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At least 1,477 records · Page 82

Remote Evaporator Vessel Repair by Robotics and Powder Injection Laser Welding - 18107

In February 2016 a leak was identified in the 25H evaporator at the Savannah River Site (SRS). The 25H evaporator is used to manage water volume in high level waste (HLW) tanks during solid salt cake and sludge removal. The location and the cause of the leak were unknown. Orano Federal Services (formerly AREVA Federal Services) applied its robotics expertise and commercial nuclear expertise to perform the inspection. Orano and Framatome (formerly AREVA NP INC) combined a BROKK, a commonly used tracked vehicle with remote control, with the KUKA, an automated robotic arm, commonly used in automobile manufacturing, to perform the partial dismantlement and inspection. Once inspection was complete and the leak was identified, Orano conducted a study on two welding processes: Gas Tungsten Arc (GTA-Tig) and Powder Injection Laser Welding. Based on the inspection of the SRS HLW evaporator's material type being Hastelloy{sup R}, along with the remote repair and material thin wall condition, the Powder Injection Laser Welding was chosen for this application. Orano has developed the remote powder injection laser welding and delivery process that will be used to conduct the repair of the SRS HLW evaporator in the fall of 2017. The process includes robotic delivery of components and robotic performance of the weld. Specialized robotic equipment were developed or adapted from other industries to perform the high hazard job of repairing an eroded section of the evaporator pot. The integration of multiple innovative remote techniques provides a unique solution in a highly radioactive environment. These techniques and innovations can be capitalized upon to solve many different remote repairs on equipment resulting in time savings, reduced dose to personnel, and recovery of initial investment in equipment. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

3-D advanced gas-cooled nuclear reactor fuel channel reconstruction using structure-from-motion - 110

During planned, periodic outages, a selection of fuel channels within the UK fleet of Advanced Gas-cooled Reactor (AGR) cores are inspected using specialist tools which record video footage and other sensory data for each channel which undergoes inspection. Current visualization techniques comprise of manually produced montages by inspection engineers of points of interest (i.e. structural defects) and 2-D panoramic images of the fuel channels automatically produced using bespoke image stitching software. Both techniques however provide limited structural information due to the loss of depth data as a result of the image formation process. By recovering the depth information from the footage, a 3D model could be constructed and subsequently, allow for more accurate profiling of specific defects observed during inspection in addition to obtaining the fuel channels structure using existing footage. This work explores the preliminary application of a 3-D visualization technique known as Structure-from-Motion (SfM) which aims to obtain 3-D information by exploiting image correspondences across multiple viewpoints of the same scene in the RVI footage. This paper investigates the difficulties of applying state-of-the-art SfM to RVI footage and we present new techniques to improve feature correspondence searching in repetitive, nondescript environments. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

An expert-systems approach to automatically determining flaw depth within Candu pressure tubes - 221

Delayed Hydride Cracking (DHC) is a crack growth mechanism that occurs in zirconium alloys, including the pressure tubes of CANDU reactors. DHC is caused by hydrogen in solution in zirconium components being diffused to any flaws present, resulting in an increased concentration of hydrogen within these flaws. An increased hydrogen concentration can lead to brittleness, followed by cracking, in high-stress regions of a pressure tube. Regular in-service ultrasonic inspection of CANDU pressure tubes aims to locate and classify any flaws that pose a potential for DHC initiation. A common approach to inspection is the use of a bespoke tool containing multiple ultrasonic transducers to ensure that each point on the pressure tube is inspected from a minimum of three angles during a scan. All flaws from within the inspected pressure tubes must be characterized prior to restarting the reactor, thus the time-consuming analysis process lies on the critical outage path. This process is manually intensive and often requires a significant amount of expert knowledge. A modular system to automatically process outage data to provide decision support to analysts has been developed. This system saves time on the critical outage path while providing repeatable and explicable measurements. Part of the analysis process requires the depth of all flaws to be measured, which is often the most time consuming stage of the analysis process. This paper describes an approach that utilizes captured analysts knowledge to perform automatic flaw depth estimation. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Exploring the Use of Muon Momentum for Detection of Nuclear Material Within Shielded Spent Nuclear Fuel Dry Casks

The inspection of the storage containers that house used nuclear fuel is an important issue facing the nuclear industry; currently, there are limited options available to provide for even minimal inspections. During the long storage life of the fuel, intermediate handling and transportation activities may take place that can create concerns regarding fuel integrity (safety) and continuity of knowledge (safeguards and security). Accidents and natural disasters also contribute to this concern. The reliable and safe management of used nuclear fuel is among the critical tasks to be addressed for the advancement of fission-based nuclear energy in the United States and elsewhere. Since the early 1950's, when the first nuclear power plant began to produce electricity, approximately 65,000 metric tons of used nuclear fuel have been generated in the United States. The postponement of the opening of a permanent repository until 2048 will lead to increased used fuel accumulation at reactor sites. A rapid increase in storage installations with more than 9,000 casks storing {approx}420,000 assemblies is anticipated by 2050 even if no new nuclear power plants are built. After used nuclear fuel has been placed inside a cask, the cask is sealed, not allowing for visual inspection. Conventional methods, e.g., x-rays, are limited in that they cannot penetrate dense, well-shielded objects. More sophisticated techniques, such as penetrating neutrons or proton radiography, require the use of an expensive accelerator. Efforts by Ziock et al. using neutron and gamma-ray imagers concluded that '...the signatures are deemed insufficient to uniquely identify individual casks of the same type...'. It was found that the gamma-ray and neutron images were dominated by diffusion and thermalization effects resulting from the large amount of shielding. One promising mode of inspection would use cosmic-ray muons. These muons are naturally generated, are able to penetrate dense materials, and are incident from all directions above the horizon. Tomography performed using these muons could potentially provide efficient, inexpensive, remote assessment of used nuclear fuel. However, current muon applications are limited in that they have not included momentum measurement. If momentum measurement could be incorporated, that would represent a big step forward because it would allow more accurate estimation of the muon observables, e.g., scattering variance. This approach has the potential to reconstruct the contents of a cask with improved resolution and identify partial defects, fuel assemblies, and individual fuel rods.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Feasibility of Lead Fast Reactor Heat Exchanger Tube Online Monitoring

Within virtually all reactor systems with heat exchangers, the thinnest barriers between primary and secondary fluids are the heat exchanger tubes. Consistent with light water reactor experience, the advanced reactor heat exchangers are the most susceptible regions for corrosion and leakage (NRC, 2019). Moreover, traditional inspections and repairs using robotics will be expensive or impractical. On-line structural health corrosion monitoring (OLSHM) is therefore desirable to detect tube degradation prior to leaks that may allow mixing of heat exchanger fluids. Rhetorically many molten salt reactor (MSR) designers plan for on-line monitoring of critical reactor components including heat exchangers but there are no proven OLSHM sensors or systems for MSR heat exchangers. Guided wave ultrasound from the tube-end or ID using conventional low-temperature piezoelectric sensors has been shown to be sensitive to pits and cracks less than 50% through-wall in long pipes and tubes (Narayanan M.M., 2019) . Mode and frequency selection are important for practical sensor design decisions and ultimate performance. The L-0 wave-mode is easily excited by L-mode transducers but they have surface normal wave motion that will be sensitive to and more attenuative because of fluid interaction with the tube surface (Rose J.L., 1994). Shear Horizontal (SH) wave modes have material motion parallel to the tube surface therefore are virtually unaffected by fluid interaction. For SH-0 to be nondispersive in steel, the frequency-thickness product (MHz-mm) must be less than approximately 1.5. SH mode transducers must be coupled by a material that can support shear stress; a thin layer of honey works well for temporary sensors and an adhesive or a brazed metallurgical bond for permanent sensors. If sensors are incorporated into the fabrication process, the same kinds of SH-0 waves can be generated from the stagnant flow area of the tube OD without compromising the heat-exchange tube function. Piezoelectric materials are also available that can withstand harsh temperatures of molten salt heat exchangers (Stevenson T., 2015) (Machura et al., 2008). Though they may not have as high-performance characteristics, their performance only needs to be good enough to detect flaws of interest. This project attempts to demonstrate feasibility to develop a sensor that can be sensitive to flaws of interest and perform long-term monitoring of a molten salt reactor heat exchanger. Benefits to the advanced reactor system include: • Minimizing the expense of a reactor shut down for periodic inspection—only shutdown for cause. • Reduce risk of unexpected tube rupture by detecting flaws before they grow to through-wall leaks. • Cost reduction by minimizing need to design for manual/robotic inspectability. Transducer design, characterization of the beam profile, wedges vs. direct application of piezoelectric sensors, and ultrasonic pulse-echo responses from a representative heat exchange tube with fabricated flaw types are discussed.

On-Line Tube Monitor, Guided Wave Ultrasound, SH-0↗

Progress Toward Molten Salt Reactor Heat Exchanger On-Line Monitoring

Within virtually all reactor systems with heat exchangers, the thinnest barriers between primary and secondary fluids are the heat exchanger tubes. Consistent with light water reactor experience, the advanced reactor heat exchangers are the most susceptible regions for corrosion and leakage (NRC, 2019). Moreover, traditional inspections and repairs using robotics will be expensive or impractical. On-line structural health corrosion monitoring (OLSHM) is therefore desirable to detect tube degradation prior to leaks that may allow mixing of heat exchanger fluids. Rhetorically many molten salt reactor (MSR) designers plan for on-line monitoring of critical reactor components including heat exchangers but there are no proven OLSHM sensors or systems for MSR heat exchangers. Guided wave ultrasound from the tube-end or ID using conventional low-temperature piezoelectric sensors has been shown to be sensitive to pits and cracks less than 50% through-wall in long pipes and tubes (Narayanan M.M., 2019) . Mode and frequency selection are important for practical sensor design decisions and ultimate performance. The L-0 wave-mode is easily excited by L-mode transducers but they have surface normal wave motion that will be sensitive to and more attenuative because of fluid interaction with the tube surface (Rose J.L., 1994). Shear Horizontal (SH) wave modes have material motion parallel to the tube surface therefore are virtually unaffected by fluid interaction. For SH-0 to be nondispersive in steel, the frequency-thickness product (MHz-mm) must be less than approximately 1.5. SH mode transducers must be coupled by a material that can support shear stress; a thin layer of honey works well for temporary sensors and an adhesive or a brazed metallurgical bond for permanent sensors. If sensors are incorporated into the fabrication process, the same kinds of SH-0 waves can be generated from the stagnant flow area of the tube OD without compromising the heat-exchange tube function. Piezoelectric materials are also available that can withstand harsh temperatures of molten salt heat exchangers (Stevenson T., 2015) (Machura et al., 2008). Though they may not have as high-performance characteristics, their performance only needs to be good enough to detect flaws of interest. This project attempts to demonstrate feasibility to develop a sensor that can be sensitive to flaws of interest and perform long-term monitoring of a molten salt reactor heat exchanger. Benefits to the advanced reactor system include: • Minimizing the expense of a reactor shut down for periodic inspection—only shutdown for cause. • Reduce risk of unexpected tube rupture by detecting flaws before they grow to through-wall leaks. • Cost reduction by minimizing need to design for manual/robotic inspectability. Transducer design, characterization of the beam profile, and ultrasonic pulse-echo responses from a representative heat exchange tube with fabricated flaw types are discussed.

On-Line Tube Monitor, Guided Wave Ultrasound, SH-0↗

Implementation of ASME Code, Section XI, Code Case N-770, on Alternative Examination Requirements for Class 1 Butt Welds Fabricated with Alloy 82/182

In May 2010, the NRC issued a proposed notice of rulemaking that includes a provision to add a new section to its rules to require licensees to implement ASME Code Case N-770, ‘‘Alternative Examination Requirements and Acceptance Standards for Class 1 PWR Piping and Vessel Nozzle Butt Welds Fabricated with UNS N06082 or UNS W86182 Weld Filler Material With or Without the Application of Listed Mitigation Activities, Section XI, Division 1,’’ with 15 conditions. Code Case N-770 contains baseline and inservice inspection (ISI) requirements for unmitigated butt welds fabricated with Alloy 82/182 material and preservice and ISI requirements for mitigated butt welds. The NRC stated that application of ASME Code Case N-770 is necessary because the inspections currently required by the ASME Code, Section XI, were not written to address stress corrosion cracking Alloy 82/182 butt welds, and the safety consequences of inadequate inspections can be significant. The NRC expects to issue the final rule incorporating this code case into its regulations in the spring 2011 time frame. This paper discusses the new examination requirements, the conditions that NRC is imposing , and the major concerns with implementation of the new Code Case.

alloy 82/182↗

Linear accelerator x-ray sources with high duty cycle

X-ray cargo inspection systems typically use a several-MV pulsed linear accelerator (linac) to produce a bremsstrahlung spectrum of x rays by bombarding a target with electrons. The x rays traverse the cargo and are detected by a detector array. Spectroscopy of the detected x rays is very desirable: if one can determine the spectrum of the transmitted x rays, one can determine the Z of the material they traversed. Even in relatively low-dose modes of operation, thousands of x rays arrive at each detector element during each pulse, unless the x rays are heavily absorbed or scattered by the cargo. For portal or fixed-site systems, dose rates, and therefore x-ray count rates, are even higher. Because of the high x-ray count rate, spectroscopy is impractical in conventional cargo inspection systems, except in certain special cases. For a mobile system, typical pulse durations are a few microseconds, and the number of pulses is on the order of 100 per second, leading to a duty factor of about 0.04%. Clearly, a linear accelerator x-ray source with much higher duty factor would be useful, since then the same number of x rays could be spread out over time, reducing the x-ray count rate. In this paper, we explore the possibility of designing a linear accelerator system, using more or less Conventional Off the Shelf (COTS) components, capable of duty cycles of 1% or greater. A survey was conducted of available linac RF source options and, given the possibilities, calculations were performed for suitable beam centerline designs. Keeping in mind that the size and cost of the accelerator system should be practical for use in a mobile cargo inspection system, only a few options are shown to be reasonably feasible, both requiring the use of klystrons instead of the magnetrons used in conventional systems. An S-Band design appears clearly possible, and there is also a promising X-Band design.

43 PARTICLE ACCELERATORS↗

Experimental study of A0 Lamb wave tomography

Corrosion damage in inaccessible regions presents a significant challenge to the petrochemical industry, and determining the remaining wall thickness is important to establish the remaining service life. Guided wave tomography is one solution and involves transmitting Lamb waves through the area of interest and using the received signals to reconstruct the remaining wall thickness. This avoids the need to access all points on the surface, making the technique well suited to inspection beneath supports. For this purpose a tomography system for pipe inspections is developed using low frequency A0 Lamb waves that are excited and detected with two arrays of electromagnetic acoustic transducers (EMATs). Two different defect depths are considered with different contrasts relative to the nominal wall thickness and in a first step, the repeatability of the measurements is demonstrated. Due to the limited view array configuration, the maximum depth of the reconstruction underestimates the true depth. In a second experimental study, the influence of a pipe clamp on the thickness reconstruction is considered, representing an inspection problem with restricted access. Preliminary results have shown that the maximum defect depth is further underestimated when compared to the thickness reconstructions without the clamp. However, it is possible to detect the defect underneath the clamp for all conducted experiments.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Image mosaicing for automated pipe scanning

Remote visual inspection (RVI) is critical for the inspection of the interior condition of pipelines particularly in the nuclear and oil and gas industries. Conventional RVI equipment produces a video which is analysed online by a trained inspector employing expert knowledge. Due to the potentially disorientating nature of the footage, this is a time intensive and difficult activity. In this paper a new probe for such visual inspections is presented. The device employs a catadioptric lens coupled with feature based structure from motion to create a 3D model of the interior surface of a pipeline. Reliance upon the availability of image features is mitigated through orientation and distance estimates from an inertial measurement unit and encoder respectively. Such a model affords a global view of the data thus permitting a greater appreciation of the nature and extent of defects. Furthermore, the technique estimates the 3D position and orientation of the probe thus providing information to direct remedial action. Results are presented for both synthetic and real pipe sections. The former enables the accuracy of the generated model to be assessed while the latter demonstrates the efficacy of the technique in a practice.

42 ENGINEERING↗

Eddy current signal comparison for tube identification

Inspection of nuclear power plant steam generator tubes is required to justify continued safe plant operation. The steam generators consist of thousands of tubes with nominal diameters of 15 to 22mm, approximately 1mm wall thickness, and 20 to 30m in length. The tubes are inspected by passing an eddy current probe through the tubes from tube end to tube end. It is critical to know exactly which tube identification (row and column) is associated with each tube's data. This is controlled by a precision manipulator that provides the tube ID to the eddy current system. Historically there have been some instances where the manipulator incorrectly reported the tube ID. This can have serious consequences including lack of inspection of a tube, or if a pluggable indication is detected, the tube is likely to be mis-plugged thereby risking a primary to secondary leak.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Optical coherence tomography for nondestructive evaluation of fuel rod degradation

Nuclear power plants regularly inspect fuel rods to ensure safe and reliable operation. Excessive corrosion can cause fuel failures which can have significant repercussions for the plant, including impacts on plant operation, worker exposure to radiation, and the plant's INPO rating. While plants typically inspect for fuel rod corrosion using eddy current techniques, these techniques have known issues with reliability in the presence of tenacious, ferromagnetic crud layers that can deposit during operation, and the nondestructive evaluation (NDE) inspection results can often be in error by a factor of 2 or 3. For this reason, alternative measurement techniques, such as Optical Coherence Tomography (OCT), have been evaluated that are not sensitive to the ferromagnetic nature of the crud. This paper demonstrates that OCT has significant potential to characterize the thickness of crud layers that can deposit on the surfaces of fuel rods during operation. Physical trials have been performed on simulated crud samples, and the resulting data show an apparent correlation between the crud layer thickness and the OCT signal.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

SICS: A Sensor-Based In-Line Control System for the Surfaces of Continuously Cast Slabs

The goal of this project was to develop and demonstrate a SICS test unit that meet the need of the steel industry for enhancing the continuous casting process for improved surface quality for the targeted benefits and that is composed of an In-line Imaging Module and a Hybrid Predictive Control Module. The In-line Imaging Module provides the real-time or near real-time Product Information to the Hybrid Predictive Control Module. The latter is able to fuse the Product Information with the Process Information. In order to support the goal, this project had the technical objectives for indexes such as inspection accuracy and in-line service life, based on the inspection coverage of the entire cast slab. The deployment of the SICS systems has the potential to provide benefits in reduction of energy waste, CO 2 emission, waste water amount, toxic waste, and so forth. It will help to uphold the competitiveness of the industry that employs approximately 150,000 people nationwide and consumes about 3% of the energy in the country. The Phase II project has been carried out in accordance to the proposed tasks and budget, based on the original and extended schedule. The R&D team designed and implemented the test unit for the full width coverage, installed the unit in a caster. The development work further included enhanced image processing, in-depth defect study and process control models. The function, operation, and maintenance of the SICS was thoroughly studied during the Phase II research. The experience indicates additional hardware and procedures are required to make the SICS a commercially ready product in operation and maintenance aspect. Such developments have been finished and the team is contacting potential customers for the first commercial installation of SICS. Additionally, OGT is exploring the possibility to team up with a US company that specializes in surface cleaning for slabs/blooms/billets such that the in-line surface inspection can be integrated with in-line surface clean up for the maximum benefit to the steel industry.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Task 1. Monitoring real time materials degradation. NRC extended In-situ and real-time Monitoring

The overall objective of this project was to perform a scoping study to identify, in concert with the nuclear industry, those sensors and techniques that have the most promising commercial viability and fill a critical inspection or monitoring need. Candidates to be considered include sensors to monitor real-time material degradation, characterize residual stress, monitor and inspect component fabrication, assess radionuclide and associated chemical species concentrations in ground water and soil, characterize fuel properties, and monitor severe accident conditions. Under Task 1—Monitoring Real-Time Materials Degradation—scoping studies were conducted to assess the feasibility of potential inspection and monitoring technologies (i.e., a combination of sensors, advanced signal processing techniques, and data analysis methods) that could be utilized in LWR and/or advanced reactor applications for continuous monitoring of degradation in-situ. The goal was to identify those techniques that appear to be the most promising, i.e., those that are closest to being both technically and commercially viable and that the nuclear industry is most likely to pursue. Current limitations and associated issues that must be overcome before commercial application of certain techniques have also been addressed.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

OSIRIS Validation and Verification Report

The On-Site Inspection RadioIsotopic Spectroscopy (OSIRIS) system is a gamma-ray spectroscopy instrument for on-site inspections conducted under the Comprehensive Nuclear-Test-Ban Treaty (CTBT). The OSIRIS software filters spectral analysis data, revealing information to users on only 17 CTBT-relevant fission-product isotopes. In this report, we review the CTBT requirements for on-site inspection radionuclide identifiers, plus additional requirements imposed by the design team. Then a series of validation tests conducted during OSIRIS development are described. The validation tests were designed to gauge if the nascent OSIRIS system met those requirements. We conclude with a set of recommended verification tests to ensure that newly-manufactured OSIRIS systems also will meet the requirements.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Damage Detection and Verification System (DDVS) for In-Situ Health Monitoring

Project presentation for Game Changing Program Smart Book Release. Detection and Verification System (DDVS) expands the Flat Surface Damage Detection System (FSDDS) sensory panels damage detection capabilities and includes an autonomous inspection capability utilizing cameras and dynamic computer vision algorithms to verify system health. Objectives of this formulation task are to establish the concept of operations, formulate the system requirements for a potential ISS flight experiment, and develop a preliminary design of an autonomous inspection capability system that will be demonstrated as a proof-of-concept ground based damage detection and inspection system.

Damage detection↗

Seeker 1.0: Prototype Robotic Free Flying Inspector Mission Overview

Seeker 1.0 is a prototype free flying robot that will one day be capable of inspecting human-rated spacecraft. Building off previous free flyer experience, this technology will eventually improve safety of human spacecraft by offering a variety of inspection capabilities for both routine and emergency scenarios providing increased capability and safety over current inspection methods. Seeker 1.0 is capable of 6 degree of freedom flight via a cold gas propulsion system and can operate up to 1 hour via a semi-autonomous guidance, navigation, and control system. The prototype spacecraft is capable of capturing still images at a variety of resolutions up to 13 MP. The initial test flight utilizes a command and data relay box called Kenobi. Kenobi is a derivative of the Seeker design and will communicate between Cygnus and Seeker and store data for post-mission downlink. Seeker and Kenobi have launched inside a NanoRacks External CubeSat Deployer (NRCSD-E) attached to the NG-11 Cygnus ISS resupply vehicle and will operate after Cygnus departs ISS and moves to a safe altitude. Operations will last approximately 30 minutes and will consist of basic vehicle maneuvers while capturing high-resolution still images. With any remaining time and propellant, Seeker will demonstrate additional safety capabilities and maneuvers required for operations around a crewed spacecraft. The Seeker project utilized the Class IE process that allows for streamlined flight hardware development and increased mission risk tolerance.

Spacecraft Inspection↗

OSIRIS User's Manual, v. 1.0

The On-Site Inspection RadioIsotopic Spectroscopy (OSIRIS) system is a gamma-ray spectroscopy instrument for on-site inspections under the Comprehensive Nuclear-Test-Ban Treaty (CTBT). [1] OSIRIS identifies fission-product isotopes with a high-resolution gamma-ray spectrometer. The spectrometer is controlled by a ruggedized notebook computer running data acquisition and data analysis software customized for CTBT on-site inspections. This manual explains OSIRIS preparation and setup for operation; startup procedures, including energy-calibration of the spectrometer; spectral measurements and spectral analyses; and shutdown procedures.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗