News and Views, Volume 55 | UPDATE: Encoded Phased Array Ultrasonic Examination Services for Cast Austenitic Stainless Steel (CASS) Piping Welds in Pressurized Water Reactor (PWR) Coolant Systems

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By:  John Hayden and Jason Van Velsor

Our initial article on this topic in News & Views, Volume 531 describes the challenges imposed by cast austenitic stainless steel (CASS) materials and the development of our CASS UT Examination solution. At the time of the prior article’s publication, SI was also conducting examinations of numerous CASS piping specimens. This article provides details of both that performance demonstration and the results of those examinations.

TYPICAL CASS PIPING WELD LOCATIONS IN PWR REACTOR COOLANT SYSTEMS
Figure 1 illustrates the presence of CASS piping components, both statically and centrifugally cast, in the primary Reactor Coolant Systems of many U.S. PWR plants. Other PWR plant designs also contain CASS components, albeit in fewer locations and only in the form of short spool piece segments, usually for reactor coolant pumps and safety injection system safe ends.

Figure 1. Locations of CASS piping components, both statically and centrifugally cast, in primary Reactor Coolant Systems of many U.S. PWR plants

REGULATORY BASIS FOR CASS EXAMINATION CAPABILITY
ASME Section XI Code Case N-824, which was approved by the NRC in 2019, provides specific direction and requirements for ultrasonic examination of welds joining CASS components. N-824 was incorporated into Section, XI, Appendix II, Supplement 2 in the 2015 Code edition. The NRC has stated (10CFR50.55a, 07/18/2017) that with use of the aforementioned N-824 methodology “Licensees will be able to take full credit for completion of the § 50.55a required in-service volumetric inspection of welds involving CASS components.” SI’s procedure development and demonstration were therefore based on these requirements.

ULTRASONIC TECHNIQUE PERFORMANCE DEMONSTRATION
Though not required by the ASME Code, SI conducted a performance demonstration of our CASS UT system at our facility in Huntersville, NC. Using CASS piping system specimens on loan from the EPRI NDE Center, SI successfully validated our ultrasonic examination system capabilities as follows.

Ultrasonic Procedure – SI’s CASS ultrasonic examination procedure is fully compliant with ASME Section XI Code documents, and NRC-imposed technical approval conditions. The procedure has also been optimized with many insights gained from our laboratory experiences while examining EPRI-owned CASS piping specimens.

Ultrasonic Equipment – The ultrasonic system components required by Code have been designed and fabricated by SI or purchased, including the following:

  • Ultrasonic instrumentation capable of functioning over the entire prescribed ranges of examination frequencies. The standard examination frequency range extends from low-frequency, 500 KHz operation for CASS pipe welds > 1.6” Tnom and 1.0 MHz for CASS pipe welds ≤ 1.6” Tnom
  • Transducer arrays were employed to meet the physical requirements of frequency and aperture size capable of generating the Code-prescribed wave mode, examination angles, and focal properties.
  • An assortment of wedge assemblies were designed and fabricated then mated with transducer arrays to provide effective sound field coupling to the CASS components being examined.

Data encoding options necessary to acquire ultrasonic data given the expected range of component access and surface conditions are available. The encoding options include:

  • A fully-automated scanning system capable of driving the relatively large and heavy 500KHz phased array probes. This system was used during our laboratory examinations of CASS piping specimens.
  • A manually driven encoding system — a proven, field-worthy tool — which may be employed in locations where fully automated systems cannot be used because of access restrictions.

Examination Personnel – The challenges that exist with the examination of CASS piping welds warrant a comprehensive program of specialized, mandatory training for personnel involved with CASS examinations. This training includes descriptions of coarse grain structures, their effect on the ultrasonic field, the expected ultrasonic response characteristics of metallurgical and flaw reflectors, and the evaluation of CASS component surface conditions.

Additionally, SI’s ultrasonic examination personnel are thoroughly trained and experienced in all elements of encoded phased array ultrasonic data acquisition and analysis in nuclear plants and hold multiple PDI qualifications in both manual and encoded phased array DM weld techniques.

EPRI CASS PIPING SPECIMENS
The EPRI CASS pipe specimens, their outside diameter (OD) and thickness dimensions, and butt weld configurations examined by SI are described below.

12.75″ OD, 1.35″ Tnom SPECIMENS
Three pipe-to-pipe specimens representative of piping found in pressurizer surge and safety injection applications were examined. Each of these specimens had the weld crown ground flush.

Figure 2. Schematic of 12.75” OD, 1.35” Tnom CASS specimens.

Figure 3, Figure 4, and Figure 5 present examples of ultrasonic data images of a flaw detected in a 12.75” OD pipe-to-pipe tapered specimen.

Figure 3. Representative ultrasonic C-Scan data image from 12.75” OD, 1.35” Tnom specimen.

The C-Scan is a 2-D view of ultrasonic data displayed as a top (or plan) view of the specimen. The horizontal axis is along the pipe circumference, and the vertical axis is along the pipe axis or length.

Figure 4. Representative ultrasonic B-Scan data image from 12.75” OD, 1.35” Tnom specimen.

The B-Scan is a 2-D view of ultrasonic data displayed as a side view of the specimen. The angular projection of the data is displayed along the examination angle. The horizontal axis is along the pipe axis, and the vertical axis is along the pipe thickness.

Figure 5. Representative ultrasonic D-Scan data image from 12.75” OD, 1.35” Tnom specimen.

The D-Scan is a 2-D view of ultrasonic data displayed as an end view of the specimen. The horizontal axis represents the pipe circumference, and the vertical axis is along the pipe thickness.

28″ OD, 2.0″ Tnom SPECIMENS
Four pipe-to-pipe specimens representative of piping found in reactor coolant loops were examined. Each of these specimens had the weld crown intact and left in place.

Figure 6. Schematic of 28” OD, 2.0” Tnom CASS specimens.

Figure 7, Figure 8, and Figure 9 present examples of ultrasonic data images of a flaw detected in a 28” OD pipe-to-pipe tapered specimen.

Figure 7. Representative ultrasonic C-Scan data image from 28” OD, 2.0” Tnom specimen.

The C-Scan is a 2-D view of ultrasonic data displayed as a top (or plan) view of the specimen. The horizontal axis is along the pipe circumference, and the vertical axis is along the pipe axis or length.

Note the ability of our UT data acquisition equipment and data analysis techniques to resolve, discriminate, and identify inside surface geometric conditions (weld root and pipe counterbore), along with detecting and sizing the flaw indication. Also, note the excellent signal-to-noise ratio achieved.

Figure 8. Representative ultrasonic B-Scan data image from 28” OD, 2.0” Tnom specimen.

The B-Scan is a 2-D view of ultrasonic data displayed as a side view of the specimen. The angular projection of the data is displayed along the examination angle. The horizontal axis is along the pipe axis or length. The vertical axis is along the pipe thickness.

Figure 9. Representative ultrasonic D-Scan data image from 28” OD, 2.0” Tnom specimen.

The D-Scan is a 2-D view of ultrasonic data displayed as an end view of the specimen. The horizontal axis is along the pipe circumference, and the vertical axis is along the pipe thickness.

28″ to 29″ OD, 2.0″ to 2.5″ Tnom TAPERED WELD SPECIMENS
Four pipe-to-pipe specimens, with tapered weld surfaces representative of piping found in reactor coolant loops were examined.

Figure 10. Schematic of 28” to 29” OD, 2.0” to 2.5” Tnom CASS specimens.

Figures 11, 12, and 13 present examples of ultrasonic data images of a flaw detected in a 28” OD to 29” OD pipe-to-pipe tapered specimen.

Figure 11. Representative ultrasonic C-Scan of a 28” to 29” OD, 2.0” to 2.5” Tnom pipe-to-pipe, with tapered weld surfaces.

The C-Scan is a 2-D view of ultrasonic data displayed as a top (or plan) view of the specimen. The horizontal axis is along the pipe circumference, and the vertical axis is along the pipe axis, or length.

Figure 12. Representative ultrasonic B-Scan of a 28” to 29” OD, 2.0” to 2.5” Tnom pipe-to-pipe, with tapered weld surfaces.

The B-Scan is a 2-D view of ultrasonic data displayed as a side view of the specimen. The angular projection of the data is displayed along the examination angle. The horizontal axis is along the pipe axis or length. The vertical axis is along the pipe thickness.

Figure 13. Representative ultrasonic D-Scan of a 28” to 29” OD, 2.0” to 2.5” Tnom pipe-to-pipe, with tapered weld surfaces.

The D-Scan is a 2-D view of ultrasonic data displayed as an end view of the specimen. The horizontal axis is along the pipe circumference, and the vertical axis is along the pipe thickness.

SUMMARY OF DATA ANALYSIS RESULTS
Documentation was provided for each EPRI specimen, which contains flaw location, length, and through-wall size to permit the comparison of UT data acquisition and analysis processes to actual flaw conditions.

All of the 23 circumferential flaws in the eleven EPRI specimens were detected. The ultrasonic examination and data analysis techniques achieved flaw location and length sizing RMS errors, which are within acceptance standards of the following ASME Section XI, Appendix VIII Qualification Supplements:

  • Supplement 2, Qualification Requirements for Wrought Austenitic Stainless Steel Piping
  • Supplement 10, Qualification Requirements for Dissimilar Metal Piping

Excellent signal-to-noise ratios were observed for all detected flaws.

For all flaws, the measured length achieved sizing RMS errors within the acceptance standards of the above Appendix VIII supplements.

For specimens with welds ground flush and for all specimens with sufficient access to interrogate the entire through-wall extent of flaws, SI’s technique achieved through-wall sizing RMS errors within the acceptance standards of the above Appendix VIII supplements.

To be clear, the examination of the EPRI CASS specimens does not meet the rigor of Appendix VIII, Supplement 9 qualification because the industry’s (PDI Program) for CASS piping welds is still in preparation. The comparison to Appendix VIII acceptance standards is provided solely as a means to describe the achieved flaw detection and sizing capabilities in CASS material in terms of already established PDI qualifications. Ongoing examination of additional CASS specimens will strengthen already existing ultrasonic examination capabilities and experience.

CONCLUSIONS
The CASS piping welds in many PWR plants provide numerous and complicated challenges to their effective ultrasonic examinations. Most, if not all, CASS RCS piping welds have not been subjected to a meaningful and effective volumetric examination since radiography was conducted during plant construction.  SI’s newly-demonstrated ultrasonic examination procedure for CASS delivers a demonstrated, Code-compliant, meaningful, and effective solution that provides full credit for completion of in-service volumetric inspection per § 50.55a.

References

  1. News and Views, Volume 53, October 2023, “Encoded Phased Array Ultrasonic Examination Services for CASS Piping Welds In PWR Reactor Coolant Systems”
  2. ASME Section XI Code Case N-824, “Ultrasonic Examination of Cast Austenitic Piping Welds from the Outside Surface”
  3. ASME B&PV Code, Section XI, 2015 Edition and later editions

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News & Views, Volume 53 | Encoded Phased Array Ultrasonic Examination Services for Cast Austenitic Stainless Steel (CASS) Piping Welds

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IN PRESSURIZED WATER REACTOR (PWR) COOLANT SYSTEMS

By:  John Hayden and Jason Van Velsor

The CASS piping welds present in many PWR plants provide numerous and complicated challenges to their effective ultrasonic examinations. To this point, a viable ultrasonic examination solution for the inspection of these piping components, as required by ASME Code Section IX,  had previously not been available. By leveraging our technical expertise in materials, technology development, and advanced NDE deployment, Structural Integrity Associates, Inc (SI) has developed a new system that will provide a meaningful solution for the examination of CASS piping components. The result of this program will be the first commercial offering for the volumetric examination of CASS components in the nuclear industry.

BACKGROUND INFORMATION
ASME Section XI Class 1 RCS piping system welds fabricated using CASS materials pose serious and well-understood challenges to their effective ultrasonic examination. For decades, utilities and regulators have struggled with the administrative and financial burdens of Relief Requests, which were, and still are, based on the inability to perform meaningful volumetric examinations of welds in CASS components. 

Many years of futility and frustration may have fostered the belief that technology allowing effective and meaningful examination of CASS materials would never be achievable. This is no longer the case.

The failure mechanism for CASS material occurs through the loss of fracture toughness due to thermal aging embrittlement. The susceptibility of CASS material to thermal aging embrittlement is strongly affected by several factors, primary of which are system operating time and temperature, the casting method used during component manufacture, and molybdenum and ferrite content. In addition to the existing ASME Section XI requirements for the examination of welds in CASS materials, the susceptibility to thermal aging embrittlement drives the requirement for additional examinations (including ultrasonic examinations) as directed by several NRC-published NUREGs required for plant license renewal. The existence of a viable, effective examination capability for CASS materials plays a very important part in both currently required Inservice Inspections (ISI) and plant license renewal.

Figure 1. An example of the widely-varying microstructure of a centrifugally cast piping segment. False-color imaging is used to aid visualizing grain variations. (Image from NUREG/CR-6933 PNNL-16292)

CASS MATERIAL PROPERTIES AND EFFECT ON ULTRASONIC EXAMINATION
Metallurgical studies have revealed that the microstructure of CASS piping can vary drastically in the radial (through-wall) direction, as well as around the circumference and along the length of any given piping segment. Large and small equiaxed, columnar and mixed (combinations of equiaxed and columnar grains), and banding (layers of substantially different grain structures) are commonly observed in CASS piping materials. None of these conditions favor the performance of effective ultrasonic examinations.

Figure 2. PWR RCS Major Components

The very large and widely varying types (equiaxed, columnar, and randomly mixed), sizes and orientations of the anisotropic grains in CASS material are very problematic. Anisotropic is defined as an object or substance having a physical property that has a different value when measured in different directions. Such physical properties strongly affect the propagation of ultrasound in CASS material by causing severe attenuation (loss of energy through beam scattering and absorption), beam redirection, and unpredictable changes in ultrasonic wave velocity. These factors are responsible for the inability of ultrasonic examination to completely and reliably interrogate the Code-required volume (inner 1/3 Tnom) of welds in CASS piping material. Interestingly, CASS materials less than 1.6” Tnom (Pressurizer Surge Piping) can be effectively examined, while CASS materials over 2.00” (Main RCS Coolant Loop Piping) are less effectively examined.  Consequently, an ASME Section XI, Appendix VIII qualification program for CASS piping components has not been established and remains in the course of preparation. Nonetheless, ASME Section XI requirements to conduct inservice examinations of RCS piping welds fabricated from CASS components remain fully in force.

ASME CODE ACTIONS AFFECTING CASS PIPING EXAMINATIONS
ASME Section XI Code Case N-824, “Ultrasonic Examination of Cast Austenitic Piping Welds From the Outside Surface,” was approved by ASME in October 2012 and by the NRC in October 2019. This Code Case provides the first approved direction for the ultrasonic examination of welds joining CASS piping components. The ASME B&PV Code, Section XI, 2015 Edition, incorporates Code Case N 824 into Mandatory Appendix III in the form of Mandatory Supplement 2. To date, these two ASME Section XI Code documents remain the sole sources approved by ASME and NRC that provide specific direction for the examination of CASS RCS piping system welds and, therefore, form the foundation of SI’s approach for the development of our CASS ultrasonic examination solution.

SI’S CASS PROGRAM DESCRIPTION
SI is developing the industry’s most well-conceived and capable ultrasonic system for the examination of welds in CASS piping components. To accomplish this objective, SI has drawn upon our internal knowledge and experience, supplemented by a careful study of numerous authoritative bodies of knowledge relating to the examination of CASS components. The development of the SI examination system has been guided by both SI’s industry-leading 17 years of experience conducting phased array examinations in nuclear power plants and the knowledge acquired through the careful study of the topical information contained within industry-recognized publications. These published results of extensive industry research provided both guidance for the selection of phased array system components and CASS-specific material insights that strengthen the technical content of our Appendix III-based procedure. 

Figure 3. RCS Coolant Pump and Crossover Piping

CASS PROGRAM ELEMENTS
SI believes that the procedure, equipment and personnel featured in this program will be equivalent or superior to those that will form the industry-consensus approach for CASS ultrasonic examinations needed to successfully achieve Appendix VIII, (future) Supplement 9, “Qualification Requirements for Cast Austenitic Piping Welds.”

Ultrasonic Procedure – SI has crafted an ultrasonic examination procedure framework that is fully compliant with ASME Section XI, Mandatory Appendix III, Supplement 2, along with referenced Section XI Appendices as modified by the applicable regulatory documents.

Ultrasonic Equipment – SI has acquired and assembled the ultrasonic system components required by Code Case N-824 and Appendix III, Supplement 2, which includes the following:

  • Ultrasonic instrumentation capable of functioning over the entire expected range of examination frequencies. The standard examination frequency range extends from low-frequency, 500 KHz operation for RCS main loop piping welds through 1.0 MHz for pressurizer surge piping. 

SI has designed and acquired additional phased array transducers that meet the physical requirements of frequency, wave mode, and aperture size and are capable of generating the prescribed examination angles with the required focal properties. SI has designed and fabricated an assortment of wedge assemblies that will be mated with our phased array probes to provide effective sound field coupling to the CASS components being examined. SI’s wedge designs consider the CASS pipe outside diameter and thickness dimensions and employ natural wedge-to-material refraction to assure optimal energy transmission and sound field focusing.

SI also possesses several data encoding options that are necessary to acquire ultrasonic data over the expected range of component access and surface conditions. The encoding options will include:

  • Fully-automated scanning system, capable of driving the relatively large and heavy 500KHz phased array probes
  • The SI-developed Latitude manually-driven encoding system, which has been deployed during PDI-qualified dissimilar metal DM weld examinations in nuclear power plants

    Figure 4. Steam Generator Details

Examination Personnel – SI’s ultrasonic examination personnel are thoroughly trained and experienced in all elements of encoded ultrasonic data acquisition and analysis in nuclear plants. SI’s examiners have a minimum of 10 years of experience and hold multiple PDI qualifications in manual and encoded techniques. SI recognizes the challenges that exist with the examination of CASS piping welds and has developed a comprehensive program of specialized, mandatory training for personnel involved with CASS examinations. This training includes descriptions of coarse grain structures, their effect on the ultrasonic beam, and the expected ultrasonic response characteristics of metallurgical and flaw reflectors, as well as the evaluation of CASS component surface conditions.

ULTRASONIC TECHNQUE VALIDATION
Although not required by the ASME Code, SI has arranged for access to CASS piping system specimens from reputable sources to validate the efficiency of our data acquisition process and the performance of our ultrasonic examination techniques. The specimens represent various pipe sizes and wall thicknesses and contain flaws of known location and size to permit the validation and optimization of SI’s data acquisition and analysis processes. SI will thoroughly analyze, document, and publish the results of our system performance during the examination of the subject CASS specimens.

Figure 5. Pressurizer and Surge Line Details

CASS PIPING SYSTEM APPLICATIONS
Typical CASS Piping Weld Locations in PWR Reactor Coolant Systems
The following graphic illustrates the location and extent of CASS materials in the RCS of many PWR plants.

RCS Main Loop Piping Welds: This portion of the RCS contains large diameter butt welds that join centrifugally cast stainless steel (CCSS) piping segments to statically cast stainless steel (SCSS) elbows and reactor coolant pump (RCP) casings. RCS main loop piping includes the following subassemblies:

  • Hot leg piping from the Reactor Vessel Outlet to the SG Inlet
  • Cross-over piping from the SG Outlet to the RCP Inlet
  • Cold leg piping from the RCP Outlet to the RPV Inlet

Steam Generator Inlet / Outlet Nozzle DM Welds: These terminal end DM butt welds are present in PWR plants, both with and without safe ends between the SCSS elbows and the ferritic steel nozzle forgings. 

Pressurizer Surge Piping Welds: This portion of the RCS contains a series of butt welds fabricated using CCSS piping segments to SCSS elbows between the Pressurizer Surge nozzle end and the Hot Leg Surge nozzle. 

SUMMARY
The CASS piping welds present in many PWR plants provide numerous and complicated challenges to their effective ultrasonic examinations. SI’s new CASS ultrasonic examination system will provide a new and meaningful solution.

PROJECT TIMELINE
SI is working to complete the development, integration and capability demonstrations of the CASS ultrasonic examination system described in this document for limited (emergent) fall 2023 and scheduled deployments beginning in spring 2024.

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