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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

A novel green hydrogen production using water-energy nexus framework

The transformation of electrical energy to hydrogen via water electrolysis consumes considerable amount of fresh water and a productive use of nontraditional water sources enhances the reliability and resilience of energy and water systems. In this study, we have designed a solid oxide electrolysis cell (SOEC) system which is an evolving hydrogen production technology at high temperatures for water electrolysis. Here, the SOEC uses steam generated from flue gas as its feedstock and is fully integrated with numerous power production units, including coal and natural gas-fired power plants as its energy feedstock. While there is a hasten global shift away from fossil fuel, integrating its asset into this technology helps limit the risk and future losses of stranded assets and reduce the cost of investment in the new technologies. But high capital expenditures and doubt concerning the future cost and efficiency upgrade are obstacles to investing in water electrolysis. Such a detailed Levelized cost of hydrogen and techno-economic analysis is conducted to show the viability and environmental impacts of this novel technology. The results show SOEC efficiency of 97.4 % and 56.3 % as thermal-to-hydrogen efficiency of the system with a daily hydrogen production of 242,400 kg at $2.9–3.5/kg H 2 . The estimates show a positive gain prospect in this technology and techno-economic challenges.

08 HYDROGEN↗
DOE OSTI2022

Bottom-up assessment of industrial heat pump applications in U.S. Food manufacturing

Decarbonization of the industrial process heat supply through electrification could contribute significantly to climate change mitigation efforts. In the U.S. industry, thermal processes accounted for more than two-thirds of the total final energy demand in 2021. Cross-cutting electrification technologies like industrial heat pumps are suitable for the process heat supply to several industrial unit operations in a sustainable way while also improving overall energy efficiency. This study employs a bottom-up approach to investigate the techno-enviro-economic potentials of deploying high-temperature and steam-generating heat pumps in the major U.S. food manufacturing sectors in different timeframes. The results show that the annual technical potential energy and CO 2 savings by electrifying process heat supply are 325 PJ (or approximately 20% of the total final energy demand in U.S. food manufacturing) and 31 MtCO 2 (equivalent to the annual CO 2 emissions from over 6 million cars in the U.S.) in 2050, respectively; however, these incur additional costs in each sector. Although there may be individual cost-effective opportunities for electrifying heat supply in specific industrial sites, the overall costs are estimated to be high in the food sectors due to the large disparity between electricity and natural gas prices and low heat source temperatures. To overcome the identified techno-economic barriers, comprehensive action plans for different stakeholders are needed. In conclusion, this study provides novel insights that should inform policymakers’ and executives’ decisions about the electrification of the current and future U.S. industrial heat supply in relevant industrial sectors.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Life cycle analysis of a hydrogen production system based on solid oxide electrolysis cells integrated with different energy and wastewater sources

Hydrogen production via water electrolysis is a promising and evolving technology. The solid oxide electrolysis cell (SOEC) is one of the several technologies for this purpose. They are alternatives to the traditional hydrogen production from fossil fuels to enhance global energy decarbonization. However, in the bid for sustainability and a green economy, these technologies are not free from causing some environmental burdens. Using life cycle assessment (LCA), the greenhouse gas emission and degree of environmental impacts by these technologies can be identified and measured throughout their lifespan. This study addresses how to quantify these CO 2 emission impacts for an electrolytic system with different energy sources. The LCA of a novel integrated hydrogen production SOEC system with energy from solar photovoltaic and bituminous powerplant is performed using simaPro, the leading global LCA solution software. Measuring the environmental impact of the electrolytic operation in terms of weight, the bituminous powerplant poses damage which is, on average 700% more than solar PV. The thermal-to-hydrogen efficiency of the SOEC system is 56%, and a probable 28% reduction in carbon footprint with heat integration. The steam generation and the manufacturing of the SOEC have a very high environmental impact potential on the system. Here, we recommend LCA and net energy analysis is carried out for every new hydrogen technology and adequate comparison to enhance sustainable and green economy.

08 HYDROGEN↗
DOE OSTI2019

Study on impact of Cr and Mo on diffusion of H in 2.25Cr1Mo steel using first-principle calculations

Chrome-molybdenum steel (2.25Cr1Mo steel) is one of the main materials of a steam generator (SG) in high-temperature reactor-pebblebed modules (HTR-PM). It is essential to analyze the source term of tritium in this material, because the behavior of tritium in a SG is important for performing source term analysis in normal and accident conditions. In this article, the diffusion behavior of H atom in 2.25Cr1Mo steel was calculated to estimate the diffusivity of tritium using first-principles density functional theory. To develop and simplify the model of hydrogen diffusion in 2.25Cr1Mo steel, the impact of Cr and Mo on the diffusion of hydrogen in bcc-Fe were first calculated, all the possible diffusion paths were considered, and the minimum energy path was obtained. The diffusion activation energy and pre-exponential factor of the diffusion coefficient were obtained from Vienna Ab initio Simulation Package combined with the climbing image-nudged elastic band method. Here the results indicate that the minimum energy path for the impurity H atom is from one tetrahedral interstitial site to an adjacent tetrahedral interstitial site. The function of the diffusion coefficient of H in 2.25Cr1Mo steel with temperature T can be expressed as D = 1.486 X 10 -7 x ($\frac{-16.350kJ/mol}{RT}$) (M2/s). The diffusion coefficient of our calculation and some of the previous experiments have an excellent quantitative agreement, which indicates the reliability of our crystalline model and the practicability of the present theoretical approach. More importantly, the computational results in this work can be treated as a good screening method to collect reasonable experimental data, which will provide a good reference for tritium source term evaluation in the SG of the HTR-PM.

36 MATERIALS SCIENCE↗
DOE OSTI2020

System code evaluation of near-term accident tolerant claddings during pressurized water reactor station blackout accidents

Following the Fukushima Daiichi nuclear accident in 2011, researches on Accident-tolerant fuels (ATFs) are currently of high interest in not only the nuclear industry but also governmental and international organizations. In this work, a quantitative evaluation of the performance of monolithic FeCrAl cladding and Cr-coated Zircaloy cladding has been performed for Pressurized Water Reactor (PWR) Station Blackout (SBO) accidents. A generic PWR model has been built in system thermal-hydraulics code TRACE based on the Surry Nuclear Power Station with counter-current natural circulation modelling capability for hotleg and steam generator U-tube components during the accidents. The base model results are then compared to MELCOR and RELAP simulations to verify the system component implementation in TRACE. Two PWR SBO scenarios were investigated, including: short-term SBO and long-term SBO with early reactor coolant pump (RCP) seal failure. These scenarios are defined to be very similar to the accidents studied in the State-of-the-Art Reactor Consequence Analysis (SOARCA) project. TRACE code is modified to reflect the oxidation kinetics of FeCrAl and Cr-coating. Larson-Miller creep rupture model is also implemented in TARCE using its built-in control systems to simulate the creep rupture of hotlegs. Additionally, the comparison between the TRACE models with and without the counter-current flow modeling resulted in significant difference when comparing ATF cladding to Zircaloy for short term SBO, while it marginal impacted the performance during long term SBO with RCP seal failure. For short term SBO, both ATF cladding underwent hot leg creep rupture ~20 min after Zircaloy cladding. While Zircaloy and Cr-coated cladding had generated significant amount of hydrogen gas (>10 kg) before the creep rupture event, FeCrAl cladding had only generated <0.5 kg of hydrogen gas. For long term SBO with RCP seal failure, significant hydrogen generation and fuel melting was predicted before hot leg creep rupture for the ATF cladding while providing only 10–20 min additional coping time compared to Zircaloy.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Seismic isolation: A pathway to standardized advanced nuclear reactors

Standardizing advanced nuclear reactors is a pathway to substantially reducing their overnight capital cost and achieving parity with other power sources, including renewables and fossil fuels. The seismic load case has thwarted standardization of nuclear power plants because site-specific seismic hazard and local near-surface geology has triggered soil-structure-interaction analysis, design, equipment qualification, regulatory review, and licensing, ensuring that each build is different. To achieve standardized or site-independent certified advanced reactor designs, the impact of the seismic load case on the engineering and construction cost and time must be substantially mitigated. Seismic isolation is a mature technology that has been used for more than 30 years in non-nuclear sectors to substantially reduce earthquake demands in buildings and other infrastructure. In this paper, seismic isolation is used to enable standardization of advanced reactor designs, aimed at the complete re-use of a site-independent, certified design and repeated procurement of safety-class equipment. A pathway to standardized designs using seismic isolation is demonstrated for two fundamentally different advanced reactors: a molten salt reactor and a high temperature gas reactor. Each reactor building is equipped with three specialized pieces of safety-class equipment, namely, a reactor vessel, a steam generator, and a control rod drive mechanism housing that is attached to the reactor head. Analysis is performed per ASCE and ASME standards to design the buildings and the equipment for two base conditions: conventional (fixed base) and base isolated. The impact of the seismic load case is characterized for the reinforced concrete walls in the buildings and for the equipment, measured using vessel wall thickness and horizontal accelerations. Here the analysis results show that the fixed-base buildings, designed for a site of low seismic hazard (peak ground acceleration, PGA = 0.15 g) could be constructed at a site of much greater seismic hazard (PGA = 0.7 g) if seismic base isolation is employed. Importantly, the scope of the site-specific analysis, design, and qualification would be limited to the seismic isolators and the isolated substructure, drastically reducing plant-specific engineering, review, and licensing, and time to construction start. Regulatory challenges and opportunities with standardized reactor designs are identified.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Mid-height seismic isolation of equipment in nuclear power plants: Numerical simulations and design recommendations

Seismic isolation can mitigate earthquake demands on safety-class equipment and is being considered for application to some advanced nuclear reactors. For tall, slender vessels that could represent an advanced reactor, a steam generator or a heat exchanger, mid-height seismic isolation has been shown to be beneficial and practical. Here, this paper focuses on numerical modeling of a mid-height isolated tall, slender vessel with two primary goals 1) investigate and quantify the benefits of mid-height seismic isolation for a range of support structure stiffnesses, isolation systems, and seismic inputs, and 2) provide analysis and design recommendations for isolation of safety-class equipment. Results of response-history analysis were in good agreement with experimental measurements and demonstrated that mid-height isolation can substantially reduce seismic demands on tall, slender vessels for a range of support structure stiffnesses, isolation systems, and seismic inputs. Importantly, the reductions in horizontal spectral accelerations in the mid-height isolated vessel from the non-isolated condition were not affected by the stiffness of the support structure. Recommendations are made for analysis and design of isolated equipment and testing of isolators used for equipment protection in nuclear facilities, which are also applicable to other industries.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

A full-scope, high-fidelity simulator-based hardware-in-the-loop testbed for comprehensive nuclear power plant cybersecurity research

Nuclear power plant (NPP) cybersecurity research often relies on hardware-in-the-loop (HIL) testbeds that integrate real hardware components into simulated environments. These testbeds allow researchers to identify vulnerabilities, evaluate attack impacts, and test security measures in a controlled setting. Furthermore, previous HIL testbeds lacked fidelity to accurately represent real nuclear systems, limiting the scope of cybersecurity analysis. This study presents the creation of a HIL testbed, devised upon a full-scope, high-fidelity NPP simulator, to facilitate realistic and comprehensive cybersecurity research. To demonstrate its capabilities, the control logic for the steam generator water level was migrated from the simulator to an external programmable logic controller. As a practical application of the developed testbed, supply chain attack scenarios were simulated by injecting malicious code into the controller logic, and the effects of manipulating sensor inputs and control commands were observed. While this HIL testbed provides more detailed simulations, enhanced realism, and wider applicability compared to other options utilizing a less complex simulator, it is also more intricate and costly. For this reason, we include a detailed comparison with some alternative architectures to aid fellow researchers and practitioners in the selection of a suitable HIL architecture based on specific research objectives.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Detecting Thermally Induced Spinodal Decomposition with Picosecond Ultrasonics in Cast Austenitic Stainless Steels

Given the existential climate crisis faced by mankind and the world, the lifetime and sustainability of nuclear reactors as a carbon-free source of renewable energy depend on the susceptibility of their structural components to environmental degradation. In particular, critical components for light water reactors (LWRs) evolve over decades in service, losing ductility and toughness due to thermal and irradiation aging. Techniques to monitor their health cannot be easily applied in the field due to their destructive, expensive, or immobile nature. Thus, non-destructive evaluation (NDE) methods are sought to monitor and evaluate the health of major LWR components such as core barrels, steam generator tubes, or primary coolant pipes and are often required by policy, such as NRC policy #10-CFR-50.65. In this work we demonstrate the use of gigahertz, non-contact ultrasonics to gauge the state of cast austenitic stainless steels (CASS), used in some of the largest components in LWR primary systems. We do so by linking changes in their surface acoustic wave (SAW) characteristics using transient grating spectroscopy (TGS) to transmission electron microscopy (TEM)-verified evidence of spinodal decomposition and G-phase precipitation. In this thesis, thermal aging is shown to induce SAW peak splitting in spinodally decomposed CASS alloys, correlated strongly with lowered toughness and decreased ductility. Furthermore, statistical testing on the number of SAW peak splits observed show that the second SAW peak significantly appears more frequently and is significantly different in frequency in comparison to counts and frequencies measured in unaged specimens. The ability of this technique to non-destructively detect microstructural degradation at a distance in a predictive manner in the case of CASS motivates extending gigahertz ultrasonics to detect other LWR material degradation modes as an in-vessel inspection technique, such as reactor pressure vessel (RPV) embrittlement. This allows for the greater use of NDE techniques for confident monitoring of LWR structural material health to 80 years and beyond, saving costs by minimizing structural replacements until needed and maximizing energy production by preventing early decommission until necessary.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Laser-sculptured ultrathin transition metal carbide layers for energy storage and energy harvesting applications

Ultrathin transition metal carbides with high capacity, high surface area, and high conductivity are a promising family of materials for applications from energy storage to catalysis. However, large-scale, cost-effective, and precursor-free methods to prepare ultrathin carbides are lacking. Here, we demonstrate a direct pattern method to manufacture ultrathin carbides (MoC x , WC x , and CoC x ) on versatile substrates using a CO 2 laser. The laser-sculptured polycrystalline carbides (macroporous, ~10-20 nm wall thickness, ~10 nm crystallinity) show high energy storage capability, hierarchical porous structure, and higher thermal resilience than MXenes and other laser-ablated carbon materials. A flexible supercapacitor made of MoC x demonstrates a wide temperature range (-50 to 300 °C). Furthermore, the sculptured microstructures endow the carbide network with enhanced visible light absorption, providing high solar energy harvesting efficiency (~72%) for steam generation. The laser-based, scalable, resilient, and low-cost manufacturing process presents an approach for construction of carbides and their subsequent applications.

25 ENERGY STORAGE↗
DOE OSTI2016

The effect of tempering temperature on pitting corrosion resistance of 420 stainless steels

The AISI Type 420 stainless steels are commonly used to steam generators, mixer blades, etc. These stainless steels are most prone to pitting in dissolved Cl{sup −} containing environments. In this paper, the effect of tempering temperature on pitting corrosion resistance of AISI Type 420 stainless steels was studied. The AISI Type 420 stainless steels specimens were heat treated at the temperature of 1050°C for 1 hour to reach austenite stabilization and then quench in the oil. After that, the specimens were tempered at the temperature of 150, 250, 350 and 450°C for 30 minutes and then air cooled to the room temperature. The electrochemical potentiodynamic polarization test was conducted at 3.5% sodium chloride solution to evaluate corrosion rate and pitting corrosion behaviour. The Scanning Electron Microscope (SEM), Energy Dispersive X-Ray Spectroscopy (EDS) were used to evaluate the pitting corrosion product. The result have shown that highest pitting potential was found in the sample tempered at 250°C and corrosion pits were found to initiate preferentially around chromium carbides.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Toward Exascale: Overview of Large Eddy Simulations and Direct Numerical Simulations of Nuclear Reactor Flows with the Spectral Element Method in Nek5000

At the beginning of the last decade, Petascale supercomputers (i.e., computers capable of more than 1 petaFLOP) emerged. Now, at the dawn of exascale supercomputing, we provide a review of recent landmark simulations of portions of reactor components with turbulence-resolving techniques that this computational power has made possible. In fact, these simulations have provided invaluable insight into flow dynamics, which is difficult or often impossible to obtain with experiments alone. We focus on simulations performed with the spectral element method, as this method has emerged as a powerful tool to deliver massively parallel calculations at high fidelity by using large eddy simulation or direct numerical simulation. We also limit this paper to constant-property incompressible flow of a Newtonian fluid in the absence of other body or external forces, although the method is by no means limited to this class of flows. We briefly review the fundamentals of the method and the reasons it is compelling for the simulation of nuclear engineering flows. We review in detail a series of Petascale simulations, including the simulations of helical coil steam generators, fuel assemblies, and pebble beds. Even with Petascale computing, however, limitations for nuclear modeling and simulation tools remain. In particular, the size and scope of turbulence-resolving simulations are still limited by computing power and resolution requirements, which scale with the Reynolds number. In the final part of this paper, we discuss the future of the field, including recent advancements in emerging architectures such as GPUbased supercomputers, which are expected to power the next generation of high-performance computers.

computational fluid dynamics↗
DOE OSTI2025

A Reinforcement Learning Approach to Augment Conventional PID Control in Nuclear Power Plant Transient Operation

The ability of nuclear reactors to operate their power conversion cycles more flexibly will enhance their value to energy grids with variable pricing. Current nuclear control systems are typically classical controllers that are often based on proportional-integral-derivative (PID) control. This paper presents a method of augmenting the existing PID control for difficult transient operations in nuclear power plants using a reinforcement learning–derived feedforward signal applied in real time. The agents, which are trained on a test thermal load-following problem, are designed to improve steam generator outlet temperature control for a range of fast load-following scenarios covering ramp rates from 9%/min to 15%/min. Several reinforcement learning algorithms were initially investigated for the training of the feedforward agents with deep Q-learning (DQN) and proximal policy optimization (PPO) networks, which were found to be the most promising. The DQN controllers utilize discrete actions, giving them a better disturbance rejection at steady state but inconsistent response to initial temperature deviations. In contrast, PPO-trained agents, which take continuous actions except for a dead zone around zero, were shown to have the best combination of high disturbance rejection at steady state and good tracking of the desired temperature value. The ability of the PPO agent was also examined, with the average time of decision making found to be on the order of 1 ms. The fault properties of the controller under the loss of the reinforcement learning agent feedforward signal were also examined. The controller showed strong performance in situations of “no-signal” faults. but was less good at handling “stuck-at” faults, where the feedforward signal remains at a set value. In both cases, however, the PID was able to successfully maintain stability, eventually returning the system to a steady state. It is hoped that this work will allow for the proposed control architecture to be examined for more difficult control problems such that it may eventually be used to adapt existing nuclear plants for more aggressive load-following on grids of the future.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Impact on Cycle Efficiency of Small Combined Heat and Power Plants from Increasing Firing Temperature Enabled by Additive Manufacturing of Turbine Blades and Vanes

The results of this study show that a 180°F (100°C) increase in firing temperature can increase the gas turbine efficiency by 1 percentage point without improving cooling effectiveness and add 2 additional percentage points in efficiency by using advanced turbine blades with higher internal cooling efficiency. The engine upgrades evaluated in this study show potential for increasing the CHP cycle efficiency by 3 percentage points while increasing the steam generation rate by 8%.

Uysal, Selcuk Can↗
DOE OSTI2023

Comparative Thermal Performance of Downdraft and Updraft Forced Convection in a Representative 3x3 PWR Fuel Assembly

A plethora of theoretical, numerical, and experimental investigations have relied on updraft forced convection of operating fuel assemblies for light water-cooled fuel assemblies. The inertial scales of turbulence in updraft flow through PWR fuel assemblies are primarily influenced by upstream mixing patterns within the lower plenum and consequent acceleration of flow through the lower core and support plates into the bottom nozzles. In secondary heat transfer applications such as steam generation, recuperation and economization, downdraft flow is utilized to retrieve maximal sensible heat from the primary coolant. Sub-channel volumes aligned vertically could also benefit from force of gravity in developing turbulent flows. A large reduction in pumping power, associated cost of operation and maintenance, and improved balance of plant is suggested to be possible through downdraft forced convection in PWR-type reactors. This article explores the impact of downdraft forced convection within the well-studied 3x3 sub-channel within a range of 20 hydraulic diameters across a representative intermediate flow mixing grid. A range of inflow Reynolds number from 10,000 to 60,000 is simulated over a range of equivalent heat loads of 20% to 100% spanning 20 hydraulic diameters. The fuel rods are represented in true geometric detail, and a constant-value heat profile is assumed for the investigation. At each inflow condition, the turbulence intensity, peak velocity, local heat transfer coefficient, peak wall heat flux, and peak wall temperature are collected across the sub-channel and compared with an updraft configuration evaluated at the same conditions.

Rao, Vivek↗
DOE OSTI2022

Sensitivity analysis of small modular reactor mPower with ATHLET

Small modular reactor (SMR) possesses the characteristics of less radioactive source term, simpler structure, modular design and features like passive safety as well as low risk of proliferation. Developed and designed by Babcock and Wilcox, the mPower reactor is one of pronouncing small modular reactors that adopts the integrated design of the pressurized water reactor, steam generator and a built-in internal control rod drive mechanism. In this paper, the code ATHLET (Analysis of fossil-hydraulics of Leaks and Transients) is used to model the mPower reactor. At the same time, the sensitivity analysis of the core structure and geometric parameters of the pipeline loop, as well as the steady-state simulation and post-exothermic simulation are carried out depending on the given scenarios. In addition, the sensitivity analysis of pressure, temperature and mass flow in the secondary loop is performed. The results of this study will mitigate some of the frequent misunderstanding in the field and will help to better understand the design of SMR and provide basic research data for further research. However, there are limitations in the current research. Considering that the mPower is still in the conceptual design, the established model is only based on the limited public data while detailed parameters are still in myth, which leads to certain level of uncertainties in the calculation. Besides, the research is mainly on the influence of sensitivity analysis under steady state conditions. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2013

Analysis of the Production Cost for Various Grades of Biomass Thermal Treatment

Process flow sheets were developed for the thermal treatment of southern pine wood chips at four temperatures (150, 180, 230, and 270 degrees C) and two different scales (20 and 100 ton/hour). The larger capacity processes had as their primary heat source hot gas assumed to be available in quantity from an adjacent biorefinery. Mass and energy balances for these flow sheets were developed using Aspen Plus process simulation software. The hot gas demands in the larger processes, up to 1.9 million lb/hour, were of questionable feasibility because of the volume to be moved. This heat was of low utility because the torrefaction process, especially at higher temperatures, is a net heat producer if the organic byproduct gases are burned. A thermal treatment flow sheet using wood chips dried in the biorefinery to 10% moisture content (rather than 30% for green chips) with transfer of high temperature steam from the thermal treatment depot to the biorefinery was also examined. The equipment size information from all of these cases was used in several different equipment cost estimating methods to estimate the major equipment costs for each process. From these, factored estimates of other plant costs were determined, leading to estimates (± 30% accuracy) of total plant capital cost. The 20 ton/hour processes were close to 25 million dollars except for the 230 degrees C case using dried wood chips which was only 15 million dollars because of its small furnace. The larger processes ranged from 64-120 million dollars. From these capital costs and projections of several categories of operating costs, the processing cost of thermally treated pine chips was found to be $28-33 per ton depending on the degree of treatment and without any credits for steam generation. If the excess energy output of the two 20 ton/hr depot cases at 270 degrees C can be sold for $10 per million BTU, the net processing cost dropped to $13/ton product starting with green wood chips or only $3 per ton if using dried chips from the biorefinery. Including a 12% return on invested capital raised all of the operating cost results by about $20/ton.

09 BIOMASS FUELS↗
DOE OSTI2014

Final Assessment of Manual Ultrasonic Examinations Applied to Detect Flaws in Primary System Dissimilar Metal Welds at North Anna Power Station

PNNL conducted a technical assessment of the NDE issues and protocols that led to missed detections of several axially oriented flaws in a steam generator primary inlet dissimilar metal weld at North Anna Power Station, Unit 1 (NAPS-1). This particular component design exhibits a significant outside-diameter (OD) taper that is not included as a blind performance demonstration mock-up within the industry’s Performance Demonstration Initiative, administered by EPRI. For this reason, the licensee engaged EPRI to assist in the development of a technical justification to support the basis for a site-specific qualification. The service-induced flaws at NAPS-1 were eventually detected as a result of OD surface machining in preparation for a full structural weld overlay. The machining operation uncovered the existence of two through-wall flaws, based on the observance of primary water leaking from the dissimilar metal weld. A total of five axially oriented flaws were detected in varied locations around the weld circumference. The field volumetric examination that was conducted at NAPS-1 was a non-encoded, real-time manual ultrasonic examination. PNNL conducted both an initial assessment, and subsequently, a more rigorous technical evaluation (reported here), which has identified an array of NDE issues that may have led to the subject missed detections. These evaluations were performed through technical reviews and discussions with NRC staff, EPRI NDE Center personnel, industry and ISI vendor personnel, and ultrasonic transducer manufacturers, and laboratory tests, to better understand the underlying issues at North Anna.

cracks↗