&D PROGRAMME
© 2016 – Materials Ageing Institute 16
MAI R&D PROGRAMME
Primary water chemistry optimization to
reduce corrosion and circuit contamination
Secondary water chemistry optimization to reduce corrosion
and Steam Generator fouling and clogging
On-site monitoring and lifetime extension of cables
Justification of safe long term operation of Reactor Pressure Vessel
Justification of safe long term operation of reactor Internals
Civil Engineering structures ageing evaluation and prediction
NDE process optimization and performance assessment
Sharing of operating feedback data: materials damaged in operation,
RPV material ageing data, fatigue data …
Knowledge sharing on material ageing mechanisms: thermal & environmental
fatigue, vibrational wear, concrete degradation…
Benchmarks of methods, models and protocols (RPV, Internals, APT …)
Major Industrial Applications
© 2016 – Materials Ageing Institute 17
2016 R&D PROGRAMME
Project Name Technical Area 2016 2017 2018 2019 2020
CORIOLIS SCC, Primary side
CAIMAN Cable Ageing
MANDENA NDE Modelling
SG Wear SG Tubes Wear
RPV Integrity RPV Integrity & Lifetime
CHEOPS Primary Water Chemistry
CORDEE 2 Steam Generators
VIP RPV Internals
CISTERN 2 Concrete structures
MODERN Fatigue & Fracture Mechanics
SHERLOCK Two retired SGs• 11M€ annual budget• Contributing members in each project
© 2016 – Materials Ageing Institute 18
CHEOPSCHEmistry Of Primary System
Industrial context
Better understanding materials and chemical species behaviors in the primarycircuit is an ongoing challenge for utilities in terms of radioprotection, safety,plant’s availability and plant’s lifetime expectancy.
Key industrial objectives
Optimization of the primary system chemistry
Reduction of the operators exposure to the primary circuitthrough a better control of the contamination for differentoperating conditions (startup, operation, shutdown)
© 2016 – Materials Ageing Institute 19
Major R&D achievements
• Development of a numerical model describing the release of corrosionproducts from steam generator (SG) tubes measured in the BOREAL loop
1st step toward the estimation of the source term as a function of thephysico-chemical parameters of the primary circuit
Associated value
lower dose exposures through a better control of SGT release (690)
CHEOPSCHEmistry Of Primary System
Temperature Effect
© 2016 – Materials Ageing Institute 20
Major R&D results expected
• Impact of surface condition of SGT on release
• Solubility of Ni and other Corrosion Products
Expected value
• Direct economic value/ lower dose exposures :
Better control of corrosion and release of SGT through the identification of surface condition criteria
• Implicit value through scientific credibility :
A better knowledge of Corrosion Products behavior in the primary system
Reliable database inputs
CHEOPSCHEmistry Of Primary System
© 2016 – Materials Ageing Institute 21
CORDEE 2Chemistry cORrosion and DEposits in the secondary circuit
Approach
• Prediction of fouling and hard sludge formation
• Mechanisms Knowledge• Kinetics versus parameters
• Evaluation of
• Remedies of fouling and blockage• Alternative chemical conditioning
Objective
Context
• Degradation of the secondary circuits
• Optimization of chemical conditioning to reduce
• Source term of fouling and blockage
• Degradation by corrosion
• Optimization of maintenance operations
© 2016 – Materials Ageing Institute 22
CORDEE 2Chemistry cORrosion and DEposits in the secondary circuit
R&D impact and valueSG Fouling
Avoid additional Cu-dedicated chemical cleaning
- Chemical cleaning operation cost saved
- Gain on NPP availability
- Environmental benefit (waste reduction)
- Gain on SG performance
Identify post-chemical cleaning copper depositionmechanisms
Prevent SG tubes plugging
Intensify final rinsing and lancing chemical cleaning
steps to prevent copper redeposition
Decrease H.P lancing applications frequency
- H.P lancing operation cost saved
- Gain on NPP availability
Reduce SG tubes plugging
- Gain on SG performance
Aluminum key role in hard sludge formation Al uses reduction in maintenance materials
Hard Sludge & SCC degradation
FAC degradation
Prevent pipes rupture
- Safety & availability benefit
PAA injection suspended on French Fleet
Prevent fouling source term increase
Highlight PAA injections impact on FAC
© 2016 – Materials Ageing Institute 23
CORIOLIS - CSIStress Corrosion Cracking (SCC) of austenitic materials exposed to primary water
Industrial context
• Need to better explain recent in-service degradations
• Bottom mounted instrumentation nozzles of the reactor vessel: nickel alloys
• Bolts of primary pumps: stainless steels
• Need to evaluate mitigation method:
• Changes in water chemistry (dissolved hydrogen content, zinc injection) to reduce SCC kinetics
• Upgrading surface finishes of components (compressive stresses, limited cold work)
Key industrial objective
• To deliver engineering SCC tool predicting the time to reach a critical crack depth
© 2016 – Materials Ageing Institute 24
Major R&D achievements
• Improvement of crack growth models
• Explicit dependence to stress intensity factor, cold work (new), temperature and dissolved hydrogen (new)
• Explicit modeling of slow and fast crack growth regimes: MAI innovative approach
• Improvement of existing initiation models
• Explicit dependence to stress, temperature, heat-to-heat variability, dissolved hydrogen (new) and zinc (new) contents
• Development of a physically-based SCC model: innovative approach
• Satisfying a recognized SCC scenario: incubation → initiation → slow crack growth → fast crack growth
• Relying on physical mechanisms: oxidation, stress concentrations, cracking of oxidized material
Associated value
• Best estimate of components lifetime
• Quantitative evaluation of mitigation techniques,material replacement, design changes
CORIOLIS - CSIStress Corrosion Cracking (SCC) of austenitic materials exposed to primary water
SCC depth
Time
Incubation
(IG oxidation
kinetics)
Initiation (failure of oxidized
grain boundaries)
Slow crack
growth Fast crack
growth
© 2016 – Materials Ageing Institute 25
Major R&D achievements
• Development of an innovative methodology allowing to apply R&D models to power plant components
Associated value
• Use of robust and advanced SCC tools by operational units
• Support to in-service failure analyses
CORIOLIS - CSIStress Corrosion Cracking (SCC) of austenitic materials exposed to primary water
Modeling of a simplified
BMI nozzle (residual
stresses after welding)
Prediction of
initiation in the BMI
(nickel alloys)
Prediction of crack growth in
a bolt (stainless steel)
© 2016 – Materials Ageing Institute 26
Objectives
• Give a scientific support to Industry for a new codification in fatigue for austenitic stainless steels
• Fatigue life curves
• Parameters (Environment) effects on fatigue life
• Improve advanced methods to assess the fatigue damage
Approach
• Fatigue tests in air and in primary water PWR environment
• Parameters effects on fatigue life (Temperature, mean stress, pre hardening, environment…)
• Statistical analyses
COFATTowards a new codification for fatigue
© 2016 – Materials Ageing Institute 27
Major achievements
• Proposal to update the design curve for austenitic SS and incorporating the environmental effect
• Robust proposal
• Incorporate the state of the art in fatigue
• Consistent with international (NUREG/CR-6909) approach
Expected value
• Characterisation of the environmental effect on fatigue
• Reasonably conservative and operational approach
• New approach should become an IAEA guideline
COFATAdvanced method for fatigue crack initiation assessment
© 2016 – Materials Ageing Institute 28
RPV LIFETIMEProviding tools and data for RPV Long Term Operation demonstration
Industrial context
• The Reactor Pressure Vessel is one of the major components of a Nuclear Power Plant
• Its replacement is not considered up to now as an industrial option (prohibitive cost)
• RPV integrity needs to be assessed for Long Term Operation (LTO)
Key industrial objectives
• Justify safe and long term operation of RPV
• Increase confidence in RPV integrity assessment models
• Identify and develop MAI common strategies
• Improve knowledge on RPV material ageing by developing new experimental campaigns with a high leverage for members
© 2016 – Materials Ageing Institute 29
Major R&D achievementsAtom probe analysis procedure benchmark
• Atom probe analysis are used by MAI members to evaluate the irradiation effects on the material micro-structure
• The benchmark allows to compare the atom probe analysis on samples
Associated value
• Strengthening confidence in the atom probe analysis results, and, as a consequence, in the understanding of the irradiation effects
• Identifying best practices in atom probe analysis
• Performing the benchmark campaign within the MAI allows a significant leverage on the associated cost
RPV INTEGRITYProviding tools and data for RPV Long Term Operation demonstration
© 2016 – Materials Ageing Institute 30
Context: Can Internal components operate safely in long term operation?
• Internal components are under very high irradiation levels and temperature.
• Long term operation affected by material degradation mechanisms: hardening, swelling, Irradiation Assisted Stress Corrosion Cracking (IASCC).
Key industrial objectives
• Determine conditions for which there is a
risk of component failure due to:
o IASCC
o Void Swelling
• Characterize operating conditions:
Dose, Temperature and Stress assessment
VESSEL INTERNALS PROJECTLong Term Operation of Lower Core Internals
© 2016 – Materials Ageing Institute 31
MAI projects (LCI, INTERNALS, VIP) have enabled EDF to share all of the findings of the past and current research programs on irradiated internals.
• Irradiated Austenitic SS evolution (2010)• IASCC initiation sensitivity (2014)
Material assessment of IASCC initiation sensitivity
• French operating experience found cracked bolts due to IASCC in the 1980’s.
• As a consequence, EDF is a historical leader in IASCC investigations.
• Since the 1990’s, EDF led multiple major international programs to collaborate on IASCC investigations (CIR, JoBB, IAC…).
• Irradiations in Bor-60 and SM2 reactors at RIAR.
• Irradiated material investigations (mechanical, microstructure).
• IASCC initiation and propagation testing.
• Operating conditions – dose, T, stress/strain calculations.
VESSEL INTERNALS PROJECTLong Term Operation of Lower Core Internals
316/316LTEM observation of Frank Loops and Cavities
© 2016 – Materials Ageing Institute 32
Void swelling of internals in PWR conditions
• Void swelling is a potential issue for western plants.
• Void swelling laws are all currently calibrated on Fast Breeder Reactor (FBR) data often at high temperature. However, research has shown that they are very sensitive to irradiation temperature and neutron energy spectrum.
A more accurate swelling law for PWR conditions is required.
• Current Vessel Internals Project aims to determine risk and kinetics of void swelling in PWR conditions.
• Microstructure and Multi-scale modelling investigations of internal components.
• Dose and Temperature validation through benchmark.
Associated value
• More accurate swelling laws are most probably less penalizing than FBR calibrated laws
• Calculation benchmark: international validation of calculation methods used by the different participants
VESSEL INTERNALS PROJECTLong Term Operation of Lower Core Internals
© 2016 – Materials Ageing Institute 33
CAIMANCable AgeIng MANagement
Industrial context
• ~1500 km of cables for one production unit
• Replacement of cables technically difficult and costly because of associated plant shutdown (a partial re wiring in Sweden took 1 year)
• Multiple designs of cables and materials that leads to the inefficiency of strategies based on large databases to cover all situations (in terms of ageing factors)
Key industrial objectives
• Benefit of robust polymer lifetime predictions
• Provide suitable techniques and methodologies for on-site monitoring of cables
• Acquire experimental data coming from cables removed from sites after several years to justify the good conditions of cables and validate their lifetime predictions
© 2016 – Materials Ageing Institute 34
CAIMANCable AgeIng MANagement
Major R&D achievements
• Modelling of polymer ageing with consideration of key chemical ingredients with regard to ageing
• Antioxidants for EPR
• Plasticizers for PVC
• Sensitivity studies of polymer oxidation as a function chemical composition and range of irradiation/temperature couple
Associated value
• Accurate lifetime predictions taking into account the polymer composition
• Lifetime variability of polymers with environment conditions thanks to numerical simulations
© 2016 – Materials Ageing Institute 35
CAIMANCable AgeIng MANagement
Major R&D achievements
• Analysis of aged cables removed from site
• 7 cables analysed after more than 30 years of service
• Characterization: Visual inspection + Physical properties + Mechanical properties
=> Good condition of PVC and EPR insulated cables aged on site (significant margins were found in relation to end-of-life criteria)
Associated value
• Real data on cables aged in service
• Consolidation of cable lifetime numerical simulations
• Identification and quantification of margins
© 2016 – Materials Ageing Institute 36
CAIMAN – POLYAGECable AgeIng MANagement – POLymer AGEing
Major R&D results expected
• Identification of cable compositions sensitivity to ageing after 60 years
• Identification of suitable criteria, measurable by NDE techniques or micro sampling techniques, to monitor the polymer ageing
• Comparison of modelling results and experimental analyses of aged cables
• Check, by simulation, the potential existence of a cliff-edge effect for EPR insulations of nuclear cables
Expected value
• Define suitable criteria to anticipate the ageing behaviour of polymers and define acceptance criteria for on-site reception of new cables
• Provide techniques and methodologies for on-site monitoring of PVC and EPR insulated cables
• Benefit of robust R&D numerical tools and studies to predict polymers ageing
© 2016 – Materials Ageing Institute 37
MANDENAModelling Approaches for NDE for Nuclear Applications
Industrial context
• Lifetime extension of existing nuclear fleet requires more efficient NDE techniques and more regular inspections of critical ageing components
• EDF develops finite element and Monte Carlo-based models, complementary to commercially available semi analytical models
• Computer modeling of NDE has high potential for method development, performance demonstration and expertise
Key industrial objectives
• To obtain validated, operational tools and methods to justify the performances and limitations of NDE techniques in support of plants needs
• To solve physical problems exhibiting complex requirements (material, geometry, flaw,…).
• Gain the required credibility for performance demonstrations of NDE applications
© 2016 – Materials Ageing Institute 38
- Evaluation of the
X-probe
performance as an
alternative to
rotating probes
- Electronic
commutation of
coils replaces
rotating movement
- Shorter inspection
time
- Modeling
accompanied first
performance
evaluation AND
subsequent initial
deployment stage
on site
MANDENAModelling Approaches for NDE for Nuclear Applications
ET modeling use case : X-probe
Plate
Tube
Multi-
coil
probe
© 2016 – Materials Ageing Institute 39
CISTERNCivil Structure Engineering Resilience for Nuclear
Industrial context
• Necessity to better plan potentially expensive maintenance policies
• Containment ageing faces several physical phenomena that were not completely anticipated and might cause definitive loss of a complete production unit
Key industrial objectives
• Improve physical modelling of reinforced concrete material and building ageing
• Provide operators with key data to face known civil engineering issues (i.e. pool leakage, liner/rebar corrosion…)
• Provide NDE techniques for civil engineering structures performance evaluation and demonstration in accordance with nuclear industry requirements
© 2016 – Materials Ageing Institute 40
CISTERN 2Civil Structure Engineering Resilience for Nuclear
Major R&D results expected
• Diagnosis : Corrosion detection
• Diagnosis : NDT international benchmark evaluation
• Forecasting : Cement addition effect on physical properties and weather condition structural influence
Expected value
• New modeling tools to better anticipate ageing of concrete and buildings
• Evaluation of new concrete (fly ashes, furnace slag…) composition effect on performance
• Improvement of maintenance policy according to NDT evaluation performance with regards to nuclear industry specific needs
© 2016 – Materials Ageing Institute 41
ACTIVE CONTRIBUTIONS FROM EPRI
CORDEE: CIRCE Version 3 code development 2013 – 2014. Ongoing up to end of 2016.
MANDENA: Experimental validation of NDE codes. 2013 – 2016.
VIP: Development of a Standardized Procedure for Acquisition and Analysis of APT Data
on Irradiated Stainless Steels. 2015-2017.
CHEOPS: Chemistry strategies for surface passivation of new replaced or
decontaminated primary circuit component. 2015-2018.
CHEOPS: Advanced modeling of nickel-based alloy corrosion and release. 2015-2016.
CISTERN2: Develop capability demonstration program for concrete. 2016-2019.
CORIOLIS: Direct Measurement of Cohesive Strength of Grain Boundaries Exposed to
PWR Environment. 2016-2017.
© 2016 – Materials Ageing Institute 42
MAI IN NUMBERS
total investment by EDF (2008 – 2016)35 M€
annual budget in 201611 M€
researchers, technicians involved100
universities/institutes associated25
members, representing 66% NPPs11
participants yearly in the E&T programme250
deliverables since 2008350
© 2016 – Materials Ageing Institute 43
MATERIALS AGEING INSTITUTE
An international centre of excellence
Led by key nuclear utilities
A truly collaborative approach
Sharing of methods, facilities, staff
Benchmark & common development
Fundamental knowledge
Promote
technical
consensus
Long-term
strategic
collaboration
Scientific
credibility
© 2016 – Materials Ageing Institute 44
Materials Ageing Institute
Getting the best of what materials can give
http://www.themai.org
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