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Property of AREVA NP - © AREVA NP All rights reserved, see liability notice
Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.1
Component Asset Management with Ultra-High Pressure Cavitation Peening
Darren H. WOOD, P.E. Global Product Development Manager Lyon, France 23 October 2017
Property of AREVA NP - © AREVA NP All rights reserved, see liability notice
Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.2
Agenda
Why UHP Cavitation Peening ?
Process Selection and Development
Tooling / Capabilities
Planning / Return on Experience
Regulatory Acceptance
Summary and Conclusions
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.3
What is Ultra High Pressure (UHP) Cavitation Peening?
Cavitation Vapor bubbles form in water
Shock Waves Occur from bubble collapse at surface generating high pressures on the material
Compressive Stresses In the surface layer of material results
High Velocity Jet Creates pressure below that of vapor pressure in water
UHP Cavitation Peening is a Well Understood, Proven Process for Surface Stress Mitigation and Improving Fatigue Life
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.4
Why discuss UHP Cavitation Peening?
PWSCC of primary components can lead to Increased inspection frequency Component repairs Component replacements
UHP Cavitation Peening is an Asset and Risk Management Tool
Greater outage scope Schedule extension Increased costs
Tensile Stress
Corrosive Environment
Susceptible Material
Property of AREVA NP - © AREVA NP All rights reserved, see liability notice
Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.5
Agenda
Why UHP Cavitation Peening?
Process Selection and Development
Tooling / Capabilities
Planning / Return on Experience
Regulatory Acceptance
Summary and Conclusions
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.6
Surface Mitigation Process Selection
2009: 99 mitigation techniques identified 2010: 10 techniques selected based on technical / economics 2011: 3 techniques selected for additional testing Cavitation Peening Laser Shot Peening Roto Peening
2012 / 2013: Several R&D projects for: Corrosion testing on Alloy 182 samples Tooling development and qualification for UHP Cavitation Peening of BMN
nozzles (ID & OD) 2014 / 2015: UHP Cavitation Peening process and tooling development RV Head Primary Nozzle
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.7
Internal Testing Summary
UHP Cavitation Peening Prevents PWSCC
Cavitation Peening induced a compressive stress state on the surface of all samples The surface remained in compression through all corrosion testing
Cracks did not initiate on “fresh” samples treated with Cavitation Peening Shallow existing cracks on “pre-aged” samples did not propagate
after treatment with Cavitation Peening No crack initiation or growth after an additional .4% strain was applied for 1000 hours S
imila
r to
MR
P-2
67 C
orro
sion
Tes
ting
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.8
Unique Technologies Cavitation peening (Patent) Hyperbaric testing Controlled depth abrasive jet
milling High speed ceramic machining Selective coating removal Precision 5-axis machining Downhole energy tooling Nuclear cleaning &
decommissioning tooling
Customers US Navy, Air Force, Army Missile defense agency NASA National Science Foundation Pratt and Whitney Rocketdyne Rolls-Royce General Electric Energy/Aircraft Engines AREVA Lockheed Raytheon ATK Boeing Baker-Hughs Sikorsky W.L. Gore General Atomic CoorsTek
Our partner Ormond has the pedigree nuclear power requires
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.9
UHP Cavitation Peening Surface Finish
Non-peened with PT Indications
Peened No PT Indications
Before Peening
After Peening
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.10
Why AREVA Selected UHP Cavitation Peening?
Safe for both personnel and component when operated within the controlled boundaries Very robust process with a large saturation zone No risk of equipment damage or material removal No foreign material concerns Smooth transition zones with no abrupt edge between peened and unpeened regions
Compressive stress depths meet or exceed EPRI MRP requirements Very adaptable and tolerant to surface conditions and complex geometries J-grooves CRDM thermal sleeve annulus BMI nozzle inside diameter
Does not require complicated tooling compared to laser or waterjet
UHP Cavitation Peening Scored Highest with Evaluation Criteria : Safety, Results, and Ease of Implementation
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.11
UHP Cavitation Peening Qualification
The peening process effectiveness was demonstrated on full scale representative mockups at the nominal, max and min ranges of essential variables used for site implementation Full scale nozzle mockups include material and geometry constraints
X-ray diffraction was used to determine the residual stress on peened full scale representative mockups Confirm the desired peening coverage and depth
of compression has been achieved A qualification report is provided to the utility that documents how all requirements are met Topical Report / Relief Request / ASME Code
Same Essential Variable Range for Qualification Mockups and Site Implementation
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.12
Process Control and Verification
Essential variables are controlled/monitored in-process to ensure acceptable results are achieved The operator has a real-time display of all essential variables If an essential variable gets outside of the qualified limits the operator is
immediately alerted The tooling control system records the value of each essential variable The electronic data may be reviewed/verified post-process
Process Quality is Ensured and May be Verified
Property of AREVA NP - © AREVA NP All rights reserved, see liability notice
Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.13
Agenda
Why UHP Cavitation Peening?
Process Selection and Development
Tooling / Capabilities
Planning / Return on Experience
Regulatory Acceptance
Summary and Conclusions
Property of AREVA NP - © AREVA NP All rights reserved, see liability notice
Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.14
Where is UHP Cavitation Peening Applicable ?
Bottom Mounted Instrumentation Nozzle
Penetrations
Safety Injection Nozzle Dissimilar Metal Weld and Safe-
End
Reactor Vessel
Alloy600 base metal
Alloy600 weld
Reactor Vessel Closure Head Penetrations
Primary RPV Nozzle Dissimilar Metal Weld and Safe-End
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.15
Bottom Mounted Instrumentation Nozzle
UHP Cavitation Peening
BMN OD Surfaces Alloy 600 (nozzle): 1 to 1.5 mm depth of compressive
stress Alloy 82/182 (j-groove weld): 1 mm depth of compressive
stress BMN ID Surfaces Alloy 600 (nozzle): 0.5 mm depth of compressive stress
Lightweight tooling easily managed from the refueling bridge
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.16
RV Closure Head UHP Cavitation Peening
CRDM OD Surfaces Alloy 600 (nozzle): from 1 mm at the minimal
parameter boundary to 1.5 mm depth of compressive stress at nominal dimensions
Alloy 82/182 (j-groove weld): 1 mm depth of compressive stress
CRDM ID Surfaces with or without Thermal Sleeve Alloy 600 (nozzle): Greater than .25 mm depth of
compressive stress on all PWSCC susceptible CRDM ID surfaces
The only process that can peen the annulus without removing or modifying the thermal sleeves
Vent Nozzle Surfaces Alloy 600 (nozzle): 0.5 mm depth of compressive stress Alloy 82/182 (j-groove weld): 1 mm depth of compressive stress
UHP Cavitation Peening is the Most Adaptive Process for these Geometries
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.17
Mega SUMO Under-Head Manipulator
NDE Synergies with Peening
Realized benefit of common manipulator Integrating and streamlining all pre-deployment
activities Delivers all peening, contingency repair, and
inspection tooling for RVCH penetrations • Simultaneous use of 2 manipulators for increased production
rates
Only one head lift necessary • Beginning of inspection • Critical path savings by installing false floor for water reclamation
before head is set, not after inspection
NDE Performance AREVA started performing Exelon head inspections
with award of peening contract Fastest full scope inspection at Braidwood: 69 hour
duration (23.2 hours ahead of schedule for 2R19)
Flexible, Robust Delivery System
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.18
Primary RPV Nozzle Dissimilar Metal Weld
UHP Cavitation Peening
Nozzle DMW ID (Weld + Heat Affected Zone) 1 mm depth of compressive stress Tool can swim NO supplemental support structures
UHP Cavitation Peening Performed from Inside the RPV, Lower Dose vs OD
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.19
Basics of the Process
Critical peening tooling (and essential variables) are the same for all applications Pumps Piping / Hoses Orifice
Observed differences are in the delivery mechanism Crawler Submarine Manually Delivered
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.20
Agenda
Why UHP Cavitation Peening?
Process Selection and Development
Tooling / Capabilities
Planning / Return on Experience
Regulatory Acceptance
Summary and Conclusions
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.21
Peening Implementation Byron and Braidwood RVCH
78 CRDM type nozzles (5 CETs, 18 open penetrations, 55 CRDM nozzles with thermal sleeves) and 1 vent line Byron 2 – Completed May 2016 Braidwood 1 – Completed October 2016 Byron 1 – Completed March 2017 Braidwood 2 – Completed May 2017
Proven process on most challenging configuration First of a kind risks have been mitigated Extensive lessons learned to benefit next
interventions
Customer headstand modifications were implemented seamlessly and did not affect critical path UHP Cavitation Peening is a PROVEN Technology that will Maintain Your
Asset for the Life of Your Plant
<30
day
outa
ges
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.22
Site Preparation & Implementation
Equipment Setup : Two (2) UHP water jet pumps + spare and
chiller 400A @ 460VAC
Operator control station in a low dose area inside or outside containment building
Two (2) sets of each tool head
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.23
Plant Configuration and Basic Logistics for
UHP Cavitation Peening
All Work with Component on Head Stand Establish minimum
height for tooling
Experience operating two tools in parallel
Lower Internals Removed from Vessel / Flooded Cavity Workers locate equipment from refuel bridge Logically plan with a 10 year RPV ISI Plan with two tools in parallel
Hot Leg Only: Fuel Offloaded / Flooded Cavity Hot Leg + Cold Leg: Lower Internals Removed from Vessel / Flooded Cavity Workers monitor from refuel bridge Crane required to introduce tool, then released Logically plan Cold Leg mitigation with a 10 year RPV ISI Plan with two tools in parallel
RV Head BMN Primary Nozzles
Average schedule dependent on plant size / configuration and to be optimized with the operator Average dose depending on plant-specific conditions
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.24
Basic Activity Planning
Pre-Outage Tasks Establish parameters based
on as-built configuration Implementation documentation Customer-specific
qualifications and readiness demonstrations
Safety Justification Inspection Relief Request (as
applicable) must be submitted before the next required inspection and can be planned after implementation
Outage Scope (N-1 Walkdown
Recommended) Inspection Contingency Repair UHP Cavitation Peening
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.25
Agenda
Why UHP Cavitation Peening?
Process Selection and Development
Tooling / Capabilities
Planning / Return on Experience
Regulatory Acceptance
Summary and Conclusions
Property of AREVA NP - © AREVA NP All rights reserved, see liability notice
Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.26
ASME Code and Safety Authority Criteria
AREVA worked with EPRI, ASME, and the NRC to lead the way for Regulatory Acceptance of cavitation peening in the USA. Code Case N-770-4 is approved by ASME Provides inspection relief for primary nozzles mitigated by peening
Code Case N-729-5 is approved by ASME Provides inspection relief for RV heads mitigated by peening
MRP-335, Rev. 3 Topical Report for Primary Water Stress Corrosion Cracking Mitigation by Surface Stress Improvement: Provides technical basis for inspection relief after peening for both RV heads
and primary nozzles NRC safety evaluation released with conditions in August 2016
• RV heads with pre-existing flaws must inspect the next 2 refuel outages after peening before returning to a 10 year inspection frequency
MRP-335, Rev. 3-A : amendment to include the NRC Safety Evaluation Conditions (November 2016)
ASME Code and US Safety Authority Requirements are Established and the Benefits of Peening are Confirmed
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.27
US Precedent
UHP Cavitation Peening Was implemented in accordance with current 10 CFR 50.59 regulatory
process • The NRC review of Byron Unit 2 50.59 noted it supported the conclusions with no
concerns
Was controlled as a 10 CFR 50 Appendix B Criterion IX “special process”
Post-Peening In-service Inspection Relief Changes in the volumetric inspection frequency specified in 10 CFR
50.55(a) requires NRC approval via the relief request process • Basis provide by MRP-335, Rev. 3-A • Typically several years before the NRC will endorse the ASME Code Cases
Exelon submitted fall of 2016 for Byron 2 and received approval September 2017
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.28
Agenda
Why UHP Cavitation Peening?
Process Selection and Development
Tooling / Capabilities
Planning / Return on Experience
Regulatory Acceptance
Summary and Conclusions
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.29
UHP Cavitation Peening Advantages
Demonstrated mitigation technology offers less complexity, more flexibility, easier and safer delivery, and higher confidence for success AREVA’s under-head experience is greatest in the industry with regard to RV head inspections and
number of nozzles repaired (predictable performance) AREVA offers both mitigation, inspection, and repair solutions from a common platform (RV head) The technology is the most adaptable process to complex geometries We are the only vendor that can peen the CRDM ID with the thermal sleeves in place, requiring no
modifications (4 loop configuration) The technology is less complex / more forgiving than laser technologies No risk of equipment damage or material removal AREVA worked closely with US NRC for peening implementation Depth of compression meets or exceeds EPRI MRP requirements
Partnering with AREVA provides access to a full scope solutions portfolio to support your unique LTO strategy NDE, engineering, contingency repair (specialized welding and machining processes), mitigation,
and even replacement components
AREVA has a proven track record in the industry of fulfilling our commitments
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.30
UHP Cavitation Peening Summary of Results
Surface Depth of Compression
AREVA EPRI / MRP CRDM Nozzle OD – Alloy 600 1 mm - 1.5 mm 1 mm
CRDM J-Groove Weld OD – Alloy 82/182 1 mm 1 mm
CRDM Nozzle ID Annulus w/ thermal sleeve – Alloy 600 .25 mm - .50 mm .25 mm
CRDM Nozzle ID (Open) – Alloy 600 .50 mm .25 mm
Vent Nozzle J-Groove Weld OD – Alloy 82/182 1 mm 1 mm
Vent Nozzle ID – Alloy 600/82/182 .50 mm .25 mm
BMN Nozzle OD – Alloy 600 1 mm - 1.5 mm 1 mm
BMN J-Groove/Repair Weld OD – Alloy 82/182 1 mm 1 mm
BMN Nozzle ID – Alloy 600 .50 mm .50 mm
Primary Nozzle DMW – Alloy 82/182 1 mm 1 mm
UHP Cavitation Peening reliably meets or exceeds EPRI MRP mitigation criteria
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Component Asset Management with Ultra-High Pressure Cavitation Peening, IAEA-CN-246-002 Darren H. WOOD p.31
UHP Cavitation Peening Concluding Thoughts
Proven Technology : demonstrated in safety conscious nuclear and aerospace industries for
Asset Management : can mitigate PWSCC susceptible components, extending their useful lifetime (depending on local accounting laws, perhaps capitalize the investment)
Risk Management : planning certainty to avoid component repairs and replacements due to PWSCC which lead to increased outage cost, schedule, and dose
Schedule Optimization : reduce inspection frequency of ‘renewed’ components
Our Vision: High-performing people and technologies for safe and competitive nuclear plants worldwide
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