News & View, Volume 47 | PEGASUS State-of-the-Art Nuclear Fuel Behavior

News & Views, Volume 47 | Introducing Pegasus: Optimize Fuel Performance

By:  Vick Nazareth and Bill LyonNews & View, Volume 47 | PEGASUS State-of-the-Art Nuclear Fuel Behavior

The Pegasus code is a culmination of nuclear fuel behavior knowledge and experience that spans a period of over five decades. It is a total fuel-cycle simulation of fuel response from initial insertion in reactor to deposition in permanent storage. The goal of Pegasus is to treat, with equal fidelity, the modeling of fuel behavior during the active fuel cycle and the back-end cycle of spent-fuel storage and transportation in a single, self-consistent, and highly cost-effective analysis approach. In the active part of the fuel cycle, Pegasus’s superior three-dimensional thermo-mechanics, coupled with validated nuclear and material behavior models, and robust fuel-cladding interface treatment make it a high-fidelity predictor of fuel-rod response during flexible power operations and operational transients.

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News & View, Volume 47 | Metallurgical Lab Case Study- Corrosion Fatigue in WaterWall Tubes Increasingly A Safety Concern as Coal Plants Cycle

News & Views, Volume 47 | Metallurgical Lab Case Study: Corrosion Fatigue in WaterWall Tubes Increasingly A Safety Concern as Coal Plants Cycle

By:  Ben RuchteNews & View, Volume 47 | Metallurgical Lab Case Study- Corrosion Fatigue in WaterWall Tubes Increasingly A Safety Concern as Coal Plants Cycle

It is well known that conventional coal-fired utility boilers are cycling more today than they ever have.  As these units have shifted to more of an ‘on-call’ demand they experience many more cycles (start-ups and shutdowns, and/or significant load swings) making other damage mechanisms such as fatigue or other related mechanisms a concern. 

The most recent short-term energy outlook provided by the U.S. Energy Information Administration (EIA) indicates the share of electricity generation from coal will average 25% in 2019 and 23% in 2020, down from 27% in 2018.  While the industry shifts towards new construction of flexible operating units, some of the safety issues that have been prevalent in the past are fading from memory.  The inherent risks  of aging seam-welded failures and waterwall tube cold-side corrosion fatigue failures are a case in point.   It is well known that conventional coal-fired utility boilers are cycling more today than they ever have.  As these units have shifted to more of an ‘on-call’ demand they experience many more cycles (start-ups and shutdowns, and/or significant load swings) making other damage mechanisms such as fatigue or other related mechanisms a concern.  The following case study highlights this point by investigating a cold-side waterwall failure that experienced Corrosion Fatigue.  While this failure did not lead to any injuries, it must be stressed that the potential for injuries is significant if the failure occurs on the cold-side of the tubes (towards the furnace wall).

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News & View, Volume 47 | Release of the First Safety of Gas Transmission Pipeline Regulation Mega-Rule

News & Views, Volume 47 | Release of the First Safety of Gas Transmission Pipeline Regulation Mega-Rule

By:  Scott Riccardella, Bruce Paskett, and Andy Jensen

News & View, Volume 47 | Release of the First Safety of Gas Transmission Pipeline Regulation Mega-RuleOn October 1, 2019 the Pipeline and Hazardous Materials Safety Administration (PHMSA) published amendments to 49 CFR Parts 191 and 192 in the Federal Register issuing Part 1 of the Gas Transmission Mega-Rule1.  This new regulation is commonly referred to as the Mega-Rule, as it represents the most significant regulatory impact on gas transmission pipelines since the original Gas Transmission Integrity Management Program (TIMP) Regulation was issued in 2003.

General Overview
As a result of numerous transmission pipeline accidents in the late 1990’s, the congressional Pipeline Safety Improvement Act of 2002 required operators of natural gas transmission lines to create TIMP Plans to identify transmission lines in High Consequence Areas (HCAs), conduct risk assessments and manage the integrity of covered segments in HCAs  by conducting periodic integrity assessments. In 2010 through 2012, multiple incidents (Deep Water Horizon, San Bruno, California, Marshall, Michigan, Sissonville, WV) created a renewed focus on pipeline safety in Congress.

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News & View, Volume 47 | Materials Lab Featured Damage Mechanism- SH:RH Fireside Corrosion in Conventional Coal Fired Boilers

News & Views, Volume 47 | Materials Lab Featured Damage Mechanism: SH/RH Fireside Corrosion in Conventional Coal Fired Boilers

By:  Wendy Weiss

Superheater/reheater fireside corrosion is also known as coal ash corrosion in coal fired units.

News & View, Volume 47 | Materials Lab Featured Damage Mechanism- SH:RH Fireside Corrosion in Conventional Coal Fired Boilers

MECHANISM
Coal ash corrosion generally occurs as the result of the formation of low melting point, liquid phase, alkali-iron trisulfates. During coal combustion, minerals in the coal are exposed to high temperatures, causing release of volatile alkali compounds and sulfur oxides. Coal-ash corrosion occurs when flyash deposits on metal surfaces in the temperature range of 1025 to 1200oF. With time, the volatile alkali compounds and sulfur compounds condense on the flyash and react with it to form complex alkali sulfates such as K3Fe(SO4)3 and Na3Fe(SO4)3 at the metal/deposit interface, which are low melting point compounds. The molten slag fluxes the protective iron oxide covering the tube, exposing the metal beneath to accelerated oxidation.

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Mark Marano CEO Announcement Post

SI appoints Mark W. Marano as President and Chief Executive Officer

San Jose, CA, February 4, 2020 – Structural Integrity Associates, Inc. (SI) announced today the appointment of Mark W. Marano as President and Chief Executive Officer, effective February 10, 2020.  Marano succeeds Laney Bisbee following his retirement in late 2019.

Marano joins SI following a brief retirement from Westinghouse Electric Company, where he previously was Chief Operating Officer where he oversaw core global products and services and played a key role in the company’s emergence from bankruptcy.  Previously, Marano served as Westinghouse President, Americas and EMEA sales regions for four years, driving strategic revenue growth in a challenging nuclear market.

Marano’s career spans over 35 years in provider and supplier sides of the power generation industry. Prior to Westinghouse, he held executive leadership positions with AREVA NP (currently Framatome) and GE Hitachi Nuclear Energy.  Marano also held several senior leadership roles at American Electric Power (AEP), a power utility company with electric transmission/distribution networks as well as nuclear, coal, natural gas and hydro generation assets.  There he provided financial and commercial leadership, plus for five years was CEO of AEP’s subsidiary, Numanco, a provider of staff augmentation services.

Barry Waitte, Chairman of the Board of SI, noted, “Mark brings tremendous experience to SI.  While his energy industry experience is an obvious fit, it’s how he achieved his success that made him the right choice – a combination of exceptional business acumen and the ability to drive employee engagement and buy-in.  His business development experience will also provide a basis for creating a platform for growth, not only in our core markets but also as we deliver our capabilities into new markets in the future.”

Marano stated, “I look forward to working with the talented SI staff and our industry partners to help deliver for our clients, and to get better in everything that we do. This is a humbling and exciting challenge for me, as SI holds a special place in the market as a highly respected technical consulting firm.”

Marano has a Bachelor of Science in business administration from State University of New York at Oswego. He will be located in SI’s Charlotte, North Carolina office.

News & View, Volume 46 | Application of Probabilistic Flaw Tolerance Evaluation Optimizing NDE Inspection Requirements

News & Views, Volume 46 | Application of Probabilistic Flaw Tolerance Evaluation Optimizing NDE Inspection Requirements

By:  Christopher Lohse

News & View, Volume 46 | Application of Probabilistic Flaw Tolerance Evaluation Optimizing NDE Inspection RequirementsThere have been several industry initiatives to support optimization of examination requirements for various items/components (both Class 1 and Class 2 components) in lieu of the requirements in the ASME Code, Section XI.  The ultimate objective of these initiatives is to optimize the examination requirements (through examination frequency reduction, examination scope reduction, or both) while maintaining safe and reliable plant operation.  There are various examples of examination optimization for both boiling water reactors (BWRs) and pressurized water reactors (PWRs).  Each of these technical bases for examination optimization relies on a combination of items.  The prior technical bases have relied on: (1) operating experience and prior examination results as well as (2) some form of deterministic and/or probabilistic fracture mechanics.   For BWRs, the two main technical bases that are used are BWRVIP-05 and BWRVIP-108.  These technical bases provide the justification for scope reduction for RPV circumferential welds, nozzle-to-shell welds, and nozzle inner radius sections.  For PWRs, the main technical basis for RPV welds is WCAP-16168.  These technical bases are for the RPV welds of BWRs and PWRs which represent just a small subset of the examinations required by the ASME Code, Section XI.  Therefore, the industry is evaluating whether technical bases can be optimized for other components requiring examinations. 

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News & View, Volume 46 | In-line Inspection Performance Validation Pipe Experiment

News & Views, Volume 46 | In-line Inspection Performance Validation Pipe Experiment

By:  Jacob Arroyo

News & View, Volume 46 | In-line Inspection Performance Validation Pipe ExperimentYou’ve just completed the first in-line inspection (ILI) of a new pipeline asset. The ILI tool results are in, and there are no required repairs! However, how sure are we of the accuracy of the results? Could the tool have under-called some of the reported anomalies? Are there any regulatory requirements beyond the “response criteria” mentioned in CFR 192 and 195 for operators of hazardous transmission pipelines? These are the problems that ILI verification is trying to solve.

Traditionally, validations can be done using costly excavations of anomalies found by the tool. In cases where those anomalies need to be repaired, this approach is effective, and the validation does not require any further excavations. For some ILI inspections, the tool does not call any anomalies that need to be repaired. The traditional approach, in this case, has been to excavate sub-critical anomalies just for validation. In such cases, an ILI validation spool can be a valuable asset. ILI validation spools can be designed to quantify the uncertainty of the full spectrum of anomaly types without additional excavations, thus freeing up valuable resources to be allocated elsewhere to improve safety, minimizing the exposure risk of excavating pipeline assets while under full operating pressure.

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News & View, Volume 46 | Baffle-Former Bolt Management- Cost:Benefit Studies

News & Views, Volume 46 | Baffle-Former Bolt Management: Cost/Benefit Studies

By:  Tim Griesbach and News & View, Volume 46 | Baffle-Former Bolt Management- Cost:Benefit Studies

For the past several years baffle-former bolt (BFB) cracking in pressurized water reactors has become a significant concern for of PWR plants. In 2016, three similar Westinghouse designed plants (Indian Point 2, Salem 1, and D. C. Cook Unit 2) experienced significant numbers of cracked BFBs, attributed to irradiation-assisted stress corrosion cracking (IASCC). These plants had common characteristics that included the 4-loop plant design, downflow configuration, and Type 347 stainless steel bolting material. BFB cracking is not an entirely new phenomenon as it was initially detected in the French PWR fleet in the 1990s. However, the extent of cracking found in some of the US plants has greatly exceeded prior cracking. Extensive industry programs have identified and categorized by tier group the most susceptible plants, and the EPRI Materials Research Program (MRP) has published guidance regarding baffle-former bolt UT inspections for PWR plants for detection of degraded and cracked bolts in the baffle-former assembly (MRP-2017-009). 

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News & View, Volume 46 | Cross-Weld Creep-Rupture Testing for Seam Weld Life Management

News & Views, Volume 46 | Cross-Weld Creep-Rupture Testing for Seam Weld Life Management

By:  Jonnathan Warwick, Terry Totemeier, and Brian Chambers, Duke Energy

News & View, Volume 46 | Cross-Weld Creep-Rupture Testing for Seam Weld Life ManagementLongitudinal seam-welded hot-reheat steam piping operating in the creep regime is a continuing life-management challenge for many older fossil-fired power plants.  In response to catastrophic seam-welded piping failures in the 1980’s, the Electric Power Research Institute (EPRI) developed a comprehensive inspection protocol to insure continued safe operation of these piping systems [1]. The protocol requires full inspection of seam-welded hot-reheat pipe once a threshold of service exposure (calculated creep life consumption) has been reached, and re-inspection at intervals after the initial inspection depending on the inspection results.  Inspection for sub-surface cracking using ultrasonic testing (conventional or advanced) is strongly recommended, in combination with checking for surface cracking using wet fluorescent magnetic particle testing (WFMT).  Initial inspection and re-inspection of these piping systems represents a large maintenance cost for utilities, especially as older plants remain in service due to the changing economics of power generation.

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News & View, Volume 46 | Multi-discipline Solution for Pressure Vessel Asset Management

News & Views, Volume 46 | Multi-discipline Solution for Pressure Vessel Asset Management

By:  David Segletes and Dan Peters

One of the strengths of the Structural Integrity Associates (SI) team lies in the diversity of the skills and capabilities in the organization. Sure, SI can perform inspection, analysis, design, metallurgy, failure investigations, risk assessments, and project management, but one of the real values of working with SI is when all of those aspects are brought together to solve an issue.

News & View, Volume 46 | Multi-discipline Solution for Pressure Vessel Asset ManagementRecently, a client approached SI after finding a through-wall flaw in an autoclave at the head-to-shell weld as indicated by a visible dye liquid penetrant examination (Figure 1). The autoclave was one of eight similar vessels used for processing the client’s product. Three of the autoclaves are identical in construction to the flawed autoclave and operate with similar process conditions. Remote visual examination by the client indicated that all four autoclaves had similar observations at the inside of the head-to-shell weld, but only one was leaking. The remaining four autoclaves are smaller and are used infrequently. The initial call from the client was for SI to provide emergent support for inspection of the three autoclaves identical to the leaking one to meet production demands. SI responded quickly and examined all four autoclaves using a manual phased array ultra-sonic technique (PAUT) from the exterior of the vessel. The manual PAUT examination provided excellent coverage of the weld region and visualization of the through wall flaw (Figure 2).

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