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    Stress Corrosion Cracking Test Pieces For Inspection Qualification and NDT Development

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    Hyujeii Mce
    The document discusses Stress Corrosion Cracking (SCC) test pieces that are used for inspection qualification and NDT development. It describes AMEC's MISTIQ SCC process for producing test pieces with realistic SCC defects in materials like Inconel alloys. The test pieces have been used to develop online NDT monitoring techniques and evaluate methods like phased array ultrasound. A case study is presented on delivering a large SCC specimen to Japan for round robin NDT trials. Future work may include SCC test pieces for other materials and geometries to improve inspections for SCC detection.

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    Stress Corrosion Cracking Test Pieces For Inspection Qualification and NDT Development

    Uploaded by

    Hyujeii Mce
    61 views25 pages
    The document discusses Stress Corrosion Cracking (SCC) test pieces that are used for inspection qualification and NDT development. It describes AMEC's MISTIQ SCC process for producing test pieces with realistic SCC defects in materials like Inconel alloys. The test pieces have been used to develop online NDT monitoring techniques and evaluate methods like phased array ultrasound. A case study is presented on delivering a large SCC specimen to Japan for round robin NDT trials. Future work may include SCC test pieces for other materials and geometries to improve inspections for SCC detection.

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    cedworkingday17april2013-ludlow

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    The document discusses Stress Corrosion Cracking (SCC) test pieces that are used for inspection qualification and NDT development. It describes AMEC's MISTIQ SCC process for producing test pieces with realistic SCC defects in materials like Inconel alloys. The test pieces have been used to develop online NDT monitoring techniques and evaluate methods like phased array ultrasound. A case study is presented on delivering a large SCC specimen to Japan for round robin NDT trials. Future work may include SCC test pieces for other materials and geometries to improve inspections for SCC detection.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    61 views25 pages

    Stress Corrosion Cracking Test Pieces For Inspection Qualification and NDT Development

    Uploaded by

    Hyujeii Mce
    The document discusses Stress Corrosion Cracking (SCC) test pieces that are used for inspection qualification and NDT development. It describes AMEC's MISTIQ SCC process for producing test pieces with realistic SCC defects in materials like Inconel alloys. The test pieces have been used to develop online NDT monitoring techniques and evaluate methods like phased array ultrasound. A case study is presented on delivering a large SCC specimen to Japan for round robin NDT trials. Future work may include SCC test pieces for other materials and geometries to improve inspections for SCC detection.

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    © All Rights Reserved
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    of 25

    Stress Corrosion Cracking Test Pieces for

    Inspection Qualification and NDT Development


    David Ludlow, AMEC
    BINDT & ICORR Symposium on Inspection and Monitoring Techniques to
    Manage the Corrosion of Valuable Assets

    The Centre, Birchwood Park, Warrington


    Wednesday 17th April 2013
    Overview

    ƒ What do we do
    ƒ Stress corrosion
    cracking (SCC)
    ƒ Inspection
    ƒ NDT test pieces
    ƒ MISTIQ SCC test
    pieces
    ƒ NDT developments
    ƒ Case study
    ƒ Future developments
    ƒ Conclusions

    2
    AMEC NDT Inspection Capability

    Inspection Validation
    Monitoring & Inspection Design Centre
    Concept Development Problem Understanding
    Research Inspection Specification Qualification Strategy

    Design Independent
    Inspection Techniques Technology Transfer Qualification Body

    Modelling and Simulation Rigs and Test Pieces


    Qualification
    Reliability Testing Deployment Consultancy

    Technical Justifications Human Factors


    Inspection Audit

    Plant Implementation Training Audit


    Procedure Development Data Analysis

    Training Human Factors Site Support

    3
    Why Inspect?

    Plant Failures:
    ƒ Flixborough explosion – SCC of
    chemical reactor, UK 1974
    ƒ Bhopal accident, India 1984
    ƒ Swiss swimming pool collapse
    caused by SCC, 1985
    ƒ Carlsbad pipeline explosion, New
    Mexico, 2000
    ƒ El Al Boeing 747 crash caused by
    SCC, Amsterdam 1992

    SCC is major degradation


    mechanism & difficult to
    detect

    4
    Stress Corrosion Cracking

    5
    SCC Initiation & Growth

    Schematic diagram showing SCC initiation and growth


    (Ref. R. Staehle, “Predicting the SCC of Reactor Components from First Principles”,
    EUROCORR, 2009, Nice, France, Acropolis Palais de Congress, 6-10 September, 2009)

    6
    SCC 2-D Morphology

    TGSCC IGSCC
    Chloride SCC in 304L ASS Left Ref. NACE (Inconel heat exchanger)
    Ref. Colorado Metallurgical Right Ref. Okamura, Japan NPP
    Services

    7
    SCC 2-D Morphology

    SKI Report 2006:24 Crack Characterisation for In-service Inspection Planning


    Nearly 100 SCC defects characterised from plant, 77% IGSCC

    8
    SCC 3-D Morphology

    9
    Inspection

    AssetHoly Grail
    Management
    ƒ Periodic NDT during outage
    ƒ Risk based approach (RBI)
    ƒ NDT needs careful design
    ƒ Technique Now?
    ƒ Equipment
    Targeted Online
    ƒ Personnel
    Monitoring
    ƒ Design needs validation
    ƒ Formal Qualification

    ƒ Universal Technique
    Future
    ƒ No Operational Interference
    Structural Health
    ƒ Early Warning Monitoring
    10
    NDT Techniques

    SCC Surface
    ƒ Visual
    ƒ Liquid dye penetrant
    (LPI)
    ƒ Magnetic particle (MPI)
    ƒ Eddy current (ECT)
    ƒ Electro-magnetic

    Volumetric
    ƒ Ultrasonics
    ƒ Radiography
    ƒ Acoustic emission

    11
    NDT Test Piece Development

    ƒ Representative test
    pieces
    – Material, geometry, defects
    ƒ Crack defects
    – EDM notches, fatigue cracks
    (smooth defects)

    E.g. UT response weaker for


    SCC compared to fatigue
    cracks leading to SCC defects
    being missed / unreported
    during plant inspections

    Requirement for realistic


    SCC defects
    (rough defects)

    12
    AMEC MISTIQ SCC Process

    ƒ Need for IGSCC in Inconel


    alloys
    ƒ Control over crack length &
    depth
    ƒ Accelerated process
    ƒ Stainless steels & DM welds
    ƒ Standard plate specimens
    ƒ Bespoke specimens
    ƒ Dedicated rigs
    ƒ FE analysis support

    13
    SCC Images

    Plant SCC AMEC MISTIQ SCC

    14
    NDT Developments using SCC Test Pieces

    ƒ Online data collection


    ƒ Gates & alarms
    ƒ Signal processing
    ƒ Enhanced visual display
    ƒ Data analysis
    ƒ Phased array
    – Total focussing method
    (TFM)
    – Full matrix capture
    (FMC)

    15
    UT Online Monitoring

    ƒ Pulse echo
    – SCC initiation
    – First stages of
    growth

    ƒ Time of flight
    diffraction
    (TOFD)
    – SCC crack depth

    16
    Online Data Collection

    Pre SCC SCC


    B-scan showing
    TOFD A-scan
    SCC initiation & TOFD A-scan
    growth

    17
    Online Data Analysis: Gates & Alarms

    Automated Recognition
    18
    Enhanced Visual Display

    A-scan from Marker

    Rotatable
    3-D View

    Slider to Move
    A-scan Marker
    3-D View Control

    Prototype UT software with enhanced visualisation


    19
    UT Phased Array

    Phased array TFM


    image superimposed on
    MISTIQ SCC
    (grade 304 plate)

    FMC is data collection


    for every transmit-
    receive combination.

    20
    Case Study

    ƒObjective
    – To deliver large DM weld
    SCC specimen to Japan for
    round robin trials
    ƒChallenges
    –Largest SCC bespoke
    specimen
    –DM weld composition
    –Rig design & loading
    conditions
    –NDT
    –Delivery schedule
    –SCC target: 20mm wide &
    20mm deep

    21
    Case Study

    ƒ Weld metal trials weld

    ƒ Loading conditions: FE analysis


    ƒ NDT cladding

    –UT specialised probes


    –DPI carbon steel

    ƒ Destructive Examination
    stainless steel
    (304)

    Ref. E.Journal of Advanced Manufacturing,


    Vol.3 No.3 NT40 & Vol.2 No.2 NT24

    NDT Destructive
    Examination
    Specimen Length Depth Length Depth
    mm mm mm mm
    1 27 29 27 23
    2 23 16 21 16

    22
    Future Developments

    ƒ SCC in ferritic steels &


    Al alloys
    ƒ TGSCC NDT specimens
    ƒ Complicated geometries
    e.g. full pipe sections
    ƒ Degradation
    mechanisms – pitting,
    general corrosion
    ƒ Thermal fatigue & H
    cracking specimens

    23
    Conclusions

    ƒ There is a real need for realistic SCC


    specimens to improve inspection
    systems for SCC detection & sizing

    ƒ AMEC MISTIQ SCC test pieces offer a


    step improvement over conventional
    test pieces for SCC inspections
    – Widely used in qualified inspections for NPP

    ƒ Targeted NDT techniques can be


    adapted for online condition
    monitoring

    24
    Questions?

    Acknowledgements
    BINDT & ICORR
    AMEC – Nick Smart, Bernard McGrath & MID Team

    Contact:
    David Ludlow
    T: 01925 254914
    E: [email protected]

    AMEC
    Clean Energy- Europe
    Walton House, Birchwood,
    Warrington, Cheshire, WA3 6GA

    25

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