Ryan M. Meyer

Online Condition Monitoring to Enable Extended Operation of Nuclear Power Plants

Safe, secure, and economic operation of nuclear power plants will remain of strategic significance. New and improved monitoring will likely have increased significance in the post-Fukushima world. Prior to Fukushima, many activities were already underway globally to facilitate operation of nuclear power plants beyond their initial licensing periods. Decisions to shut down a nuclear power plant are mostly driven by economic considerations. Online condition monitoring is a means to improve both the safety and economics of extending the operating lifetimes of nuclear power plants, enabling adoption of proactive aging management. With regard to active components (e.g., pumps, valves, motors, etc.), significant experience in other industries has been leveraged to build the science base to support adoption of online condition-based maintenance and proactive aging management in the nuclear industry. Many of the research needs are associated with enabling proactive management of aging in passive components (e.g., pipes, vessels, cables, containment structures, etc.). This paper provides an overview of online condition monitoring for the nuclear power industry with an emphasis on passive components. Following the overview, several technology/knowledge gaps are identified, which require addressing to facilitate widespread online condition monitoring of passive components.

Prognostics health management and life beyond 60 for nuclear power plants

There is growing interest in longer-term operation of the current US nuclear power plant (NPP) fleet. This paper presents an overview of prognostic health management (PHM) technologies that could play a role in the safe and effective operation of nuclear power plants during extended life. A case study in prognostics for materials degradation assessment, using laboratory-scale measurements, is briefly discussed, and technical gaps that need to be addressed prior to PHM system deployment for nuclear power life extension are presented.

Developing effective continuous on-line monitoring technologies to manage service degradation of nuclear power plants

Recently, there has been increased interest in using prognostics (i.e, remaining useful life (RUL) prediction) for managing and mitigating aging effects in service-degraded passive nuclear power reactor components. A vital part of this philosophy is the development of tools for detecting and monitoring service-induced degradation. Experience with in-service degradation has shown that rapidly-growing cracks, including several varieties of stress corrosion cracks (SCCs), can grow through a pipe in less than one fuel outage cycle after they initiate. Periodic inspection has limited effectiveness at detecting and managing such degradation requiring a more versatile monitoring philosophy. Acoustic emission testing (AET) and guided wave ultrasonic testing (GUT) are related technologies with potential for on-line monitoring applications. However, harsh operating conditions within NPPs inhibit the widespread implementation of both technologies. For AET, another hurdle is the attenuation of passive degradation signals as they travel though large components, relegating AET to targeted applications. GUT is further hindered by the complexity of GUT signatures limiting its application to the inspection of simple components. The development of sensors that are robust and inexpensive is key to expanding the use of AET and GUT for degradation monitoring in NPPs and improving overall effectiveness. Meanwhile, the effectiveness of AET and GUT in NPPs can be enhanced through thoughtful application of tandem AET-GUT techniques.

Waterless coupling of ultrasound from planar contact transducers to curved and irregular surfaces during non-destructive ultrasonic evaluations

The Applied Physics group at the Pacific Northwest National Laboratory (PNNL) in Richland, WA has evaluated a method for waterless/liquidless coupling of ultrasonic energy from planar ultrasonic contact transducers to irregular test surfaces for ultrasonic non-destructive evaluation applications. Dry couplant material placed between a planar transducer face and a curved or uneven steel or plastic surface allows for effective sound energy coupling and preserves the integrity of the planar transducer sound field by serving as an acoustic impedance matching layer, providing good surface area contact between geometrically dissimilar surfaces and conforming to rough and unsmooth surfaces. Sound fields radiating from planar ultrasonic contact transducers coupled to curved and uneven surfaces using the dry coupling method were scanned and mapped using a Pinducer receiver connected to a raster scanner. Transducer sound field coverage at several ultrasonic frequencies and several distances from the transducer contact locations were found to be in good agreement with theoretical beam divergence and sound field coverage predictions for planar transducers coupled to simple, planar surfaces. This method is valuable for applications that do not allow for the use of traditional liquid-based ultrasonic couplants due to the sensitivity of the test materials to liquids and for applications that might otherwise require curved transducers or custom coupling wedges. The selection of dry coupling material is reported along with the results of theoretical sound field predictions, the laboratory testing apparatus and the empirical sound field data.

Progress towards prognostic health management of passive components in advanced small modular reactors

Sustainable nuclear power to promote energy security and to reduce greenhouse gas emissions are two key national energy priorities. The development of deployable small modular reactors (SMRs) is expected to support these objectives by developing technologies that improve the reliability, sustain safety, and improve affordability of new reactors. Advanced SMRs (AdvSMRs) refer to a specific class of SMRs and are based on modularization of advanced reactor concepts. Prognostic health management (PHM) systems can benefit both the safety and economics of deploying AdvSMRs and can play an essential role in managing the inspection and maintenance of passive components in AdvSMR systems. This paper describes progress on development of an experimental setup for testing and validation of PHM systems for AdvSMR passive components. The experimental set-up for validation of prognostic algorithms is focused on thermal creep degradation as the prototypic degradation mechanism. The test bed enables accelerated thermal creep aging of materials relevant to AdvSMRs along with multiple nondestructive evaluation (NDE) measurements for assessment of thermal creep damage. NDE techniques include eddy current, magnetic Barkhausen noise (MBN), and linear and non-linear ultrasonic measurements. Details of the test-bed design as well as initial measurements results for specimens at different levels of thermal creep damage are presented.

Review of Literature for Model Assisted Probability of Detection

This is a draft technical letter report for NRC client documenting a literature review of model assisted probability of detection (MAPOD) for potential application to nuclear power plant components for improvement of field NDE performance estimations.

Requirements for prognostic health management of passive components in advanced small modular reactors

Advanced small modular reactors (aSMRs), which are based on modularization of advanced reactor concepts, may provide a longer-term alternative to traditional light-water reactors and near term small modular reactors (SMRs), which are based on integral pressurized water reactor (iPWR) concepts. aSMRs are conceived for applications in remote locations and for diverse missions that include providing process or district heating, water desalination, and hydrogen production. Several challenges exist with respect to cost-effective operations and maintenance (O&M) of aSMRs, including the impacts of aggressive operating environments and modularity, and limiting these costs and staffing needs will be essential to ensuring the economic feasibility of aSMR deployment. In this regard, prognostic health management (PHM) systems have the potential to play a vital role in supporting the deployment of aSMR systems. This paper identifies requirements and technical gaps associated with implementation of PHM systems for passive aSMR components.

Materials Degradation and Detection (MD2): Deep Dive Final Report

An effort is underway at Pacific Northwest National Laboratory (PNNL) to develop a fundamental and general framework to foster the science and technology needed to support real-time monitoring of early degradation in materials used in the production of nuclear power. The development of such a capability would represent a timely solution to the mounting issues operators face with materials degradation in nuclear power plants. The envisioned framework consists of three primary and interconnected “thrust” areas including 1) microstructural science, 2) behavior assessment, and 3) monitoring and predictive capabilities. A brief state-of-the-art assessment for each of these core technology areas is discussed in the paper.

Calibration monitoring for sensor calibration interval extension: Identifying technical gaps

Currently in the United States, periodic sensor recalibration is required for all safety-related sensors, typically occurring at every refueling outage; and it has emerged as a critical path item for shortening outage duration in some plants. International application of calibration monitoring has shown that sensors may operate for longer periods within calibration tolerances. This issue is expected to also be important as the United States looks to the next generation of reactor designs (such as small modular reactors and advanced reactor concepts), given the anticipated longer refueling cycles, proposed advanced sensors, and digital instrumentation and control systems. Online monitoring (OLM) can be employed to identify those sensors that require calibration, allowing for calibration of only those sensors that need it. The U.S. Nuclear Regulatory Commission (NRC) accepted the general concept of OLM for sensor calibration monitoring in 2000, but no U.S. plants have been granted the necessary license amendment to apply it. This paper summarizes a recent state-of-the-art assessment of online calibration monitoring in the nuclear power industry, including sensors, calibration practice, and OLM algorithms. This assessment identifies key research needs and gaps that prohibit integration of the NRC-approved online calibration monitoring system in the U.S. nuclear power industry. Several technical needs were identified, including an understanding of the impacts of sensor degradation on measurements for both conventional and emerging sensors; the quantification of uncertainty in online calibration assessment; determination of calibration acceptance criteria and quantification of the effect of acceptance criteria variability on system performance; and assessment of the feasibility of using virtual sensor estimates to replace identified faulty sensors in order to extend operation to the next convenient maintenance opportunity.

Review of NDE Methods for Detection and Monitoring of Atmospheric SCC in Welded Canisters for the Storage of Used Nuclear Fuel

Dry cask storage systems (DCSSs) for used nuclear fuel (UNF) were originally envisioned for storage periods of short duration (~ a few decades). However, uncertainty challenges the opening of a permanent repository for UNF implying that UNF will need to remain in dry storage for much longer durations than originally envisioned (possibly for centuries). Thus, aging degradation of DCSSs becomes an issue that may not have been sufficiently considered in the design phase and that can challenge the efficacy of very long-term storage of UNF. A particular aging degradation concern is atmospheric stress corrosion cracking (SCC) of DCSSs located in marine environments. In this report, several nondestructive (NDE) methods are evaluated with respect to their potential for effective monitoring of atmospheric SCC in welded canisters of DCSSs. Several of the methods are selected for evaluation based on their usage for in-service inspection applications in the nuclear power industry. The technologies considered include bulk ultrasonic techniques, acoustic emission, visual techniques, eddy current, and guided ultrasonic waves.