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INSPECTION OF STEAM GENERATOR TUBES

INETEC is performing Eddy Current inspection of PWR and VVER steam generators with its own highly sophisticated equipment.

Eddy Current theory overview

• Eddy Current (EC) is a type of Non-Destructive material testing method. The underlying principle is the electromagnetic induction of eddy currents in the conductive test material by means of excitation coils:a varying electrical current in the coils creates a varying magnetic field perpendicular to the coil plane, which in turn induces eddy currents in the plane parrallel to the coils.
• Because of the nature of induction, coils do not have to be in a direct electrical contact with the material, and therefore special coupling media is not needed between the probes and the test object.
• EC is used to detect defects and to measure mechanical, metallurgical and some simple geometrical properties
  As the probe passes by a defect, the impedance of the coil changes.
• The signal assumes a distinct shape from which various characteristics of the defect can be deduced like: depth, width, length, orientation of the cracks etc.
• EC is a volumetric testing method since different excitation frequencies can be used to inspect specific the material.

Nuclear Power Plant Steam generators

• The Primary Side of Steam Generators (SG) is classified as “Safety 1” component as there is  extreme importance for safe operation and operation reliability
   (Safety series 50-SG-D1 paragraph A.3.)
• The timely detection and reliable sizing of defects on tube is prerequisite to void possible tube rupture and subsequent leakage. World experience has shown that the most suitable type of inspections in term of reliability and safety for the SG tube bundle is the EC examination method.
• SG tubes are affected by a number of factors:
  • Chemistry control (during operation + using a permanent
  chemistry parameter monitoring system)
  • Components containing Copper (in the secondary loop)
  • Condenser tube leakage (material choice, regularity of nspections)
  • Blowdown system (controlling sludge concentration)
• Degradation mechanisms are both mechanical and chemical

INETEC services and worldwide experience

• Experience on WWER 440 and WWER 1000 type SG includes inspections in Armenia, Hungary, Bulgaria and Russia
• Experience on PWR type SG includes inspections in Brazil, Belgium, Slovenia, Taiwan and USA
• INETEC offers a wide variety of inspection related services:

Inspection equipment 

• Commonly used probes:
  • Bobbin probes – the most commonly used probes because of their speed and reliability;  special metal beaded and metal shielded models for severe cases
  • Rotating probes – utilize coils that rotate with high speed
  • Array probes – multiple coils arranged with phase shifts on the probe circumference

Advanced probes like rotating and array probes are used to confirm defects detected by bobbin probes, and to collect additional information like defect orientation and shape. They are also used in places where bobbin probes do not provide satisfactory results.

• INETEC offers a wide range of manipulators, each specifically engineered to suit specific customer needs

Standard model

• can use different probes (bobbin, rotating)
• moderate pull-pushing force
• push-pulling device is located  outside collector
• probe is easily substituted on top of the manipulator
• In some cases, special metal beaded (pearl) probes have to be used.

Advanced Standard model

• same as standard model with push pulling device located outside collector, but additionally it has an auxiliary pneumatic pusher near the tube entrance
• can use different probes (bobbin, rotating)
• strong pull-pushing force
• probe is easily substituted on the top of manipulator

Special high force model

• special high power push-pulling device located inside collector
• can use only bobbin probes
• extremely strong pull-pushing force
• faster pushing and pulling speed in comparison with other models
• probe change slower than on the other models

Dual Guide Tube manipulator

• capable of inspecting two tubes at the same time
• can use different probes (bobbin, rotating)
• strong pull-pushing force
• probe easily substituted on top of manipulator

Typical time schedules for inspection of one WWER 1000 SG with two sets of equipment

Manipulator type Inspection time

Standard manipulator	14 days
Advanced standard manipulator	12 days
Special high force manipulator	10 days
Dual Guide Tube manipulator	6 days

EddyOne software package:

EddyOne Data Acquisition
 
- Supports various EC instruments including:
• MIZ 70 (ZETEC)
• MIZ 30 (ZETEC)
• MIZ 18A (ZETEC)
• MIZ 43 (ZETEC)
• TC 7700 (R/D Tech)
• Omni 100 (CoreStar) with RFT upgrade
 
- Supports various EC probes including bobbin, rotating (up to 32 coils), Plus Point and Array probes 
- Supports various INETEC manipulators (see above) 
- Supports various manipulator modes of operation:
• Free run
• Manual mode
• Test mode
• Totally automated mode
 
- Simple and quick calibration routines 
- Easy handling and self explaining environment

EddyOne Inspection Planning and Data Management
 
- Tube Sheet Modeler
• adaptable to all tube sheet types
• 1200 different coordinate system combinations
• supports creating several different tube sheet representations of a single SG 
- Inspection planning
• implements powerful tools for creating complex test plans within minutes
• integrated interface providing true control over processes 
- Inspection Management
• powerful visualization tools
• user friendly tools for complete Tube Report control
• estimation of completion time based on current progress speed
  Statistical Data Analysis
• statistical data analysis per generator and also per each unit or for the entire plant consisting of several units
• automatic creation of degradation progress rates per steam generator, unit,  or plant, based on EC results

EddyOne Data Analysis

• Easy on-screen data handling
• Customizable screen display
• Calibration curves
• Auto-calibration
• Mix routines
• Digital Filtering routines
• Landmark utilities
• Final report organization
• Indication code editor
• Compare feature for resolution analysts
• Semi-Automatic and Automatic Analysis
• Windows friendly user interface
• 3D Lissajous view
• Signal composer
• Signal Adviser
• History Management
• Rotating probe analysis package
• Various presentation formats
• Artificial intelligence features