3nd International Conference on NDE in Relation to Structural Integrity for Nuclear and Pressurized Components, Nov 14-16, 2001, Seville Spain

X-Probe ^ฎ Summary

• X-Probe: bobbin coil + high-density, high-speed ECT array
• 40x faster than rotating probes (20”/sec. at 32 samples/inch)
• Non-contact coils, no mechanical rotation or motors: 10 to 50x life of a surface-riding rotating probe
• Analysis similar to that of rotating probe, from color 3D views and familiar Lissajous plot
• X-Probe significantly reduces inspection time, consumable costs, and radiation exposure dose with minimal tradeoffs
• 17 field trials, all successful; no inspection transients
• Trials performed in all tube sizes (0.5”, 5/8”, 3/4”, 11/16”, 7/8”) and all tube regions, including low-row u-bends.
• Appendix H Qualified

Fig 1:

What You See Is What You Get!

• Excellent discrimination between circumferential and axial indications. Easy call on intersecting flaws
• Excellent resolution and separation on axial flaws
• Correct calls on closely spaced parallel axial flaws which could be otherwise easily confused with a circumferential flaw

Fig 2a:

Fig 2b:

Fig 2c:

X-Probe ^ฎ : How Does It Work? (1/2)

• Transmit-receive coils offer directional sensitivity
• Clear separation of circumferential and axial indications, even in the case of intersecting flaws
• Transmit-Receive reduces interference from expansion transition
• Lift-off only affects amplitude, not phase
• Drawings courtesy of AECL

Fig 3a:

Fig 3b:

X-Probe ^ฎ : How Does It Work? (2/2)

Fig 4a:

Axial flaw detection (36 channels for 7/8” design)

• Transmit from C₁ to A ₁ to get a first axial measurement
• Transmit from C ₁ to A ₂ to get second axial measurement from same emitter

Circumferential flaw detection (36 channels for 7/8” design)

• Transmit from B ₁ to B ₃ = 18 Absolute circumferential channel
• Transmit from C ₁ to C ₃ = 18 Absolute circumferential channel (total: 36)

Fig 4b:

• Step and repeat 6 times, 3 poles at a time, at over 38,000 RPM

Calibration

• Bobbin: Calibrate using normal cal. tube: 20% and 60% OD FBH, 100% hole, 20% OD Groove, and 20% ID groove
• Array: Requires 30% OD groove and rolled expansion.
• Other calibration flaws will be required for sizing techniques
• Calibration rotates expansion signal to horizontal (all channels) and sets amplitude with OD groove (all channels)
• Complete calibration takes less than a minute
• Expansions and dents produce horizontal signals whereas all other indications produce a vertical signal

Fig 5a:

Fig 5b:

Analysis

1. Four frequencies: Use 200 to 300 kHz absolute channels for detection, other frequencies to confirm or size
2. Two plots are created for each frequency, one showing axial indications and the other showing circumferential indications
3. Calibration rotates expansion signal to horizontal and sets amplitude with OD groove (all channels)
4. Expansions and dents produce horizontal signals. All other indications produce a vertical signal
5. Cracks produce vertical signal component on either axial or circumferential channels, depending on their orientation
6. Volumetric indications (wear, IGA, pitting, MBM) produce vertical signal component on both axial and circumferential channels; Cracks at IGA clearly show up as crack-like indications
7. Copper, ferromagnetic, and sludge OD deposits produce negative signal component on axial and circumferential low-frequency channels
8. Magnetic deposits generate weak negative signal component on both axial and circumferential low-frequency channels

Fig 6: ID Axial SCC at Tube Support Plate

Fig 7: Circumferential PWSCC within TSP

Fig 8: Shallow OD Circ. SCC vs. Tube Deformation

Fig 9: Circ. Cracks with Multiple Axial SCC at TTS

Fig 10: Axial PWSCC at Dented Intersection

Fig 11: Volumetric Flaws: Pitting

Fig 12: Volumetric Flaws: Wear Scars at Supports

Volumetric Flaws: Wear Scars at Supports

• Field data from OTSG
• Volumetric indications appear on both axial and circumferential channels

Fig 13:

Fig 14: MBM

Fig 15: Deposits or PLP

Fig 16: Axial Flaw at MBM

Fig 17: Performance in U-bends and Square-Bends

Fig 18: Performance at Tube Ends

Fig 19: Small diameter X-Probe for 5/8” CANDU

Fig 20: Phase Spread

Fig 21: Filtering techniques

Automated data screening

Fig 22: Automated data screening

Fig 23: Resolution: X-Probe Vs. rotating probe

• Data screening software presently under independent development by Westinghouse, Argonne National Labs, and R/D Tech

X-Probe Construction

• X-Probe is many probes in one:
  • Bobbin coil probe
  • Multi-channel profilometry probe
  • High resolution Transmit-Receive ECT array
    – 3x18 (7/8”)
    – 3x16 (3/4”, 11/16”)
    – 3x14 (5/8”)
    – 3x8 (0.5”)
    
• Probe life similar to that of a bobbin probe
• Passes 6” radius U-bends with special version for low-row U-bends

Fig 24a:

Fig 24b:

Fig 24c:

X-Probe Model for Low-Row U-Bends

• Capable of inspecting rows 1, 2, and 3
• Excellent performance demonstrated in field conditions.
  • Much higher probe life
  • Considerably speeds up inspection
  • Reduces waste & radiation exposure dose

Fig 25a:

Fig 25b:

Fig 25c:

X-Probe Model for Low-Row U-Bends

• Capable of inspecting rows 1, 2, and 3
• Imperfect centering in U-bend shows extrados vs. intrados in C-scan
• Excellent performance demonstrated in field conditions.
  • Much higher probe life
  • Considerably speeds up inspection
  • Reduces waste & radiation exposure dose

Fig 26a:

Fig 26c:

Fig 26b:

MultiView Software

• Data acquisition and analysis software for bobbin, rotating, and array probes
• Runs under Windows NT or Windows 2000 on standard PCs, (500 MHz Pentium III with 256 MB RAM, for dual X-Probe)
• Supports ANSER, EddyNet, and RDTIFF formats (bobbin and RPC)
• Automatic landmark detection
• Conditional data recording
• Automatic data screening (Fall 2001)
• Documented software interface to manipulator and probe-pusher controllers
• Fast probe calibration:Bobbin, rotating probes, and X-Probe: All channels and mixes, in under 1 minute!

Fig 27a:

Fig 27b:

TC7700 Data Acquisition System

• Very powerful 8-frequency tester
  • Dual X-Probes array at 20”/sec.
  • Up to 4 conventional probes (bobbin, RPC, MRPC, RG3-4, +Point, etc.)
  • Up to 2,560 high-speed channels
• Meets worldwide requirements
  • Meets or exceeds all EDF, ASME, and Japan’s JEAG 4208 requirements
  • Meets the requirements of rev. 6 of PWR SG Examination Guidelines
  • CE marked
• Non-multiplexed, multiplexed, and Super-Multiplexed^™ operation
• Quad encoder interface allow for encoder-based data acquisition
• Very low noise electronics and high noise immunity
• Industry standard 100Base-T Fast Ethernet
• Bobbin and rotating probe data compatible with EddyNet, ANSER, and MultiView
• Built-in real-time alarms, allows automatic probe pusher start/stop on exit
• System self-test feature for quick diagnostic
• Four independent coil drivers with separate excitation
• Wide range coil auto balance
• Option to operate multiple probes fully independently from each other

Fig 28:

Fig 29:

TC7700 Conditional Data Recording

• Position-dependent recording
  • This feature limits the collection of high resolution data to the zones of interest. Example: Array inspection may be limited to special interest zones (ex: supports and TTS, as shown in red color)
  • Allows bobbin and high-resolution inspection to be performed in a single pass
  • Requires MultiView software
  • Sample file sizes for different settings:
    – Full length data acquisition, bobbin only: ~1 MB
    – Full length with both array and bobbin: ~40 MB
    – Array at intersections & full length bobbin: ~4 MB
    – Array and bobbin for 20” TTS: ~1 MB
    

Summary of 1999-2000 field experience

#	Plant (type)	Date	Scope / comments	P
1	Takahama 2 (W)(Japan)	10/1999	Dual probing of 2x 400 tubes full length, including row 4 U-bends.Excellent probe life demonstrated	2
2	Palo Verde (CE)	01/2000	Inspection of highly ovalized square bends. PID of +Point indications. Good detection near tube ends	1
3	Gentilly 2	04/2000	100 tubes, full length	1
4	Do๋l 2 (W)(Belgium)	05/2000	5,600 tubes over 40”. Averaged 100 tubes per hour and per probe with automatic acquisition	2
5	Bruce (CANDU)	10/2000	315 tubes (0.510” OD), full length (~25m long) high-resolution. Less than 2 minutes / tube	1
6	Watts Barr (W)	10/2000	PID of +Point indications at 24 intersections	1
7	Palo Verde (CE)	10/2000	200 tubes over 18’ long, in square bend and horizontal area. Less than 1 min per tube with dual probing. Also acquired 4 tubes over full length, including U-bend	2
8	Salem (W)	10/2000	PID of 301 intersections from over 200 tubes. Data collected on the hot leg from the cold leg; data parsing	1
9	SONGS (CE)	11/2000	PID of +Point indications at 36 intersections, some dented. Data collected on the hot leg, inspecting from the cold leg	1
10	Oconee (OTSG)	12/2000	PID on 94 tubes (mostly at the upper end of the generator) from the lower end	1

Summary of 2001-2002 field experience

#	Plant (type)	Date	Scope / comments	P
11	Bruce (CANDU)	04/2001	Candy cane inspection of 110 tight-radius tubes (0.5” OD) with heavy magnetite deposits, in 3 hrs and with single probe. 60 hrs with +Point	1
12	ANO 1 (OTSG)	04/2001	160 tubes, air to air. Some issues with wear of probe centering device which have been corrected since.	1
13	Comanche Peak	04/2001	PID on 55 tubes with TTS circ flaws, DSIs, FS dings/dents, volumetric flaws and MBMs. 55 tubes in just over 4 hrs	1
14	Gentilly 2	04/2001	111 tubes with X-Probe. Some OD deposits at SP9	1
15	Argonne mockup	09/2001	Inspection of Argonne mockup tubes with X-Probe	1
16	Crystal River	10/2001	PID on 105 tubes	1
17	TMI	10/2001	PID on about 180 tubes in SG “B” and 70 tubes in SG “A” over 20 feet, with rate of 130 tubes per hour (single probe)	1
18	Bruce 6 (CANDU)	03/2002	Inspection of 620 tight radius U-bends at 10 ips. 150 - 200 tubes per shift (+Point ~ 20 tubes per shift). 3 probes lost to mishandling	6
19	Ginna	03/2002	169 tubes in replacement SG: 34 full length and 135 tubesheet exams (TTS + 4" to the tube end) in about 2 hrs. MBM, denting, deposits	1
20	Bruce 4 (CANDU)	Delay’d	Official inspection of TBD tight radius U-bends. XX tubes per shift.	?
21	Gentilly (CANDU)	05/2002	Inspection of ?? Tight-radius U-bends
22	Gentilly (CANDU)	05/2002	100% inspection of tubes in leaky HX.
23	Bruce 3 (CANDU)	06/2002	Inspection of 202 tight radius U-Bends in two boilers	1

Do๋l inspection statistics (May 2000)

Parameter	Steam Generator A		Steam Generator B
Probe Type	+Point	X-probe	+Point	X-Probe
Number of tubes and Inspected length (TS)	+Point not used on SG “A”	2,970 tubes TE+31”	2,670 tubes 600 mm (24”)	2,670 tubes TE+31”
Number of tubes (straight & U-bends		55	0	0
Axial density (points per inch)		75 ppi	75 ppi	75 ppi
Insertion speed		500 mm/s (20”/s)	300 mm/s (12”/s)	500 mm/s (20”/s)
Pull speed		170 mm/s (7”/s)	12.5 mm/s (0.5”/s)	170 mm/s (7”/s)
Rotation speed		Not applicable	750 RPM	Not applicable
Inspection time TS area only		37.5 hrs	122 hrs	27 hrs
Probes used		1 (TE+31”and U-bends)	14 (TTS only)	1 (TE+31”)

Framatome ANP’s evaluation

• An independent X-Probe evaluation, published by Framatome ANP presents probe performance evaluation on various ID and OD axial, circumferential, volumetric flaws, and IGA in different conditions
  
  X-Probe ^ฎ Experience and Capabilities; Barry Everett (Framatome ANP); 2001 EPRI Steam Generator NDE Workshop
• Framatome’s conclusion
  • X-Probe and associated analysis technique offer good flaw detection for all the flaw types covered in the study
  • Some issues are to be addressed before deployment of the probe on an industrial basis. Most points have been addressed since
    

    – Single operator acquisition	Now available
    – Fast analysis	Now available
    – Resolution software	Now available
    – Cal group control	Now available
    – Analyst training	Now available
    – Performance tracking	Available summer of 2002
    – Historical comparison	Available summer of 2002
    – Full data recall	Available summer of 2002

EPRI Qualification Status

• Current Appendix H Qualifications
  • ETSS 20400.1, 20400.2: X-Probe OD circ indications at expansion transitions
  • ETSS 20402.1, 20402.2: X-Probe OD axial indications at support structures
  • ETSS 20403.1, 20403.2: X-Probe OD axial indications in freespan
  • ETSS 20500.1, 20500.2: X-Probe circ. PWSCC 0.054" at expansion transitions,
  • ETSS 20501.1, 20501.2: X-Probe axial PWSCC 0.054" at expansion transitions
  • ETSS 20502.1, 20502.2: X-Probe axial PWSCC at <2V dented supports
• Future Appendix H qualifications
  • Qualification of low-row version
  • Qualification for square bends
  • Qualification of 3x16 version for 7/8” tubes
  • Qualification for detection and sizing of pitting, AVB wear, and thinning wear
  • Qualification for ODSCC sizing
  • Qualification for use in CANDU NPP underway at AECL

Next Steps

• Further optimize software for production
• Rev. 6 compliance, including real-time data quality verification (2002)
• Formal training programs for acquisition and analysis
• Additional probe qualifications: sizing techniques, low-row U-bends
• Automated data screening trials and refinements (prototype ready)

Acknowledgements

• Val Cecco, Laura Obrutsky and the team of AECL
• NEL (Japan) and EPRI for their outstanding contributions
• EDF and MoreTech for their participation and encouragement throughout the development

Summary and Conclusion

X-Probe benefits


• Qualified to appendix H
• All significant trial issues resolved. No inspection transients expected. Excellent positive identification of deposits
• Significant reductions of inspection time, consumable costs, radiation exposure dose, and contaminated waste
• 10 to 20x faster than rotating probes
• Allows reduction of on-site personnel and equipment; allows high-resolution inspection of cold leg from hot leg

When to use X-Probe?


• To significantly reduce time / cost of low-row U-bend exams
  • CANDU, Square bends, low-row U-bends
• Whenever cost of rotating probes is significant
• Whenever inspection time with rotating probe is significant

References

1. New Generation ECT Array Probe and System as High Speed Alternative to Rotating Probes; G. Lafontaine (R/D Tech); 18th Annual EPRI Steam Generator Workshop
2. Transmit-Receive Probes: “The Next Generation”; L. Obrutsky, V. Cecco, R.Lakhan, and S. Sullivan (AECL); 18th Annual EPRI Steam Generator Workshop
3. The result of Comparative Tests for a New High-Performance Multi-Array Probe; Y. Harada, K. Maeda, J. Shimone, Y. Kishi (NEL); 18th Annual EPRI Steam Generator Workshop
4. Array Probe for Steam Generator Tubes; G. Henry (EPRI); 2nd Int’l Conference on NDE in Relation to Structural Integrity for Nuclear and Pressurized Components
5. New High-Performance ECT Array Probe for Steam Generator Tubes; K. Maeda,Y. Harada, et al. (NEL); 2nd Int’l Conference on NDE in Relation to Structural Integrity for Nuclear and Pressurized Components
6. X-Probe examinations; Doug Hansen (Arizona Public Services, Palo Verde Nuclear Generating Station); TAG meeting SLC - 2001
7. Palo Verde Experience with X-Probe; Douglas Hansen (Arizona Public Service); 19th EPRI Steam Generator NDE Workshop, Monterey, California, July 9-12, 2000
8. X-Probe^™ ECT array: A high-Speed Replacement for Rotating Probes; Guy Lafontaine, Florian Hardy, Joe Renaud, Paul Malette (R/D Tech); 19th EPRI Steam Generator NDE Workshop, Monterey, California, July 9-12, 2000
9. Field Experience and Detectability Test of High Performance ECT Array X-Probe in Japan; Yutaka HARADA, Kotaro MAEDA, Junri SHIMONE, Yasutada KISHI (NEL); 19th EPRI Steam Generator NDE Workshop, Monterey, California, July 9-12, 2000
10. The Dream is Alive: Field Experience with the X-Probe at the Do๋l 2 NPP; Raymond De Graeve, Olivier Scauflaire (Laborelec); 19th EPRI Steam Generator NDE Workshop, Monterey, California, July 9-12, 2000
11. SPNR^™ (Spinner) Probe- Long-life, high-performance rotating probe; Joe Renaud, Paul Malette, Guy Lafontaine, Curtis Fogal (R/D Tech); 19th EPRI Steam Generator NDE Workshop, Monterey, California, July 9-12, 2000
12. X-Probe ^™ : Eddy Current Array Probe as a High-Speed Alternative to Rotating Probes; Rich Guill, Gary Henry (EPRI); EPRI Centerlines Newsletter, Volume 10, No. II
13. X-Probe^™ ECT array: A high-Speed Replacement for Rotating Probes, an update; Guy Lafontaine, Florian Hardy, Joe Renaud, Paul Malette (R/D Tech); 20 th EPRI Steam Generator NDE Workshop, Orlando, Florida, July 2001
14. X-Probe^™ ECT array: A high-Speed Replacement for Rotating Probes, an update; Guy Lafontaine, Florian Hardy, Joe Renaud, Paul Malette (R/D Tech); 20 th EPRI Steam Generator NDE Workshop, Orlando, Florida, July 2001
15. X-Probe ^™ Experience and Capabilities; Barry Everett – Framatome ANP; 20 th EPRI Steam Generator NDE Workshop, Orlando, Florida, July 2001
16. X-probe^™, The year in review: Qualification and field trial experiences from the fall 2000 / spring 2001 inspection seasons; Joe Renaud (R/D Tech); 20th EPRI Steam Generator NDE Workshop, Orlando, Florida, July 2001
17. X-Probe^™ Experience and Capabilities; Barry Everett (Framatome ANP); 2001 EPRI Steam Generator NDE Workshop

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