Doosan Babcock Asset Management NDT Capability & Experience in - - PowerPoint PPT Presentation

“Bringing our Values to Life”

Doosan Babcock

Asset Management

NDT Capability & Experience in the Nuclear Sector NIA Decommissioning and Existing Generation Group

13 February Energus, Cumbria Gregor Campbell – NDT Department, Doosan Babcock

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Overview

Doosan Babcock Nuclear Experience 2 Doosan Babcock NDT Capability/Experience 3 Summary 4 Overview 1

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Overview

Doosan Babcock and Nuclear Experience 2 Doosan Babcock NDT Capability/Experience 3 Summary 4 Overview 1

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Doosan Babcock

Built on more than a century of innovation, Doosan Babcock is a specialist engineering company delivering diverse and innovative full life cycle engineering and support services to global clients across a range of industry sectors. Working collaboratively with our clients, our extensive experience ensures we consistently provide them with advanced and cost effective technical solutions and long term value.

Process and Energy

• OEM New Build and Retrofit
• Servicing and Optimising Plant Output
• Project Management
• Technology Innovation & Digital Systems
• Asset Integrity Management

Nuclear Power

• New Build
• Operational Plant Support
• Outages and Maintenance
• Plant Life Extension & Innovation
• Decommissioning
• Waste Management

Asset Management

• Strategic Consultancy
• Asset Performance Management
• Critical Component Replacement
• Testing and Equipment Qualification
• Asset Integrity Management :
• NDT, Metallurgy & Welding, Integrity Engineering,

Fabrication, Testing and Equipment Qualification

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Doosan Babcock Nuclear Experience Extensive track record through the full nuclear plant lifecycle

1952 1891 2006 2013 2016 1976 1995 2018 2017 2019

Babcock & Wilcox established Design, manufacture & installation of first nuclear plant Supply, manufacture & installation in UK AGR fleet Signed Lifetime Enterprise Agreement with EDF Energy Deliver Reactor Sites Strategic Alliance with Magnox Babcock acquired by Doosan Group Sellafield EPC project delivery REF, SPP1 & SAV – 2005-2016 Supply, manufacture & installation of UK PWR Barakah Maintenance Integration Planning Agreement (MIPA) Sellafield Decommissioning Delivery Partnership (DDP) Lot 1 partner Sellafield Programme and Project Partnership (PPP)

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Overview

Doosan Babcock Nuclear Experience 2 Doosan Babcock NDT Capability/Experience 3 Summary 4 Overview 1

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Nuclear NDT – General Capabilities

▪Nuclear NDT provide expertise in the design and

application of Automated NDT Inspections / Remote

• perations for the Nuclear Industry.

▪Asset Management, 200+ highly qualified Engineering,

Technical and Scientific staff.

▪Based in Renfrew Technology & Engineering centre. ▪Our team has a range of engineering and inspection

skills from inspection development and qualification, technical justification through to site delivery.

▪Capability in PSI/ISI and Manufacturing Acceptance

Inspections in Global Nuclear Power Generation Industry;

Technology & Engineering Centre, Renfrew

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Nuclear NDT - General Capabilities

▪

30+ years experience in design and application of Ultrasonic inspections within the Nuclear Industry;

▪

Design & development of Inspection Manipulators for multiple applications within the Nuclear Industry;

▪

Design and development of Mock-ups and Test Specimens;

▪

Design of Inspection Techniques and Modelling Capability (eg CIVA);

▪

Extensive Experience of Inspection Qualification [ENIQ, ASME XI, RSE-M ];

▪

State of the art automated inspection systems;

▪

Extensive experience of ISI/PSI application within the global nuclear market;

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Overview

Doosan Babcock Nuclear Experience 2 Doosan Babcock NDT Capability/Experience 3 Summary 4 Overview 1

• NDT Experience in UK Nuclear markets

“Bringing our Values to Life”

• The Sizewell B RPV was manufactured by Framatome during the

late 1980s and early 1990s

• The UK nuclear regulator required that qualified, automated UT be

applied to the RPV by an independent organisation.

• Babcock was selected and went on to inspect :
• all of the RPV forgings (nozzle and shell forgings)
• all of the RPV seam and nozzle welds.
• These inspections were subject to a programme of Performance

Demonstration at the UK Inspection Validation Centre (IVC);

• Following the Forging ASI, Babcock was awarded contract in early

1990s to carry out automated Pre-Service Inspections (PSI) of the RPV welds during manufacture;

• This qualification process adopted for SZB formed the basis of the

current ENIQ guidelines for Inspection Qualification in Nuclear industry;

Nuclear NDT UK Experience - EdF Energy UK

Sizewell B – Automated Shop Inspections (ASI) of RPV Welds and Forgings Slide 9 of 22

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Nuclear NDT UK Experience - EdF Energy UK

Sizewell B Closure Head Dome to Flange Weld ASI and PSI;

• Sizewell replaced the RPV Closure Head in 2006
• Doosan Babcock selected to undertake the ASI and PSI on the

Dome-Flange Weld

• Original Design of UT Inspection Techniques;
• Design and commission of Inspection Manipulator;
• Performance Demonstrated for ASI/PSI;
• ASI and PSI Inspections performed at AREVA factory in Chalon-sur-Saone

in 2006;

• 3rd party inspection qualification by Inspection Validation Centre (IVC), UK;

Sizewell B – PSI and ASI of Replacement Closure Head

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Nuclear NDT UK Experience - EdF Energy UK

Automated NDT Partnership with EDF Energy

• Since 2001, Doosan Babcock have partnership with EDF

Energy for all automated NDT on their fleet of nuclear plant in the UK

• This includes for having full responsibility for such activities

as follows:

• Liaison with outage management and planning at site;
• Supply of all SQEP personnel for the following roles;
• Site Management
• Acquisition Engineers
• Data Interpretation Engineers
• Ultrasonic and Manipulator Technicians
• System support;
• Commissioning of all data acquisition equipment;
• Training and participation of equipment and blind trials
• Reportage of all data results to structural integrity branch
• Management, storage and maintenance of all fleet-wide Automated

NDT Equipment

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Nuclear NDT UK Experience - EdF Energy UK

Automated NDT Partnership with EDF Energy

EDF Energy Advanced Gas cooled Reactors (AGR’s)

• Doosan carry out automated UT on the UK advanced gas

cooled reactors at:

• Dungeness B , Heysham 1 & 2, Hunterston B, Hinkley B, Hartlepool,

Torness.

• Much of this is on the complex, stainless-steel piping

systems associated with the heat exchangers surrounding the reactor core. EDF Sizewell B PWR

• For Sizewell B Doosan Babcock continue to carry out

automated UT during ISI on the Sizewell B Reactor system

• During each outage we inspect :
• Class 1 / IOF Components and Auxiliary Systems;
• Our teams take part in RPV inspections:
• Closure Head Dome-to-Flange;
• RPV inspection supporting Westinghouse;

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Nuclear NDT UK Experience Rolls Royce / BAe Systems

1997 - 99 (Rolls Royce)

• Supply of equipment and services for ISI of RPV, Steam Generator, Pressuriser &

Piping Welds (Vanguard class);

2000 - Present (Derby Specialist Fabricators (now part of Rolls Royce)

• In-Manufacture Automated NDT of Astute Class Primary circuit components (MAI);
• RPV Seam Welds / Supports / Nozzles / Closure Head MSTs / Pressuriser Seam

Weld inspections;

• Equipment Preparation, Technique Development, Technical Justification and

Performance Demonstration (ENIQ);

• 3rd party Inspection Qualification Body Approval (IQB);

2000 - Present (BAE Systems)

• In-Manufacture Automated NDT of Astute Primary Piping;
• Equipment Preparation;
• Technique Development;
• Technical Justification (ENIQ);

Inspection of Small PWRS during Manufacture - (Naval Submarines)

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Overview

Doosan Babcock Nuclear Experience 2 Doosan Babcock NDT Capability/Experience 3 Summary 4 Overview 1

• NDT Experience in Overseas Nuclear markets

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Nuclear NDT Overseas Experience - Nucleoelectrica Argentina SA (NA-SA)

PSI at Atucha 2, Argentina

• PHWR, Siemens design, unique to Argentina;
• Doosan Babcock developed all Equipment and Procedures for Pre-Service

Inspection of 16 inspection areas:

• RPV Seam Welds / Internals / Support Lugs / Flange
• RPV Nozzle Belt (Main Coolant/ Safety Injection/ Fuel Failure / Moderator/ etc)
• RPV Studs / Closure Head
• Primary Pipework (2 loops)
• Designed a permanently installed manipulator for access to RPV;
• Trained NA-SA personnel to support PSI;
• Pre-Service Inspection performed in 2013;

ISI at Atucha 1, Argentina

• RPV Seam / Long Welds & Moderator / Main

Coolant Nozzles;

• Performed Major RPV ISI at Atucha 1 during 1998,

1999, 2005, 2008, 2013 and 2015;

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Nuclear NDT Overseas Experience - Electricite de France

• To develop and qualify inspection techniques for welds on the

safe-end of the pressuriser surge-line nozzle;

• Qualified in accordance with French RSE-M code;
• Initial contract to apply these ISI techniques to all EDF plants
• ver a four year period 1996 – 2000 (40 interventions);
• Further contract extensions to 2009;
• Contract recently extended to 2020;
• In 2017 - awarded new contract for design upgrade,

qualification and future interventions over a 10 year period.

ISI of Surge Line Welds (PWR)

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Nuclear NDT Overseas Experience - Electricite de France

Customer requirement:

• To develop and qualify inspection techniques to detect thermal fatigue

cracks at the inner radius and the bore of primary circuit penetrations;

• Use of Phased Array technology;

To qualify the techniques in accordance with French RSE-M code; To apply the ISI techniques to EDF plant during 2009 to 2016.

• In 2018 - awarded new contract for design upgrade, qualification and

future interventions over a 10 year period

ISI of Primary circuit Branch Nozzles (PWR)

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Nuclear NDT Overseas Experience - Forsmark Kraftgrupp: BWR ISI

External ISI of Reactor Vessels

–

Main Seams; Skirt-Shell;

–

Bottom Dome; Closure Head;

• Qualification by SQC (ENIQ);
• Programme of ISI : 2002 – 2004 (units 1 – 3);
• 2005 – Inspection of “sister” station at

Oskarshamn

External ISI of Reactor Vessels (BWR)

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Overview

Doosan Babcock Nuclear Experience 2 Doosan Babcock NDT Capability/Experience 3 Summary 4 Overview 1

• Example NDT Developments

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Nuclear NDT Example NDT Developments– HDPE Inspection

• High Density Polyethylene (HDPE) – now used more widely in industry for new / replacement piping systems
• E.g replacement of cast iron Tertiary water systems on Nuclear plant;
• This Pipework is Erosion and Corrosion resistant, lightweight, simple joining process and

easy to deploy.

• Application of Nuclear Quality Assurance requirements / Safety case means volumetric

inspection required on the fusion joint :

• Defects: Lack of fusion / cold fusion / inclusions;
• HDPE Phased Array system developed by Doosan Babcock:
• The inspection system can be applied to a broad range of pipe geometries;
• Capability has been extended to mitre bends, electrofusion joints;

HDPE Pipework Phased Array Inspection System

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Overview

Doosan Babcock Nuclear Experience 2 Doosan Babcock NDT Capability/Experience 3 Summary 4 Overview 1

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Summary

• Established for over 125 years, Doosan Babcock as a company has over 65 years of nuclear

experience and is a leader in UK industry;

• With respect to Automated NDT, Doosan Babcock have a solid track record in providing

expertise in the design and application of Automated NDT Inspections within a global Nuclear Industry;

▪Our team has a range of engineering and inspection skills from inspection development and qualification, technical justification through to site delivery; ▪Capability in PSI/ISI and Manufacturing Acceptance Inspections in Global Nuclear Power Generation Industry;

• Although Doosan Babcock Automated NDT and Remote operations capability is focused on

existing generation, many of the skills and knowledge are transferable within a decommissioning arena, e.g. remotely deployed automated manipulators and systems, remote operations services, etc.

“Bringing our Values to Life”

Thank you !