Engineering topics

Moran, Traci L.

Publications and source records attributed to Moran, Traci L..

At least 19 records

DOE OSTI2020

Progress on Advancing the Robotic Air-slot Volumetric Inspection System (RAVIS) for Hanford Under-tank Inspection - 20519

The 27 in-service double-shell tank (DST) systems at Hanford provide interim storage for nearly 56 million gallons of nuclear and hazardous chemical legacy waste. The safe and reliable storage of the waste is critical to the site's extended cleanup mission. While in service, the leak integrity of the DSTs must be demonstrated to satisfy the Washington Administrative Code, inform decisions on tank management, and gauge fitness for continued service beyond originally intended design lives. The carbon steel plates and welds that comprise DST primary tank sidewalls and lower knuckles are routinely 'sampled' for volumetric non-destructive testing using ultrasonic inspection technology to determine whether corrosion pitting, cracking, or general corrosion are occurring that could compromise tank leak integrity. However, the carbon steel plates and welds that comprise the bottoms of primary tanks have not been thoroughly inspected since the DSTs were constructed (i.e., since 1968-1986) due to limited physical access to the exterior tank bottoms. The Robotic Air-slot Volumetric Inspection System, or 'RAVIS,' is being engineered to overcome the challenge of tank bottom in-service inspection. The system will be deployed under primary tanks within the small cooling channels/air-slots in the refractory pads upon which the tanks rest and will use ultrasonic guided wave inspection technology to volumetrically inspect physically inaccessible regions that make up ∼90% of a tank bottom, as well as regions that are physically accessible from the air-slots but comprise only ∼10% of a tank bottom. This paper describes the air-slot sensor and robotic deployment system and focuses on the testing approach and methods that are being applied to support (1) design feedback and performance acceptance (requirement verification) and (2) performance repeatability/reliability assessments (qualification) to ensure the RAVIS is prepared for successful inservice inspections of primary tank bottoms. Test progress made against the test plan, the results of 2019 testing, and the future outlook are included. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2019

NDE Reliability Issues for the Examination of CASS Components

The relatively low cost and corrosion resistance of cast austenitic stainless steel (CASS) materials resulted in their extensive use for piping systems in nuclear power plants (NPPs). However, CASS component welds are among the most challenging volumetric examinations required to be performed for detection of potential service degradation. Effective and reliable inspection methods for CASS materials are essential to achieving the objectives of defense-in-depth. A complicating issue is the presence of thermal aging embrittlement, a known degradation mechanism that occurs in CASS NPP materials. Further, while not as yet reported in CASS, many unforeseen instances of cracking in safety-related piping system welds have been experienced in other austenitic materials. Currently, a performance-based method to qualify NDE in CASS is not available. Pacific Northwest National Laboratory (PNNL) has performed nondestructive examination (NDE) research under the sponsorship of the U.S. Nuclear Regulatory Commission (NRC) for over four decades. A primary objective of the research has been to assess the effectiveness and reliability of conventional and advanced NDE methods for the inspection of light-water reactor components. One of the tasks being performed within this framework is to evaluate state-of-the-art technical approaches for examining safety-related nuclear reactor components that pose significant challenges to traditional NDE methods. A specific area of research in this regard is the volumetric examination of coarse-grained weldments and base materials. This report summarizes, compiles, and assesses relevant investigations performed by PNNL and other domestic and international organizations for welds adjacent to CASS components to provide a comprehensive evaluation on this subject. The primary objectives of the report are to assess the overall feasibility for advanced NDE methods to reliably and effectively examine field CASS piping components and to determine if techniques similar to those described in existing standards could be applied to develop performance demonstration requirements for CASS piping components. This report discusses improving the reliability of CASS examinations through the use of advanced low-frequency phased-array techniques, coupled with other “best practice” examination parameters, and makes recommendations for consideration by NRC Staff regarding the development of effective performance-based qualifications for CASS weldments. In addition to the PNNL research documented here, over 230 historical and more recent publications have been reviewed in the development of this document. The report is expected to be a useful resource for engineers and scientists involved in NDE of CASS for purposes of inservice inspection on existing plants during current and extended periods of operation. Finally, researchers and NDE practitioners conducting future investigations to advance the state-of-the-art should find the information contained in this report to be beneficial.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Final Report on the Viability of Acoustic Techniques for Density and Mass Flow in Enrichment Plants

The primary purpose of this research is to study the viability of acoustic signatures and sensors that could support accurate, noninvasive, and unattended measurement of uranium hexafluoride (UF6) gas density and mass flow rate in situations representative of gaseous centrifuge enrichment plants (GCEP) under safeguards by the International Atomic Energy Agency. The measurement method under development can be readily retrofitted to the exterior of piping in existing systems, potentially facilitating acceptance by facility operators. The findings from the demonstration of a preliminary prototype design and first-generation analysis algorithms in this project will inform the safeguards community as to whether continued acoustic instrument and methods development are warranted. This project conducted two types of measurements, depending on the flow conditions of the gas. For static measurements, the focus is on understanding the acoustic properties at low pressure for non-flowing UF6. For flow measurements, the focus is on understanding the performance of the acoustic system in a simulation of a GCEP pipe using a surrogate gas under fully developed flow conditions. Testing with flowing UF6 was not considered because the cost of building a flowing UF6 system with flow similar to a GCEP was considerably greater than allocated project resources. This document summarizes the results of research conducted over the course of the project. Based on the results to date, the approach is seen to be promising with non-invasive acoustic measurements shown to be possible at the desired pressures. The project has demonstrated • 5% uncertainty of the UF6 gas density for static measurements at pressures relevant to GCEP operations over a 5-minute measurement window with a clear path forward to achieving considerably lower uncertainties over a two-hour period, • Measurements of flowing surrogate gases at pressures relevant to GCEP operations. However, additional research remains to be done to further develop the measurement approach and transition the technology for field use. These development needs include: • Understand the impact of flowing gas on gas density measurements, • Adding sensors and improving the measurement procedure, • Augmenting the data analysis methods by leveraging machine learning approaches, • Reevaluating uncertainty requirements for density and mass flow given observed Online Enrichment Monitor (OLEM) measurement uncertainties, • Designing a robust instrumentation package for field-testing, and • Evaluating measurement results to understand the potential impact on mass balance calculations within GCEP facilities.

42 ENGINEERING↗

DOE OSTI2018

NDE Technology Development Program for Hanford DST Non-Visual Volumetric Inspection Technology – Phase II; Technical Letter Report on Air-slot NDE Sensor Maturation Testing

The Pacific Northwest National Laboratory (PNNL) located in Richland, Washington, hosted and administered Phase II Flaw Detection Performance Tests in August 2018 that allowed the newly matured ultrasonic guided wave phased-array (GWPA) air-slot NDE sensor—“Hanford-Probe A”—developed by Guidedwave to be evaluated for its flaw detection capability and repeatability. A portion of the Phase II Flaw Detection Performance Tests was performed on a subset of test flaws on which the original GWPA sensor was evaluated during Phase I Sensor Effectiveness Testing (SET) to facilitate a comparison in flaw detection performance between Hanford-Probe A and the original GWPA sensor demonstrated in Phase I. The objective of the performance comparison was to determine the extent to which GWPA sensor design changes impacted the flaw detection performance upon which selection of the sensor technology was originally based for the purpose of determining whether the flaw detection performance of the newly matured Hanford-Probe A GWPA air-slot NDE sensor is at least equal to that of the original GWPA sensor evaluated under Phase I SET. This technical letter report presents the results produced by the new Hanford-Probe A on the Phase I test flaws and the results of the flaw detection performance comparison between Hanford-Probe A and the original GWPA sensor demonstrated in Phase I.

47 OTHER INSTRUMENTATION↗

DOE OSTI2018

Acoustic Techniques for UF6 Density and Mass Flow Measurements

A key enabling capability for enrichment plant safeguards is high-accuracy, non-invasive, unattended measurement of UF6 gas density and mass flow rate. Acoustic techniques are currently used to non-invasively monitor gas flow in industrial applications; however, the operating pressures at gaseous centrifuge enrichment plants (GCEPs) are roughly two orders magnitude below the capabilities of commercial instrumentation. Pacific Northwest National Laboratory is refining acoustic techniques for estimating density and mass flow rate of UF6 gas in scenarios typical of gaseous centrifuge enrichment plants, with the goal of achieving 1% measurement uncertainty. Proof-of-concept laboratory measurements of UF6 have demonstrated signature sensitivity to gas density at pressures equivalent to 10-50 Torr of UF6, typical pressures for GCEP unit header pipes. This sensitivity was clearly observable above background acoustic interference. Current efforts involve developing a test bed for conducting acoustic measurements on flowing surrogate gas, air and SF6, at representative flow rates and pressures to ascertain the viability of conducting gas flow measurements under these conditions. Density and flow measurements will be conducted to support the evaluation. If successful, the approach could enable an unattended, non-invasive approach to measure UF6 density and mass flow in unit header pipes of GCEPs.

International safeguards instrumentation, acoustic↗

DOE OSTI2018

NDE Technology Development Program for Non-Visual Volumetric Inspection Technology - Phase I Summary Report

This report provides a summary of the outcomes and findings of the sensor testing and evaluation work performed in FY2017 and first quarter of FY2018 under Phase I of the NDE Technology Development Program. The objective of this summary report is to provide a condensed version of the information provided in the Phase I program plan, Phase I test plan, the two comprehensive Phase I interim test reports issued for Technology Screening and advanced Sensor Effectiveness Testing, and the results from testing and demonstrations conducted Post-Sensor Effectiveness Testing for the purpose of supporting the selection of sensor technologies for maturation under Phase II. The orthogonal research and planning that should accompany technology maturation to support Phase II and Phase III are also included. The full details of the test mock-ups and flaws, sensor technologies, tests, evaluation criteria, and evaluation results are included in Phase I and provided in the interim Phase I test reports on Technology Screening and Sensor Effectiveness Testing.

47 OTHER INSTRUMENTATION↗

DOE OSTI2017

UF6 Density and Mass Flow Measurements for Enrichment Plants using Acoustic Techniques

A key enabling capability for enrichment plant safeguards being considered by the International Atomic Energy Agency (IAEA) is high-accuracy, noninvasive, unattended measurement of UF6 gas density and mass flow rate. Acoustic techniques are currently used to noninvasively monitor gas flow in industrial applications; however, the operating pressures at gaseous centrifuge enrichment plants (GCEPs) are roughly two orders magnitude below the capabilities of commercial instrumentation. Pacific Northwest National Laboratory is refining acoustic techniques for estimating density and mass flow rate of UF6 gas in scenarios typical of GCEPs, with the goal of achieving 1% measurement accuracy. Proof-of-concept laboratory measurements using a surrogate gas for UF6 have demonstrated signatures sensitive to gas density at low operating pressures such as 10–50 Torr, which were observed over the background acoustic interference. Current efforts involve developing a test bed for conducting acoustic measurements on flowing SF6 gas at representative flow rates and pressures to ascertain the viability of conducting gas flow measurements under these conditions. Density and flow measurements will be conducted to support the evaluation. If successful, the approach could enable an unattended, noninvasive approach to measure mass flow in unit header pipes of GCEPs.

Good, Morris S.↗

DOE OSTI2017

NDE Technology Development Program for Non-Visual Volumetric Inspection Technology; Sensor Effectiveness Testing Report

The Pacific Northwest National Laboratory (PNNL) located in Richland, Washington, hosted and administered Sensor Effectiveness Testing that allowed four different participants to demonstrate the NDE volumetric inspection technologies that were previously demonstrated during the Technology Screening session. This document provides a Sensor Effectiveness Testing report for the final part of Phase I of a three-phase NDE Technology Development Program designed to identify and mature a system or set of non-visual volumetric NDE technologies for Hanford DST primary liner bottom inspection. Phase I of the program will baseline the performance of current or emerging non-visual volumetric NDE technologies for their ability to detect and characterize primary liner bottom flaws, and identify candidate technologies for adaptation and maturation for Phase II of the program.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

NDE Technology Development Program for Non-Visual Volumetric Inspection Technology: Technology Screening Report

The Pacific Northwest National Laboratory (PNNL) located in Richland, Washington, hosted and administered a Technology Screening test that allowed four different participants to demonstrate the NDE volumetric inspection technologies that were proposed in response to the WRPS EOI. This document provides a Technology Screening test report for the initial part of Phase I of a three-phase NDE Technology Development Program designed to identify and mature a system or set of non-visual volumetric NDE technologies for Hanford DST primary liner bottom inspection. Phase I of the program will baseline the performance of current or emerging non-visual volumetric NDE technologies for their ability to detect and characterize primary liner bottom flaws, and identify candidate technologies for adaptation and maturation for Phase II of the program.

42 ENGINEERING↗

DOE OSTI2016

Acoustic Techniques for Density and Mass Flow in Enrichment Plants

In recent years, the IAEA has pursued innovative techniques and an integrated suite of safeguards measures to address the verification challenges posed by advanced centrifuge technologies and the growth in capacity at gaseous centrifuge enrichment plants (GCEPs) [1; 2]. A prominent theme in the development of a new generation of safeguards measures for GCEPs is the use of permanently installed, unattended instruments that can provide continuous monitoring of facility activities, while also reducing the need for on-site inspections [3]. For example, the U.S. Support Program to the IAEA leads the development of an On-Line Enrichment Monitor (OLEM) [4; 5] and an Unattended Cylinder Verification Station (UCVS) [6]. OLEM units will provide continuous enrichment measurement for 100% of the declared gas flowing through unit header pipes, thereby improving the IAEA’s capabilities to verify operator declarations of enrichment. The OLEM concept requires an accurate determination of gas density in order to produce accurate enrichment calculations (Fig. 1). The current OLEM design assumes that this gas density is derived from a pressure transducer signal shared with the operator. The IAEA has expressed the desire for a technology that can independently and noninvasively measures gas density, in support of a next-generation OLEM design.

IAEA, Enrichment Plants, Acoustic Techniques, OLEM↗

DOE OSTI2016

Nondestructive Examination Guidance for Dry Storage Casks

In this report, an assessment of NDE methods is performed for components of NUHOMS 80 and 102 dry storage system components in an effort to assist NRC staff with review of license renewal applications. The report considers concrete components associated with the horizontal storage modules (HSMs) as well as metal components in the HSMs. In addition, the report considers the dry shielded canister (DSC). Scope is limited to NDE methods that are considered most likely to be proposed by licensees. The document, ACI 349.3R, Evaluation of Existing Nuclear Safety-Related Concrete Structures, is used as the basis for the majority of the NDE methods summarized for inspecting HSM concrete components. Two other documents, ACI 228.2R, Nondestructive Test Methods for Evaluation of Concrete in Structures, and ORNL/TM-2007/191, Inspection of Nuclear Power Plant Structure--Overview of Methods and Related Application, supplement the list with additional technologies that are considered applicable. For the canister, the ASME B&PV Code is used as the basis for NDE methods considered, along with currently funded efforts through industry (Electric Power Research Institute [EPRI]) and the U.S. Department of Energy (DOE) to develop inspection technologies for canisters. The report provides a description of HSM and DSC components with a focus on those aspects of design considered relevant to inspection. This is followed by a brief description of other concrete structural components such as bridge decks, dams, and reactor containment structures in an effort to facilitate comparison between these structures and HSM concrete components and infer which NDE methods may work best for certain HSM concrete components based on experience with these other structures. Brief overviews of the NDE methods are provided with a focus on issues and influencing factors that may impact implementation or performance. An analysis is performed to determine which NDE methods are most applicable to specific components.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

EVALUATION OF ULTRASONIC PHASED-ARRAY FOR DETECTION OF PLANAR FLAWS IN HIGH-DENSITY POLYETHYLENE (HDPE) BUTT-FUSION JOINTS

The desire to use high-density polyethylene (HDPE) piping in buried Class 3 service and cooling water systems in nuclear power plants is primarily motivated by the material’s high resistance to corrosion relative to that of steel and metal alloys. The rules for construction of Class 3 HDPE pressure piping systems were originally published in Code Case N-755 and were recently incorporated into the American Society of Mechanical Engineers Boiler and Pressure Vessel Code (ASME BPVC) Section III as Mandatory Appendix XXVI (2015 Edition). The requirements for HDPE examination are guided by criteria developed for metal pipe and are based on industry-led HDPE research or conservative calculations.

HDPE↗

DOE OSTI2016

Viability of Acoustic Techniques for Density and Mass Flow in Enrichment Plants

A key enabling capability for enrichment plant safeguards approaches being considered by the International Atomic Energy Agency (IAEA) is high-accuracy, non-invasive, unattended measurement of UF 6 gas density and mass flow rate. The Office of Defense Nuclear Nonproliferation is funding this project to evaluate the viability of acoustic techniques for measuring density and mass flow rate of UF 6 gas in scenarios typical of gaseous centrifuge enrichment plants, with the goal of achieving better than 1% measurements. This report is a review of the progress in the first five months of the project. Initial results are encouraging: Air is a suitable surrogate gas for UF 6 for the initial research effort; Measurable acoustic energy transferred through the air from the transmitting to the receiving transducer for equivalent UF 6 pressures of 10 Torr; There is a monotonic relationship between air pressure and acoustic energy transferred through the air for equivalent UF 6 pressures down to 10 Torr; The acoustic energy transferred through the air is observable above the acoustic energy transferred through the pipe wall. While there is considerable research left to determine the viability of using acoustic techniques to noninvasively measure the gas flow for gaseous centrifuge enrichment plants, these initial results are very encouraging and warrant the continued research effort.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

Using Phased Array Ultrasonic Testing in Lieu of Radiography for Acceptance of Carbon Steel Piping Welds

The Pacific Northwest National Laboratory (PNNL) is conducting studies for the U.S. Nuclear Regulatory Commission (NRC) to assess the capability, effectiveness, and reliability of ultrasonic testing (UT) as a replacement method for radiographic testing (RT) for volumetric examination of nuclear power plant (NPP) components. This particular study focused on evaluating the use of UT on carbon steel plate welds. Welding fabrication flaws included a combination of planar and volumetric types, e.g., incomplete fusion, lack of penetration, cracks, porosity, and slag inclusions. The examinations were conducted using phased-array (PA) UT techniques applied primarily for detection and flaw type characterization. This paper will discuss the results of using UT in lieu of RT for detection and classification of fabrication flaws in carbon steel plate welds.

NDE reliability↗

DOE OSTI2012

Understanding the Challenges in the Transition from Film Radiography in the Nuclear Power Industry

Nondestructive examination (NDE) applications in the nuclear power industry using film radiography are shrinking due to the advent of modern digital imaging technologies and advances in alternative inspection methods that do not present an ionizing radiation hazard. Technologies that are used routinely in the medical industry for patient diagnosis are being adapted to industrial NDE applications including the detection and characterization of defects in welds. From the user perspective, non-film inspection techniques provide several advantages over film techniques. It is anticipated that the shift away from the application of film radiography in the nuclear power industry represents an irreversible trend. The U.S. Nuclear Regulatory Commission (NRC) has noted this trend in the U.S. nuclear power industry and will be working to ensure that the effectiveness and reliability of component inspections is not compromised by this transition. Currently, specific concerns are associated with 1) obtaining a fundamental understanding of how inspection effectiveness and reliability may be impacted by this transition and 2) ensuring training standards and qualifications remain compatible with modern industrial radiographic practice. This paper discusses recent trends in industrial radiography and assesses their advantages and disadvantages from the perspective of nuclear power plant component inspections.

digital radiography↗

DOE OSTI2012

An Empirical Study on Ultrasonic Testing in Lieu of Radiography for Nuclear Power Plants

Research is being conducted for the U.S. Nuclear Regulatory Commission (NRC) at the Pacific Northwest National Laboratory (PNNL) to assess the capability, effectiveness, and reliability of ultrasonic testing (UT) as a replacement method for radiographic testing (RT) for inspecting nuclear power plant (NPP) components. A primary objective of this work is to evaluate UT techniques to assess their ability to detect, locate, size, and characterize fabrication flaws in typical NPP weldments. This particular study focused on the evaluation of four carbon steel pipe-to-pipe welds on specimens that ranged in thicknesses from 19.05 mm (0.75 in.) to 27.8 mm (1.094 in.) and were 355.6 mm (14.0 in.) or 406.4 mm (16.0 in.) in diameter. The pipe welds contained both implanted (intentional) fabrication flaws as well as bonus (unintentional) flaws throughout the entire thickness of the weld and the adjacent base material. The fabrication flaws were a combination of planar and volumetric flaw types, including incomplete fusion, incomplete penetration, cracks, porosity, and slag inclusions. The examinations were conducted using phased-array UT (PA UT) techniques applied primarily for detection and length sizing of the flaws. Radiographic examinations were also conducted on the specimens with RT detection and length sizing results being used to establish true state. This paper will discuss the comparison of UT and RT (true state) detection results conducted to date along with a discussion on the technical gaps that need to be addressed before these methods can be used interchangeably for repair and replacement activities for NPP components.

NDE reliability↗

DOE OSTI2012

In-situ Characterization of Cast Stainless Steel Microstructures

Cast austenitic stainless steel (CASS) was commonly used in selected designs of nuclear power reactor systems for corrosion resistance and enhanced durability in service. CASS materials are generally coarse-grained and elastically anisotropic in nature, and are consequently difficult to inspect ultrasonically, largely due to detrimental effects of ultrasonic wave interactions with the coarse-grain microstructures. To address the inspection needs for these materials, new approaches that are robust to these phenomena are being developed. However, to enhance the probability of detecting flaws, knowledge of the microstructure and the corresponding acoustic properties of the material may be required. This paper discusses the application of ultrasonic backscatter measurement methods for classifying the microstructure of CASS components, when making measurements from the outside surface of the pipe or component. Results to date from laboratory experiments demonstrate the potential of these measurements to classify the material type of CASS for two homogeneous microstructures—equiaxed-grain material or columnar-grain material. Measurements on mixed or banded microstructures also show correlation with the estimated volume-fraction of columnar grains in the material. However, several operational issues will need to be addressed prior to applying this method for in-situ characterization of CASS microstructure.

CASS↗

DOE OSTI2012

Ultrasonic Evaluation of Two Dissimilar Metal Weld Overlay Specimens

Two dissimilar metal weld (DMW) pipe-to-nozzle specimens were implanted with thermal fatigue cracks in the 13% to 90% through-wall depth range. The specimens were ultrasonically evaluated with phased-array probes having center frequencies of 0.8, 1.0, 1.5, and 2.0 megahertz (MHz). An Alloy 82/182 weld overlay (WOL) was applied and the specimens were ultrasonically re-evaluated for flaw detection and characterization. The Post-WOL flaw depths were approximately 10% to 56% through-wall. This study has shown the effectiveness of ultrasonic examinations of Alloy 82/182 overlaid DMW specimens. Phased-array probes with center frequency in the 0.8- to 1.0-MHz range provide a strong coherent signal but the greater ultrasonic wavelength and larger beam spot size prevent the reliable detection of small flaws. These small flaws had nominal through-wall depths of less than 15% and length in the 50-60 mm (2-2.4 in.) range. Flaws in the 19% and greater through-wall depth range were readily detected with all four probes. At the higher frequencies, the reflected signals are less coherent but still provide adequate signal for flaw detection and characterization. A single inspection at 2.0 MHz could provide adequate detection and sizing information but a supplemental inspection at 1.0 or 1.5 MHz is recommended.

36 MATERIALS SCIENCE↗