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VNIIAESVNIIAES, 109507,, 109507, Moscow,Moscow,FerganskayaFerganskaya strstr.,., 2525
EE--mailmail:: baranenkovi@[email protected]
[email protected]@erec.ru
IAEA Technical Workshop Erosion-corrosion wear including flow
accelerated corrosion (FAC) and environmentally assisted racking (EAC)issues at nuclear plants
April 21-23, 2009, Moscow, Russian Federation
VNIIAES V.I. Baranenko
On Development and Implementation of Normative Documentation on Evaluationof Technical Status and Residual Life of NPP Pipelines
Subjected to Erosion-Corrosion Wear
VNIIAES
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Developed Normative Documentation
on Erosion-Corrosion Wear (E/C) 1. Software ECI-02. ECI-02 software registration and qualification
certificate date is 17.03.2003, passport issued 19.09.2003.
2. Software ECI-03. ECI-03 software registration and qualificationcertificate date is 17.03.2005, passport issued 23.06.2005.
3. Guidelines Norms of permissible thickness for pipelineelements from carbon steel at nuclear plants RD EO 0571-2006. Putinto force in 01.11.2006.
4. Methodological instruction Analysis of steel chemicalcomposition by spectral and photoelectric method. Pipelines andcomponents at power units 3&4 of Novovoronezh NPP .
27.18.05.010-2004. Methodological instruction. Agreed byM.Miroshnichenko, Director of nuclear plant safety control departmentof Federal Service on environmental and nuclear inspection,25.11.2004.
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Factors Considered by the Software Tools
Software tools consider erosion-corrosioninfluence of the following factors:
water chemistry indicators (type of amine applied,water , oxygen content in water);
parameters of mode (water velocity andtemperature);
content of chemical elements in pipeline metal(chromium, molybdenum and copper);
pipeline geometry (inner diameter, wall thickness,Keller factor);
duration of operation (start and finish of pipelineoperation).
steam wetness (for ECI-DS software)
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Software Possibilities
ECI-OS & ECI-DS software allows for:
Data input for calculations;
Checking correctness of data input; Calculations of initial, final and average rate of E/C and wall
thinning for a defined time period
With one set of initial parameters;
With many sets of initial parameters (one or two variableparameters);
Output calculation results in graphs and tables:
to display;
to printer;
to file; Adjust graphic presentation of calculation results;
Get help working with a software.
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Dialog Box of ECI 02.1 Software
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Example of Calculations by
ECI-02.1 Software
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Comparison of Calculation Results by
ECI-01 Software with Operating Measurement Data of Wall
Thinning in Feedwater Pipelines
Measurement, mm
Calculation,m
m
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RD EO 0571-2006 Guidelines
Permissible thickness of pipeline elements
from carbon steel at nuclear plants.Put into force 01.11.2006
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Erosion-corrosion wearVNIIAES
Local Wear of Pipeline Wall with Main Dimensions
Circumferencedirection
Axial direction
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VNIIAES
Scanning of Pipeline Surface Divided into Three Areas
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Permissible Depth and Length of Local Thinning Area(fig. )
Lt/
R
sr
La/Rsr
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VNIIAES
Comparison of Permissible Thickness Calculations by Developed Method and by Data
fig. A when Lt1 = 1,0, Rsr, and L t1 = 2,65RS(1,2 Guideline, 1, 2 data fig. )
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VNIIAESDevelopment of norms for permissible thinning of NPP pipelines subjected to E/C wear
Graphs Defining the Values for Permissible Thickness ofPipelines with 53028 mm Diameter
Initial dataInitial dataInitial dataInitial data Calculated valuesCalculated valuesCalculated valuesCalculated values
SteelSteelSteelSteel
typetypetypetype
OuterOuterOuterOuter
diamdiamdiamdiam.,.,.,., DDDDaaaa
(2(2(2(2RRRRaaaa)))) mmmmmmmm
Nom.Nom.Nom.Nom.
thicknthicknthicknthickn.....,.,.,.,
ssss,,,, mmmmmmmm
Temp.Temp.Temp.Temp.
tttt,,,,
InnerInnerInnerInner
press.press.press.press..,.,.,.,
,,,, MPaMPaMPaMPa
Add.Add.Add.Add.stressstressstressstress
[[[[],],],],
MPaMPaMPaMPa
Calc.Calc.Calc.Calc.
thicknthicknthicknthickn.,.,.,.,
ssssRRRR,,,, mmmmmmmm
LLLLctctctct,=,=,=,=
0.250.250.250.25DDDDaaaa
mmmmmmmm
RRRRaaaassssRRRR,,,,mmmmmmmm
LLLLcacacaca====
8888RRRRaaaassssRRRR,,,,
mmmmmmmm
20202020 530530530530 28282828 230230230230 12,012,012,012,0 130,67130,67130,67130,67 23,323,323,323,3 416,26416,26416,26416,26 76,476,476,476,4 611.4611.4611.4611.4
Circumferential defect dimension, mm
Axial defect dimension, mm
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Distribution scanning of
06- elbow wall thickness
(1996 and 2002, top andbottom correspondingly)
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Influence of Corrosion Products Deposits on
Reliability of Wall Thickness Measurements
During Operating Inspections
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1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 18 19 2 0 21 22 2 3 24 25 26 2 7 2 8
1
2
3
4
5
6
7
8
9
10
11
12
-2 ,00 --1, 75 -1 ,75 --1, 50 -1, 50--1 ,25 -1, 25--1 ,00 -1 ,00 --0, 75 -0 ,75--0, 50 -0, 50--0 ,2 5
-0,25-0,00 0,00-0,25 0,25-0,50 0,50-0,75 0,75-1,00 1,00-1,25 1,25-1,50
19961996 20002000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1
6
11
1,75-2,00
1,50-1,75
1,25-1,50
1,00-1,25
0,75-1,00
0,50-0,75
0,25-0,50
0,00-0,25
-0,25-0,00
-0,50--0,25
-0,75--0,50
-1,00--0,75
-1,25--1,00
-1,50--1,25
-1,75--1,50
-2,00--1,75
VNIIAES
Distribution of thickness change between 1996 and 2000 measurements
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VNIIAES
Elbow
NDate of
meas.
Number Values, mm Thicknessdifference range.
In different
hours, mm
Sectio
n Meas.
S,
mm
S
,
mm S, mm
Elbow
1996 31 372 12,96 20,86 7,90 1,8 3,6
Elbow
2002 30 360 13,50 18,72 5,23 1,6 2,3
Elbow
1995 33 394 13,84 19,94 6,10 1,9 2,1
Elbow
1996 29 342 13,95 20,13 6,18 2,1 2,2
Elbow
2000 29 348 13,76 20,12 6,37 2,2 2,6
Total, average
value231 2964 13,40 19,83 6,43 1,9 2,6
Date and Number of Measurements, Minimum and Maximum Values for Each
Thickness Elbow, Thickness Difference, Range of Elbow Wall Thickness Change in
Different Sections of Feedwater Pipeline with 46516 mm diameter
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VNIIAES
Wall Thickness Behavior of 46516 mm Pipeline Elbow
within the Period from 1996 to 2002 in 12th hour
Section number
Wallthickness
change,mm
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VNIIAES
Wall Thickness Behavior of 46516 mm Pipeline Elbowwithin the Period from 1996 to 2002 in 6th hour
Section number
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VNIIAESDevelopment of norms for permissible thinning of NPP pipelines subjected to E/C wear
Wall Thickness Behavior of 46516 mm Pipeline Elbowwithin the Period from 1996 to 2002 in 3rdhour
Section number
Wallthickness
change,mm
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VNIIAESAnalysis of Wall Thickness Behavior of 46516 mm Pipeline
Elbow within the Period from 1996 to 2002 in 9th hour
Wallthickness
change,mm
Section number
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Development of Normative Documentation on Secondary Circuit
Components and Pipelines Resource Management at NPPs with VVER
Thickness Distribution Graphs in 30 Sections of Pipeline Elbow. Measurement
of 11.09.2002, 46516 mm
VNIIAES
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Thickness Distribution Graphs in 29 Sections of Pipeline Elbow. Measurement
of 11.09.96, 46516 mm
VNIIAES
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VNIIAESDevelopment of norms for permissible thinning of NPP pipelines subjected to E/C wear
Generation of relatively strong turbulence Unstable position of flow axis Faster circumferential flow velocity than B-train
A-trainB-train
Unstable
(Generation oflarge turbulence)
Stable
Generation of relatively weak turbulence Stable position of flow axis Slower circumferential flow velocity than A-train
Analytical result also shows that turbulence appeared in A-train is larger than that in B-train.
Turbulent Flow Downstream of Orifice (Mihama)
D l t f f i ibl thi i f NPP i li bj t d t E/C
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VNIIAESDevelopment of norms for permissible thinning of NPP pipelines subjected to E/C wear
Degree of pressure fluctuation: A-train>B-train>Straight pipe
Characteristics of A-train: Pressure fluctuations at 0is larger than 180
Characteristics of B-train and straight pipe: No difference between 0and 180
Distribution of Pressure Fluctuation (Mihama)
Distribution of Circumferential Pressure Fluctuation
Non-dimensional pressure fluctuation= RMS of pressure fluctuation/Averaged dynamic
pressure in a pipe
Comparison of non-dimensional pressure fluctuations between A-train
and B-train (circumferential distribution at L/D = 0.8)
A-train
B-train
Straight pipe
Distribution of Axial Pressure Fluctuation
A-train
B-train
Non-dimensional axial distance (I/D)
Distribution of Non-dimensional pressurefluctuation (Comparison between A-train and B-
train)
Non-d
imensionalpressurefluctuation
Viewed from upstream
A-train pressure fluctuation at 0
A-train pressure fluctuation at 180
B-train pressure fluctuation at 0
B-train pressure fluctuation at 180
Straight pipe pressure fluctuation at 0
Straight pipe pressure fluctuation at 180
D l t f f i ibl thi i f NPP i li bj t d t E/C
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VNIIAES
1.001.001.001.00
0.950.950.950.95
0.960.960.960.96
0.850.850.850.85
0.890.890.890.89
0.900.900.900.90
0.870.870.870.87
0.960.960.960.96
LLLL////DDDD ====1111....74747474))))LLLL////DDDD ====1111....75757575
A-train B-train
Welding line
0.820.820.820.82
0.810.810.810.81
0.940.940.940.94
0.820.820.820.82
0.840.840.840.84
0.820.820.820.82
0.880.880.880.88
0.920.920.920.92
LLLL ////DDDD ====1111....74747474 LLLL ////DDDD ====1111....75757575
0.00.00.00.00.20.20.20.20.40.40.40.40.60.60.60.60.80.80.80.81.01.01.01.0
-1-1-1-1 0000 1111 2222 3333 4444 5555
LLLL////DDDD
0000
0000
0.00.00.00.00.20.20.20.20.40.40.40.40.60.60.60.60.80.80.80.81.01.01.01.0
-1-1-1-1 0000 1111 2222 3333 4444 5555
LLLL ////DDDD
0000
0000
Axial direction Axial direction
Axial wall thinning: wall thinning trends at the actual plant corresponds to pressure
fluctuation trends in visualization test.
Circumferential wall thinning: wall thinning trends at the actual unit (A>B) corresponds to
pressure fluctuation trends in visualization test (A>B).
Actual wall thinning (0side)
Pressure fluctuation in test(0side)
Welding line
Comparison Between Actual Wall Thinning and
Visualization Test (Mihama)
Actual wall thinning (L/D 1.74)
Pressure fluctuation in test L/D=1.75)
Circumferential directionActual wall thinning (L/D 1.74)
Pressure fluctuation in test L/D=1.75)
Circumferential direction
Actual wall thinning (0side)
Pressure fluctuation in test 0side
Non-dimensional
pressure
fluctuation
Non-dimensiona
l
wallthinning
Non-dimensionalpressurefluctuation
Development of norms for permissible thinning of NPP pipelines subjected to E/C wear
Development of norms for permissible thinning of NPP pipelines subjected to E/C wear
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Conclusions
1. The set of normative documents on calculation of erosion-corrosion
wear has been developed including software tools, guidelines on calculations
of permissible thickness for pipeline elements, guidelines on establishingchemical composition of pipeline metal
2. Application of normative documents provides for optimization of
operating inspection scope and frequency, evaluation of technicalstate and definition of residual life.
3. It was found that availability of corrosion products deposits
influences significantly on UT measurements reliability of pipeline wallthickness.
VNIIAES
Development of norms for permissible thinning of NPP pipelines subjected to E/C wear