JAPANESE PD EXAMINATIONS FOR DEPTH SIZING OF SCC IN AUSTENITIC STAINLESS STEEL PIPES FROM 2006 TO 2012

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1 JAPANESE PD EXAMINATIONS FOR DEPTH SIZING OF SCC IN AUSTENITIC STAINLESS STEEL PIPES FROM 2006 TO 2012 Keiji Watanabe, Hajime Shohji, and Koichiro Hide PD center, Central Research Institute of Electric Power Industry, ABSTRACT The PD Center of Central Research Institute of Electric Power Industry (CRIEPI) commenced Performance Demonstration (PD) examinations for testers conducting flaw depth sizing of stress corrosion cracking (SCC) in austenitic stainless steel pipes in March As of January, 2012, 34 such examinations have been held, and 37 out of 47 candidates have passed the examination, including those who passed the recertification examination. There has been an increase in the ratio of successful applicants, which shows that skill in depth sizing was improved through the PD examination. It also was found that conducting depth sizing with a combined technique involving phased array and the conventional ultrasonic testing (UT) technique resulted in the greatest success in passing the examination. The unsuccessful candidates had problems in the sizing of SCC depth which was 20% to 70% of wall thickness while the successful applicants measured the SCC depth with an almost constant error range regardless of the SCC depth. INTRODUCTION Japan Society of Mechanical Engineers (JSME) issued the first edition of a fitness-for-service code (FFS code) for nuclear power plants in The FFS code was endorsed by the Nuclear and Industrial Safety Agency (NISA) and it has been in effect since October 2003 [1]. In June 2005, the first Japanese PD standard, NDIS 0603 Qualifications and certification of personnel for performance demonstration testing of ultrasonic testing systems, was issued [2]. The NDIS 0603 is basically to the same as Appendix VIII and Section XI of the ASME Code, having the same fundamental content with some modifications reflecting Japanese technical expertise on IGSCC ( innergranular SCC ) in austenitic stainless steel welds. The 1st Japanese PD qualification examination was held in March, 2006 and as of January, 2012, 34 examinations have been conducted. In December 2010, the 1 st PD recertification candidate took an examination. 34 out of 44 candidates passed the examination after PD qualification examination. Among these 34 passing candidates are 7 candidates who passed the PD recertification examination a. PD CERTIFICATION SYSTEM IN JAPAN Operating organization Figure 1 shows the organizations that have roles in the Japanese PD qualification examination system for the crack depth sizing in austenitic stainless steel pipe welds in nuclear power plants [3]. The PD advisory committee oversees the PD qualification system. The PD advisory committee consists of academic experts and staff of government and public inspection organizations. The PD advisory committee reviews activities of the PD related organizations (PD qualification activity, PD test center, and PD training center) and makes recommendations to them. Another important role of the PD advisory committee is international coordination with the PD systems in other countries. There is a PD certification body that certifies PD related organizations. The Japanese Society of a 9 candidates took the PD recertification examination. An examination applicant is considered to be a new examinee after the license time limit has expired. 117

2 Non-Destructive Inspection (JSNDI) takes this role. The PD certification body of JSNDI consists of two committees, a PD steering committee to manage the PD system and a PD planning committee to plan PD systems for the future. The PD qualification body organizes the qualification examination, i.e. prepares and maintains the test specimens, the test facility and the quality control documents. The PD examination center operates the PD qualification examination under the direction of the PD qualification body. The PD Center of CRIEPI takes the roles of the PD qualification body and the PD examination center. The PD training center has two functions in the PD system. One is to train the personnel who fail their first PD examination and hope to take a re-examination within 30 days. The other is annual training for license renewal. Japan Power Engineering and Inspection Corporation (JAPEIC) and Electron Science Institute (ESI) have been qualified as PD training centers. NISA: Nuclear and Industrial Safety Agency JSNDI: The Japanese Society for Non-Destructive Inspection JAPEIC: Japan Power Engineering and Inspection Corporation ESI: Electron Science Institute Fig.1 Organizations involved in Japanese PD qualification examination Outline of qualification examination Though the Japanese PD standard NDIS 0603 is basically to the same as ASME Code Section XI and Appendix VIII, some adaptations have been incorporated to reflect our findings on IGSCC in austenitic stainless steel welds. These adaptations are; (1) All the cracks in the test sample should be IGSCC (2) At least one IGSCC should be deeper than 15mm (3) At least one IGSCC should penetrate into the weld material (4) No undervalue of more than -4.4mm should be permitted Below is an outline of the Japanese PD qualification examination. The qualification test specimens are butt welded austenitic stainless steel pipes with artificially introduced IGSCC. Weld crowns are ground flush. A total of 10 IGSCC must be tested in pipes of the following three different sizes. Nominal diameter: 600 mm with 35mm wall thickness Nominal diameter: 350 mm with 25mm wall thickness Nominal diameter: 150 mm with 10mm wall thickness 118

3 Cracks in the depth sizing sample set shall be distributed according to the specifications in Table 1. The remaining cracks may be in any of these categories. Table 1 Distribution of crack depth Crack depth h (% wall thickness) minimum percentage 0 < h <= 30 % 20 % 30 < h <= 20 % 60 % 60 < h < 20 % 100 % For each candidate, the allowable examination time is 5 days for 10 samples, 8 hours per specimen. Carryover of a specimen to the next day is not allowed. The test specimens are given one at a time. Acceptance criteria are; Root mean square error (RMSE): less than 3.2mm Critical mistake: less than -4.4mm. The RMSE is derived from the following formula RMSE = m i : Measured SCC depth t i : True SCC depth n : Number of Test specimens The term of validity of the PD certification is one year and can be extended up to 5 years at most if the qualified personnel received PD training at the PD training center. TEST RESULT The 1st PD qualification examination was in March, 2006, and during the past 6 years, 57 personnel have taken the examination, 44 of these receiving passing marks. The cumulative total number of examinees, counting twice those who took the recertification test, is 85. Figure 2 shows the changes in the numbers of candidates and successful applicants from March 2006 to January This figure shows that the number of candidates in a period has been decreasing gradually during the past 6 years. However, looking at the results from a different point of view, the required number of qualified personnel for the Japanese nuclear industry was almost achieved within 3 years after the start of the examination. After this point, the number of candidates in each period seems stable. These persons took the examination with a view to their future in their organization. Though the pass rate of each period shows fluctuation, the overall tendency has been toward gradual improvement. From the information obtained by interviewing the candidates, this improvement seems to be the result of education and training at their company. 119

4 Figure 2 Change in the numbers of candidates and successful applicants Figure 3 shows the relationship between the root mean square error (RMSE) and the average UT time for all the candidates. Around 90% of the successful applicants measured the SCC depths with an error within 1~2mm. This degree of sizing error of the successful applicants shows that the depth of SCC can be sized very accurately. Several candidates whose RMSE fulfilled the acceptance criteria failed because of a critical mistake. It can be seen from these results that many candidates took about minutes for inspection of one specimen. However, there was no link between the average time of inspection and pass/fail ratio in all the tests. Figure 3 Relationship between the average UT time and Root mean Square Error 120

5 SIZING PROCEDURE Figure 4 shows the numbers of candidates who used each of various types of crack depth sizing procedures in the PD examination and the number of those who passed. Conventional UT mentioned above refers to manual examination shown here, that uses a conventional A-scan type UT instrument. Various types of angled beam transducers for crack tip identification and a high angle longitudinal transducer for crack depth classification were used for the conventional UT. Phased array UT refers to encoded scanning with linear phased array transducers. Though several types of phased array systems were used in the examination, all the procedures were similar in the data collection and analysis method. The majority of the candidates used a combination of Phased array and Conventional UT technique (this is called Advanced UT ). The test result shown in Figure 4 indicates that Advanced UT is the most successful procedure. Phased Array UT is a procedure for sizing flaw depth using only a phased array technique. At present, the pass rate of Phased array procedure is low, indicating that phased array procedures require some kind of improvement. In the first examination, 3 candidates passed the examination using the Manual UT procedure. However, no candidate has passed the examination by manual UT procedure since the 2 nd examination and of those candidates who failed once, none who took the PD re-examination passed using Manual UT. Figure 4 Type of flaw depth sizing procedure In order to see the influence of the depth of SCC on the test outcome, Figure 5 shows the relationship between the depth of SCC and the standard deviations of the measurement error of the successful and the unsuccessful candidates. The unsuccessful candidates had problems in sizing SCC with depths 20% to 70% of wall thickness, while the successful applicants measured the SCC depth with an almost constant range of error regardless of the SCC depth. 121

6 Figure 5 Crack depth dependence of sizing error of candidates STATISTICAL ANALYSIS of SIZING RELIABILITY In order to clarify the depth sizing reliability, PD center did a statistical analysis of the test data accumulated from the 1st examination to the most recent examination. Table 2 shows the results of statistical analysis of the SCC depth sizing error. The mean error and the standard deviation of successful candidates were 0.31mm and 1.90mm, respectively, while the mean error and the standard deviation of all candidates were 0.65mm and 3.77mm, respectively. Table 2 Statistical analysis of PD result candidate Candidate group Number of data Mean error (mm) Standard deviation (mm) All Pass Fail Figure 6 Distribution of depth sizing error (mm) 122

7 The bar chart shown in Figure 6 is the frequency distribution of different degrees of error in the depth sizing of the successful candidates. Figure 6 also contains the probability density curves of the successful applicants, calculated from each of their standard deviations N(, 2 ). The probability distribution which expresses the standard deviation and the average is shown in the following equation. The probability density distribution in Fig. 6, which is derived from =0 (N(0.0, )), was calculated to clarify the deflection of the probability density curve from the results of the successful applicant. It can be seen from Figure 6 that the frequency mode is about 0 and the frequency distribution is almost symmetrical. However, the frequency distribution has been obviously biased to the plus side in the skirts of the distribution curve. It should be pointed out that one reason for this bias is the overestimation of the SCC depth. This overestimation could be caused by the lack of skill in distinguishing the base metal-to-weld metal interface echo and the SCC tip echo. Moreover, the possibility of psychological bias is also incontrovertible because candidates are under pressure not to make a -4.4mm critical mistake. It is not necessary for the tester to be very careful not to make -4.4mm critical mistake when the successful PD applicant subsequently measures SCC depth in actual operations [4]. Therefore, it is likely that the distribution of the actual operation measurement error is close to the probability density distribution. P(x), which is the probability that the measurement of a successful PD applicant will make a -4.4mm critical mistake, is derived from the N (0.00, ) and the following equation, P(x) is calculated to be (0.66%) from this Equation (2). Furukawa et al have reported that the maximum probability that a -4.4mm critical mistake will be made when a successful PD applicant measures SCC depth sizing is 5% [5]. These figures indicate that a successful Japanese PD applicant will measure crack depth with sufficient precision and reliability. CONCLUSION The Japanese PD qualification examination for flaw depth sizing started in March, 2006, and during the 6 years afterwards, 34 out of 44 candidates passed the examination. The outcome of Japanese PD examinations can be summarized as follows. (1) The average depth sizing error was 0.31mm with the standard deviation of 1.90mm for the successful applicants. (2) Depth sizing using a phased array plus the manual UT technique was the procedure most used by successful PD applicants. (3) The unsuccessful candidates has problems in the sizing SCC with depths 20% to 70% of wall thickness, while the successful applicants measured the SCC depth with an almost constant range of error regardless of the SCC depth. REFERENCES 1) Kashima K, Nomura T and Koyama K, Current status of Japanese Code on Fitness-for-Service for Nuclear Power Plants PVP- Vol. 480, Pressure Vessel and Piping Codes and Standards, San Diego USA, ) Sasahara T, Yamashita T and Nomura, UT Performance Demonstration in Japan Fifth Int. conf. on NDE in Relation to Structural Integrity for Nuclear and Pressurized Components, San Diego, USA, ) Sasahara T, and Hide K, Japanese PD Examination of IGSCC Depth Sizing 8th Int. conf. on 123

8 NDE in Relation to Structural Integrity for Nuclear and Pressurized Components, Berlin, Germany, ) Sasahara T, Jikimoto T, Hide K and Inoue H, Evaluation of SCC Depth Sizing Candidate and Performance Maintenology, Vol.9 No.1, p.44, ) Furukawa T, Komura I, Yoneyama H, and Yamaguchi A, Guideline for the Direction of Instructional Training in SCC Depth Sizing by Ultrasonic Flaw Detection Maintenology, Vol.4 No.3, p.54,

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