REVIEW OF ELABORATIONS, EXECUTED FOR INDUSTRY’S ENTERPRISES BY STATE ENTERISE “KOLORAN”

8/10/2019 REVIEW OF ELABORATIONS, EXECUTED FOR INDUSTRY’S ENTERPRISES BY STATE ENTERISE “KOLORAN”

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REVIEW OF ELABORATIONS, EXECUTED FOR INDUSTRY’S

ENTERPRISES BY STATE ENTERISE “KOLORAN”

OF INSTITUTE OF PHYSICAL CHEMISTRY

NAMED BY L.V. PISARZHEVSKIY, ACADEMY OF SCIENCES

OF UKRAINE

Institute of physical chemistry named by L.V. Pisarzhevskiy has a large experience of works

on an atomic subject. Already in 1939 under the guidance of academic A.I. Brodskiy technology ofreceipt of heavy water was developed. The results and specimen of D2O were successfully used at

creation of domestic nuclear industry.

Continueing these traditions SE “KOLORAN”, from 1984 executes works on creation and

production of facilities and technologies of non-destructive control, repair and defence of NPP

equipment.

1. Non-destructive control and diagnostics.

1.1. Elaboration and organization of ecologically clean material’s production for the

“dye” penetrant control.

Work is executed by order “Prometheus” Institute in connection with the necessity of

leadthrough of non-destructive control of the weld-fabricated connections into the compartments of

atomic submarine boats and high toxicness of applied penetrants.As a result we synthesized dye “basic raspberry”, unique properties of which allowed to develop

a gamut of fully harmless, easily reutilizable “penetrants”. These materials are entered in the

“Compatible methodic of control of basic materials, weld-fabricated connections of equipment and

pipelines of NPP. Capillary control (PNAE G-7-018-89) (fig.2)”

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(fig.2)

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(fig.3)

(fig.4)

The nature of dye allowed to construct penetrants, which includes such opposite on the

properties komponents, as water and kerosene,

lubricants and alcohol et cetera. Materials and

technology of finding out microflaws of

submicrometer sizes are as a result developed

including on the rough surfaces (fig.4). The specialists

of “NIKIMT” are set high radiation firmness of

penetrant “PC-KOLOR”, that allowed him to use it

for distance televisional non-destructive control of

elements of the 1st contour of nuclear reactors systems.

In SE “KOLORAN” the production of dye penetrans“PC-KOLOR” is organized, which during 20 years

apply on domestic and foreign NPP.

Harmlessness and ecological safety of

penetrants “PC-KOLOR” is confirmed the

sanitary-hygenic conclusion of Ministry of

helth safety of Ukraine, in obedience to

which they can be applied including infood industry (fig.3).






1.2. Development of high temperature dye penetrants.It was executed within the framework of project “SHOYAT” (System of storage of exhaust nuclear

fuel) with the purpose of leadthrough of capillary control of the weld-fabricated container for storage

of exhaust nuclear fuel (fig.5).

(fig.5)

(fig.6)

In accordance with developed in welding

Institute, named by E.O. Paton technology of

assembling the lid of such container is welded

on in a few passage-ways, after each check up

the hot welding by capillary method. Therefore

SE “KOLORAN” elaborated materials and

technology of the high temperature dye

penetrant control , which are also produced by

our enterprise. All park of containers, set to the

present on Zaporozhia NPP, passed non-destructivecontrol with the use of high temperature “PC-

KOLOR” dye penetrant (fig.6).






1.3. Development of means for leakage revealing in the “tank for keeping of boric acid

solution”.

One of elements of the system of safety of NPP is the so-called “tank of boron”. It is intended

for storage of plenty of water solution of boric acid, applied in an emergency situation for stopping

out nuclear reaction. A “tank of boron” is a hall, facing by stainless steel with 8-10 mm thickuess. In

connection with the use of the hand welding ther quality of the weld-fabricated connections, as a rule,

is unsatisfactorily. And the considerable losses of solution of boric acid which gets in the drainage

system appear because of presence of large number of through defects, and then it comes outside of thestation. Thereby there is radiation contamination of environment. Thus possible norms on losses from

the system of the coniferous “tank-boron” arrive at hundreds of litres per a day.

Therefore the task to develop effective and simple method leakaze revealing of “tank of

boron” was put before SE “KOLORAN”. This task we succeeded to decide within the framework of

capillary method of non-destructive control, developing compositions, chemically reactive on water

solution of boric acid. Such “developer” is inflicted on the weld-fabricated joints into a tank after

removal of solution and drying of surface. Penetrant-solution of boric acid takes out by developer

from defects. The painted indicator “trace,”, appears as a result of chemical reaction and defect could

be find out. The offered method is comfortable and practically does not influence on the technology of

exploitation and repair and is not expensive. During the row of years it is used on Zaporozhia NPP

in the process of the planned repair of “tank boron”.

(fig.7)

1.4. Development of facilities of

magneto particles inspection (MPI).

From 1989 our enterprise together with

the department NDT of the Institute of

welding, named by E.O. Paton, is

engaged in creation of new technologies,

rigging and materials for MPI.

We produce modernized devices on

permanent magnets, which are completedwith standard specimens the calibrateddefects and materials for MPI. Many years

they used on NPP during exploitation and

repair.






1.5.Application of thermography for control of internal corrosion and thickness of pipelines.

All examples of works described higher, executed SE “KOLORAN” for non-destructive control of

systems of NPP, are based on visual registration of defects with the use of different materials and

devices. Therefore fully appropriately, that for control of wear of pipelines NPP we applied a IR

apparatus, allowing to register the thermal field of object.

Presently the basic method measure of walls thickness of pipelines because of corrosive-

erosive wear is ultrasonic method. It is supposed by the contact of sensor with the surface of pipeline, I.e. local sampling test, that reduces his productivity sharply.

(fig.8)

In conditions of OP “Zaporozhia NPP”

pipelines, tested earlier by UT melhod, were

inspected. Application of thermography

confirmed thickness lost of wall of pipelinesconfidently (fig.9). By IR-thermografhic

control it is possible to find out corrosive

shells and thickness lost of walls a depth

more than 40 % of wall thicknesses, I.e. it is

confirme that sensitiveness IR thermografhic

control is higher of sizes of defects, possible

for secure work of pipes.

(fig.9)

In the letter of SE NAEK “Energyatom” is confirmed expedience of further works on

application of thermography with the purpose of exposure of corrosive-erosive damages and

prognostication of remaining resource of equipment and pipelines of NPP.

This failing allows to remove application of IR

method. In process, executed jointly with the

Kharkov National university of radioelectronics,

the specimen of imperfect pipelines, cut out

during repair of constructions OP “Yuzhno-

Ukrainian NPP, were investigatied” (fig.8). The

got results confirm the conclusion of foreign

researchers about perspective of application of

thermography for non-destructive control of

erosive-corrosive shells and lost thickness of

pipeline’s walls.






1.6. Finding out flows in the system of pumpings aggregates of GNC- 195 M.

Impermeability of many aggregates and systems of NPP is a necessary for their normal

operating condition. A prime example, confirmative it, is the system of cooling of engine of VASES –

215 pumpings aggregates. From bad quality of welding of pipelines and loss of cooling liquid –

lubricant repeatedly there was a situation, fraught a fire at the station. In this connection before

SE “KOLORAN” the task of timely discovery of losses of heat exchage material from the system ofcooling of engine of pumpings aggregates OP “Yuzhno-Ukrainian NPP” was put.

For the decision of task of verification of impermeability of the systems of cooling of electric

motor we use the method of luminescent penetrants. A luminofor , which will well dissolve in

lubricant and possesses a quantum output near to one, was synthesized. The offered luminofor and

penetrant on it basis behaves to the IV class of toxic substances (R6M 12.1.005-88). Addition in an

amount 1-3 grammes of luminofor on the litre of lubricant provides visual registration of leakade with

a high sensitiveness (PNAE G-7-019-89 the “Compatible methodic of control of basic materials,

weld-fabricated connections equipment and pipelines of NPP. Control of impermeability), that allows

in shot time to find out the losses of lubricant from the system of cooling of electric motor and

eliminate possibility of origin of fire.

1.7. Non-destructive control of pipes of NPP heat changers.

A question about a discovery and repair of through defects gets up during exploitation of NPP

heat exchange apparatuses (condensers, air cooling et cetera). So during work of turbine steam is

condensed on heat-exchange tubes, which, form a cooling surface that divides steam and aquatic parts

of condenser. During exploitation due to corrosion and erosion the thin-walled tubes maden from a

copper-nickeliferous alloy are easily damaged and the “bouquet” of admixtures, presented in cooling

technical water, contaminates info a runback. Thermophysical descriptions of steamgenerator get

worse as a result.

Yet more sharply the question of control of impermeability stands during exploitation of MCP

(main circulation pump). The electric motor of pump cools down by air. Air cools down in air cooling by technical water from a pond-cooler. Under influence of erosive-corrosive processes in pipe walls

through defects form (fig.10, 11). As a result water gets on the puttee of electric motor, that results in

a short circuit.

(fig.10, 11)






Therefore extraordinarily important for providing of effective work of heat changers is an

exposure of the initial stages of forming of through defects.

To that aim SE “KOLORAN” and NPP department of Welding Institute, named by

E.O. Paton, offered equipment and technology, allowing to conduct monitoring of the state of art of

heat-exchange tubes and timely discovery of mikroleakages in tubes walls. For this purpose we use

complex apporoach of NDT by:

– “Acoustic Eye” defectoscope (fig. 12,13), which allows to detect such defects as

pitting, erosion, leaks, blockages and so on. Inspection time of one tube independently

of it’s longitude and diameter is about 30 second due to computer programme,

– virtual Eddy current defectoscope “Wirlwind” (fig.14), which allows to confirm

defect’s presence and was elaborated with special computer programme,

– examination of defects by use in addition an endoscope, which produced by ourselves

(fig.15,16). By such device it can be examined inside wall of the tube, during Eddy

current testing,

– define leaks by“pipe leaktester” (fig.17. 18), which is based on manomentry method.

Such complex intends for quick testing of heatexchager with exact definition of defect’s type

(fig. 12) (fig. 13)

(fig.14)






(fig.15) (fig.16)

(fig. 17) (fig. 18)

2. Repair of imperfect heat-exchange tubes.For the removal of defects of tubes constructions State Enterprise “KOLORAN” offered the

followings non-standard technologies.

2.1 Repair of through defects by the method of soludering. The method of soldering of defects found

application mainly for repair oil and gas pipelines without their stop. It is suggested to use this method

by us for repair of heat-exchange tubes in the case when access is impossible to the outward surface. A

mikroheating element is for this purpose constructed combined with a device for causing of lowtemperature solder (<1000 C), such instrument allows to conduct the removal of flows inside tubes.

2.2.Repair of through defects with the use of anaerobic sealants.

Many repair tasks, arising up in the process of exploitation of equipment NPP, can be decided

with the use of polymeric anaerobic compositions. These materials widely use in an aviation and

rocket production, on a railway transport, in shipbuilding et cetera. Liquid in the initial state polymeric

compositions harden in absence of air, for example, in through defects (flows), in screw-thread

connections et cetera Thereby, for example, they can be used and as effective glue.

In connection with that at tubes repair access to the surface is possible only from the side of pipe board, we are offer technology of repair of through defects in the walls of tubes by imposition on the

area of defect from within a compression, fixed on-the-spot anaerobic glue. For realization of such

technology we developed a device, pinning and gluing pressure-sealing material to the internal

surface of tube (fig.19).






(fig. 19) (fig. 20)

As a result of setting of experimental party of compressions on tubes defects of condenser TG K-

1000-60 OP “Zaporozhia NPP” was confirmed perspective of this method of repair of through defects

of heat-exchange tubes.

2.3. Application of electrochemical coverages for anticorrosive and antierosive defence and

repair of constructions of NPP.

It was suggested by us for protecting from erosion to inflict on an internal surface electrochemical

coverage, containing nanoparticles of diamond. Technology of causing of such coverage is developed

for an internal tubes surface. On fig.20 the sight of tube is presented with the protective coverage.

At the thickness from 10 to 30 mkm protective cover possesses mechanical durability, which exceeds

durability of tubes alloy.

The results of researches of physical and chemical properties of protective cover are below

resulted.

Research objects:8 metal-backer coverages on the standards of alloy of 6UNIVE and electric copper, differentiating

between itself by terms of causing, closeness of current, temperature of electrolyte, composition of

electrolyte, lining type and presence of antifactious additions.

Research methods:

Physical and chemical descriptions of the presented standards were tested in a laboratory ondevelopment of paint and composition materials of firm ISI by a personnel, passing the special

preparation for work on an equipment, answering the standard of ASTM.

Description of exclusive methods is resulted in protocol of tests and in an appendix with

description of methods and applied devices.

The results of tests are resulted in the enclosed protocol.

PROTOCOL

of tests of standards of sheeting on copper plate.

Methods of tests.[1] – Thickness of coverage is measured the electronic gaugemeter of DUALSCOPE MP 40 with the

measuring head of ED of firm Helmut Fischer Gmbh+co.KG in the mode of Nc/nf (cover on

unmagnetic conducting plate). Note. The unevenness of thickness of coverage exceeds 100%. In the table of results the thickness of

area of coverages is indicated on which a test was conducted on elasticity. [2] – Adgeziya of coverage

to copper plate is measured on ASTM D 3359-02 Standart Test Methods for Measuring Adhesion to

by Tare Test. (Higher index – 5 marks correspond an index 1.1 for GOST, a worst index is 0 marks). A






test is conducted with the use of device of Cross-cut-tester Model 5120 firms of BYK- Gardner and

ribbons of Scotch 898.

[3] – Hardness of coverage is measured on ASTM D 3363-00 Standart Test Methods for Film

Hardness by Pencil Test with the use of set of slate-pencils of PH 5802 firms Byk-gardner. Hardness

of Scratch is indicated in the table of results of tests (marings).

[4] – Elasticity of coverage at squeezing out is measured on the method of firm Erichsen GMBH with

the use of device of Erichsen Midel 202 C. By character * results are indicated where destruction of

copper plate had happened.

[5] – Firmness of coverage to the abrasive wear by means of bombardment a shot is tested on themethod of firm Erichsen GMBH on the device of Stone Hammer Blow Testing Instrument Model 508.

The scale of estimation includes 10 degrees from 0-1 (higher estimation) to 5 (the worst result). In a

table the results of estimation of degree of damage of coverage after bombardment of 1 kg of cast-

iron shot are indicated during 20 with at accelerating pressure of 2 Barins.

Results of tests.

Index Method Values of indexes for the standards of coverages

1 2 3 4 5 6 7 8

Thickness of

coverage, mkm[1] 10,2 28,4 17,6 18,6 19,4 20,1 29,5 19,9

Agdeziya ofcoverage, mark

[2] 5 5 5 5 5 5 5 5

Hardness on a

graphite scale[3] Higher

10G

Higher

10G

Higher

10G

Higher

10G

Higher

10G

Higher

10G

Higher

10G

Highe

10G

Elasticity at

squeezing out, mm[4] 9,4 6,9 8,2 2,3* 3,8* 7,9* 6,3* 8,9

Firmness to theabrasive wear,

mark the

[5] 1-2 1 1 1 1-2 1-2 1 1-2

Abrasive wear in a

water environment[6] 2 1-2 1-2 1-2 2 2 1 2

The tests showed stability of sheeting by 5 % Nacl during 120 hours.Conclusions:On the basis of the got results, most preferable to application pilot-scale, there is a standard of

coverage 7, rotining the greatest ball at the tests of abrasive firmness in a liquid environment, here

possessing mechanical durability higher than durability of alloy.

Thereby causing of the developed electrochemical coverage provides the assured defence of

metal of heat-exchange tubes.

Corrosion and erosion protection of equipment NPP.Along with development of the new high-efficiency means of anticorrosion defence our

enterprise produces and supplies customers on NPP with exclusive paints, including radiation-proof

coverages and protective materials of the special purpose.

As an example it is possible to point materials for preservation of the weld-fabricated connections onthe period between repairs. On existent technology before the leadthrough of the planned non-

destructive control of the weld-fabricated connections one must conduct their mechanical cleaning.

Thus you damage the roller of strengthening of the weld-fabricated connections.

On a task the laboratory of metals SD “Zaporozhia NPP” by our enterprise was developed

technology of preservation of the weld-fabricated connection on the period between repairs. For this

purpose after the leadthrough of next cycle of non-destructive control the weld-fabricated sutures

protectes by heat-resistant (to 3500 C), moisture-proof coverage, which guarantees a corrosion

protection up to next repair (on 1-4 years).

To form such cover we form special heat-resistent defence, which is firmed in radiation’s

conditions.






(fig. 21)

All described works demand for the realization fundamental testing and metrology base. In this

connection at SE “KOLORAN” was created and accreditated testing laboratory (fig. 22), and also

attestation of SE “KOLORAN” was conducted as the Head metrology service the National academy

of sciences of Ukraine (Certificate k 2T – AN from 17.03.2008 fig. 23).

(fig.22) (fig.23)

Conclusions:

1. The results of works, executed by State Enterprise of “KOLORAN” IPC NAN of

Ukraine on the requests of enterprises of atomic industry, resulted in a report are inserted

to a branch documents (Universal methodice PNAE G-7-18-89, PNAE G-7-19-89) and

used in the process of exploitation of NPP.During 20 year state enterprise “KOLORAN” is the leader of Ukraine in elaboration and

*roduction of different means for Non-destructive testing, repaire and defence of NPP

constructions.

Before next repair a “cocoon” easily retires

(fig.21) and control is conducted without

mechanical cleaning. Such technology,

guarding the weld-fabricated sutures, got a

high estimation on Zaporozhia NPP.Anticorrosion defence of weld-fabricated

connections was applied during several years

in industrial condition.

At the working temperature of the weld-

fabricated sutures less than 1000 C we

suggest to use for preservation between

repair’s period heat-shrinkage tapes.






2. In obedience to the letter of the 1th Vice-president of State Enterprise NAEK

“Energyatom” expedience of continuation of works of SE “KOLORAN” is confirmed on

development of the systems of diagnostics and monitoring of the state of equipment and

pipelines of NPP with the use of thermography and interest in their introduction in

subdivisions of NAEK “Energyatom”.

3. Developed by SE “KOLORAN” technical decisions in area of diagnostics of the state,

repair and defence of heat-exchange tubes of condensers and cooling systems of NPP gotthe positive estimation of the World association of organizations, which use the atomic

stations. In the decision of Seminar of specialists of VAO NPP from 25.11.2009 (Odessa)

perspective of the offered solutions is marked for the corrosion and erosion protection of

heat transfer surfaces of condensers of turbines.

Documents

REVIEW OF ELABORATIONS, EXECUTED FOR INDUSTRY’S ENTERPRISES BY STATE ENTERISE “KOLORAN”