NDE Approaches for Enhanced Performance and

Mitigation of Risks in Demanding Technologies

Baldev Raj
E-mail: baldev.dr@gmail.com

President-Research PSG Institutions

President-
President Indian National Academy of Engineering
President, International Institute of Welding
JC Bose, National Fellow; DST

Coimbatore
WCNDT-2012, Durban, South Africa, 16th April, 2012
Plenary Address – 18 WCNDT-
Challenges …..

Increasing demands on clean and competitive energy,

water, agriculture and healthcare.
(These demands are to be met with ethics and equity)

Longetivity – old age problems – newer strains of diseases

Ageing assets and new high performing assets

Globalisation of economies – increased competitions – to

be met with competence, innovations and ethics

Increased social and work stresses

Human resources (engineers) to meet the challenges

 Directions of Technology

Technologies performing at frontiers of limits of performance

Very large structures plants to nano devices

Design, analysis, virtual reality, health diagnosis, Asset Management

Innovations in all stages of life cycle of technology (evolutionary, paradigm

changes, cascade, …innovation ecosystem)

Newer materials processes and performance (modelling and simulation,

advanced characterization, testing and analysis for extreme conditions)

Advanced sensors, wireless networks, embedded systems, on-line

measurements and their analysis.
Management……

Simple and Robust management principles and practices

Paradigm shifts in management concepts

(fast, diverse, organic vs inorganic growth,…)

Interdisciplinary decisions : A wide spectrum in cultures of

countries, religions, competences, bureaucracies,
priorities.

Ethics, Equity

Engineering Challenge – Fractured linkages leading to

weakness in decisions
Accidents ……

Bhopal gas tragedy Dec.

1984
Concorde disaster – July 2000
Challenger disaster, Jan 1986

Gulf of Mexico Apr. 2010 Fukushima accidents, Mar. 2011

Prediction, Management of black swan, fat tail, low probability but high risk accident scenarios
 Analysis……

Improper Design and Materials (Challenger),

Inadequate safety and regulatory practices (Bhopal)

Improper PSI, ISI, TQM (Gulf of Mexico)

Inadequate defense in depth and lack of organisational

decision making (Fukushima)

Common Thread in all the above ….

 Measurements(relevance,adequacy,sensitivity,robustness)

 Inadequate analysis and correlation to performance in

steady state and accident scenarios
 DNA of Plant longetivity with risk mitigations….
Knowledge of
Asset

Steady State
Performance

On-
On-line and Extended life
Periodic in-
in-situ with robust
Monitoring using Measurements performance
advanced + and enhanced
technologies productivity
NDE
Plan
Improve Probabilistic + Deterministic
Implement
with Risk Analysis
Demonstrate
Feed-
Feed-
Measure
back
Analysis

Review+
Minimum Feedback
Excursions
and Outages
 NDE Waves ….
Nurturing
Multi relevant
NDE and Human
Fusion of Resources
images Synergy of Expertise
and signals
and facilities

Infrastructure
and
Facilities
NDE

Basic Physics
Materials Science
Modelling and
Simulation Challenges in newer
Sensors and
Materials – design,
Instrumentation development
and manufacturing

Enhanced Capability….
 A Visionary’s Dream on Nuclear Equity through Technology

NUCLER OPTION FOR SUSTAINABLE

Sodium Cooled Reactors . . . .

“ The country that learns to build

breeder reactor would have solved
10
its energy problems for ever ”

“ The country which first develops

a breeder reactor will have a great

ENERGY
competitive advantage in Atomic
Energy ” - India made an early entry to
1901 - 1954 Enrico Fermi Nuclear Generating Station
Nuclear Energy
Enrico Fermi, Meeting in April 26, 1944 Breeding ratio: “ . . . it obviously must be greater
With Wigner, Szilard and Others on :
than one ”.
“ The serious objection to these fast chain piles is
“ How the Chain Reaction would be used for
the production of power ” the removal of heat ”.

“ The coolant for this type of pile would be a

bismuth--lead alloy and would flow downward
bismuth
through the pile between the static and rotating
rods. The possibility of using liquid sodium in
place of bismuth-
bismuth-lead should also be looked into ”.
[ India pursues a vibrant Fast Reactor Program]
 FBR PROGRAMME IN INDIA
Credible
confidence in Innovative
State-of
State- of--
fuel cycle 25 years of concepts
successful art
operation concepts

07 08
10 09

Hu m 06
r eso a n
urce Ø11950
s

13725
Future FBR
04 05 11

• 1000 MWe
03
02 01
12
• Pool Type
• Metallic fuel
CFBR
• Serial
• 500 MWe
construction
PFBR • Pool Type
• Beyond 2025
FBTR • 1250 MWt (500 MWe) • UO2-PuO2
• 40 MWt (13.5 MWe)
MWe) • Pool Type
• Six units (3 twin units)
• Loop type reactor • UO2-PuO2
• PuC
PuC – UC • Indigenous design and • To commission in 2023
construction
• Design: CEA, France
• To commission in 2012
Since 1985…
 Technological Challenges in FBR
Compact Reactor Core With High Fissile Content
Use of Liquid Na as Coolant at high temperatures ( ~ 823 K)
Design and fabrication of Materials that can withstand intense neutron dose, temperature, and
loadings including Seismic
Reprocessing of highly active spent fuel
High Level waste management is very important for the success of Nuclear Option

Achieving High
Performance with
risk mitigation
Our approaches to challenges …

Analysis based on
Modelling and
Simulation
Validation through
accurate and
sensitive
measurements
Technology
Development (1:1 or
scaled down
models)
Knowledge
Management,
feedback Design,
Visionary ISI
ISI of FBR Components
 In-Core Components
 Fuel subassemblies
 IHX, Roof slab
 Discharge pipe etc.
Issues - Access constraints, background radiation,
temp., opaque sodium thus limited possibility
for inspection
Approach - Stringent quality assurance (QA)
Visual examination & under Sodium Ultrasonic’s
viewing employed
 Out-of-Core Components
 Main vessel / Safety vessel
 Steam generators / Sodium circuit pipes
 Concrete containment etc.
Issues: Access restrictions, temperature, time of inspection
Approach: Stringent QA +Advance NDE methods + Robotic devices
developed for ISI
Visual Examination Ultrasonic Test System
System
Test Trolley
developed
for
validation
of
kinematic
parameters
High Temperature Test
 Temperature during
FacilityISI - 150
°C

 MV
MV--SV Inter-
Inter-space - 300 ± 50
mm

DISHA Model Image of an artificial

crack through the Visual ISI marking on SV for
DISHA examination system navigation of ISI device
Assembly
Existing ISI Device for SG tubes Improved ISI device for SG
tubes
Robot’s base

Linear Actuators
Pulleys
Flexible
Robotic
arm

Spider Robot On Mock-

Mock-up Improved Device for ISI of SG
SG Tube Sheet tubes
WINCH
(SPATIAL HYPER REDUNDANT
ROBOT)
Exciter

Receiver
Depleted U
rings

ISI Device being deployed in SG for One set of

Computer aided
testing simulation Disc
 Remote Field Eddy Current Technique

Exciter Detector
Discretised mesh location
RFEC technique Principle
FEM predicted poynting
RFEC technique involves detection of back entered low-
low-frequency
magnetic fields (energy) in tubes using a receiver coil
vector plots of energy
-5
x 10
2
-6
x 10 700 Hz 1
5 900 Hz Model
1.8 1100 Hz Optimal 0.9
Experimental
40% WL
Induced voltage in the Receiver coil, Volts

1300 Hz
RFE C Intensity, Volts

1.6
3
1500 Hz
1100 Hz Experimental excitation 0.8

frequency & 30% WL

RFEC Amplitude, Volts

2 0.7
1.4

1.2
1
1100 Hz (optimum) detector location 0.6

800 900 1000 1100 1200

Frequency, Hz
1300 1400
where RFEC 0.5 20% WL
1

RFEC zone for intensity is 0.4

0.8 detector maximum 0.3 10% WL

0.6 determined using 0.2

0.4 3D finite element 0.1

0.2 model and 0

50 100 150 200 250 300 350 400 450 500 550
Instrumentation difficulty Scan position, mm
results validated
0
1.9 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Model validation
Receiver coil location, ID (12.6 mm) times

S. Thirunavukkarasu, B.P.C. Rao, S. Mahadevan, T. Jayakumar, Baldev Raj, Z. Zeng, L. Udpa and S.
Udpa, Journal of Research in NDE (USA), Vol. 20, 2009, pp 1-
1 -8
 Development of Optical Fiber based Raman
Distributed Temperature (RTDS) Sensor
RTDS sensor developed for temperature
measurement on sodium loops (up to 700°C with
Pulse Laser
Acrylic ~ 100ºC spatial resolution of 1 m and temp. resolution of
Polyamide ~ 300ºC
5°, limited by laser pulse width)
Fiber Bragg gratings designed and developed for
strain measurement on a test loop

Thermally influenced
molecular vibrations
cause Raman back
scattered light whose
intensity and arrival
time are used for
temperature and
location monitoring Single fiber grid was used to increase
the spatial resolution up to 10 times
 Leak detection is possible. For technology demonstration,
controlled leaks were simulated using hot water as coolant.
Spatial, statistical and temp. dependent errors analyzed to
improve the leak detection capability in coolant loops of
reactors. Test loop for testing
 Laser scattering for Sensing Surface Damage
Most of the Damage Mechanisms initiate from the surfaces
1 .0 1.0
Specular reflection, Arb. units

0 .8 0.9

FWHM (X 10mm)
0.8
0 .6
0.7

0 .4
0.6

0 .2 0.5

0.4
0 .0
0 20 40 60 80 0 20 40 60 80
AS POLISHED AFTER IGC ATTACK
E tc h in g tim e , se c Etching tim e, sec

Evaluation of Intergranular Corrosion in SS

20 s 80 s

20 s 80 s

23
Pitting Corrosion Effect of etching time on IGC in SS
Intergranular corrosion detection in Waste tanks by EC-
EC-GMR sensor
Giant magneto-resistive (GMR) effect is large change in resistance of nano layers due to applied
magnetic field as a result of spin dependent scattering of electrons. In order to pick-up feeble
magnetic fields produced by eddy currents (EC) at sub-surface corroded regions, GMR
sensor has been integrated with eddy current coil. GMR sensitivity: 10 nano Tesla
Exciter – Eddy current coil,
Receiver:: GMR sensor
Receiver

Un-Corroded
4mm
Corroded
GMR chip

7mm
EC coil
GMR

9mm
0 .5 0
E C -G M R re s p o n s e
0 .4 5 0 .5 h r
Sensor Output Difference, mv

1 hr
0 .4 0 2 h rs
0 .3 5

0 .3 0
E C re s p o n s e
0 .5 h r
12mm thick AISI type 304L
1 hr
plate (Oxalic acid attack) EC-GMR Images
0 .2 5 2 h rs
0 .2 0

0 .1 5

0 .1 0

0 .0 5 EC-GMR sensor is capable to detect corrosion

0 .0 0
4 5 6 7 8 9 9 mm below the surface
D e p th b e lo w S u rfa c e , m m

Successful application for detection of internal corrosion in 12 mm thick 304 L

waste vault tank by scanning from outer surface – ISI tool with robotics
robotics..
 Corrosion an Inherent Problem-Solution through Innovative Approach
with Advanced NDE

Quantitative Estimation Two Novel and

Complementary
of Techniques
Corrosion in Structural
Elements
Robust
Phase Image- Lock in Thermography Life
Monte Carlo Numerical Prediction Prediction
for
Asset History
Structural
Environmental Details
Longevity
Modelling
Risk Management

Potential techniques for one sided inspection

suitable for large structures. Can give quantitative
Compton Back Scattering
estimation of corrosion and also detect rebar
corrosion
 TOFS2
−2
0.3225
For the Inconel 625
2
0.3200 wrought cracker TOFL
tubes at HWP, Thal ν =
0.3175 and HWP, Tuticorin
 TOFS2 
2 − 
in various thermal
Service 0.3150 exposure conditions 1
2
exposed
0.3125  TOFL 

Poisson's ratio
(SE) :
NH3 0.3100 Accuracy ~ ± 0.0006
cracker 0.3075

tube at 0.3050
Virgin (Thal)
~873 K RSA (Thal)
Ultrasonic measurements
0.3025
V+747 h (Tuti) can be used to monitor the
0.3000
RSA+23000 h (Thal)
1 hr and V+57194 h (Tuti) degradation in mechanical
Failed in 1982 (Tuti)
600 hrs
0.2975
MC (~20000h) (Tuti) properties
0.2950 120000 h (1-35, Thal)
120000 h (36-70, Thal)
0.2925 Life span of these tubes for
120 140 160 180 200 220 240 260 280 300 320 340 360 380
resolution annealing should
Hardness, VHN not be based on merely the
service duration, but on some
Variation in Poisson’s ratio practically measurable
with hardness for cracker parameter, such as Poisson’s
Reused tubes in different service ratio and hardness
after exposed conditions at heavy
rejuvenati water plants at Thal and Assessment of rejuvenation
on by Tuticorin. (V-Virgin, MC-Mini heat treatment of the tubes
resolution Cracker, RSA-Re-solution using ultrasonic
annealing annealed) measurements
(RSA)
 Magnetic Flux Leakage (MFL) Imaging

Yoke
Scanner
GMR Sensor
Carbon steel plate

MFL images of defects are obtained by MFL image of a notch located at

scanning Giant Magneto-
Magneto-Resistive (GMR) 6.2 mm below surface in a 12 mm
sensor in a raster manner over the object. thick carbon steel plate

Scan
5 saw cuts direction

Array of 8 GMR sensors Wire rope of HWP, Manuguru

A flexible array of eight GMR sensors developed Response of GMR array

for automatic fast detection of flaws and loss of sensor to saw cuts in 64 mm
metallic area (LMA) in multi-
multi-strand steel wire ropes diameter wire rope
 Structured Approach to Asset Management

Design Objectives

Materials and Asset Management

Pre-service Data Repairs and
(Fabrication, In-service Data
Machining,Welding
Qualification, etc)
International Experiences

Asset and Knowledge Base essential for plants

intended to serve for more than 40 years. The
knowledge base is designed to serve as an expert
system for bigger plants.
 Asset and Knowledge Management System (AsKMe)

Archives more than 40,000 documents,

records and drawings pertaining to
Demonstration Fuel Reprocessing Plant.
Unique features that distinguish it from
conventional database
Radiographic archive with user defined
(based on experience) software for
image analysis and measurements
Provision for Ultrasonic signals and
images with analysis
Knowledge capsule _ Interviews with
senior/retired project colleagues on field
problems and their innovative solutions.
Quality Circle problems and solutions
First of its kind attempt in DAE and
internationally. Appreciated by
Regulators.
Implementation of Six Sigma
Study envisaged the application
of six sigma in the fabrication
of complex and high density
piping. 35,000 weld joints.
12,000 studied.
 Main types of defects that arise
could be identified.
 Root causes of the defect could be
ascertained to prevent in future
pipings.
R & D initiated – for example
oxidation occurs because of lack of
purging gas.
Feasibility studies on using Flux
cored / covered TIG welding filler
wires to completely eliminate the
purging.
Trial implementation made in
complex piping.
100 % oxidation free joints
achieved.
 SUCCESSFUL LIFE CYCLE
PERFORMANCE REQUIRE…
VALIDATED FOCUSSED
DESIGN INTER-
DISCIPLINARY
RESEARCH PROVEN
MANUFACTURING
TECHNOLOGIES

INNOVATIVE APPROACHES, SEAMLESS

INTEGRATION OF DISCIPLINES AND
ENABLING TECHNOLOGIES INTEGRATED
ASSET AND KNOWLEDGE MANAGEMENT ROBUST
INSPECTION
and TQM

SYSTEMATIC, RELIABLE
PLANNED ISI, SENSORS,SYSTEMS
LIFE SAFE
ASSESSMENT OPERATION
PROCEDURES
Approach for Implementing Innovations
• Critically review the internationally evolving designs and failure
experiences
• Detail out the prospective options for future SFRs
• Involve Industries to design and manufacture innovative
concepts
• Academic institutes for design optimisation by analysis
• Testing in air at Industries and testing in sodium at IGCAR

• Recognising priorities, breakthrough areas by experts, young

students and research scholars at the core of innovation
• Innovations eco-system with intertwining of young, senior,
academic, research and industry
• Quality and motivated human resources with enabling
networks and management ethics is a key to the safety of SFR
Challenges : Miniature IR sensors, thermal noise, feature detection and identification – robust
fuzzy logic based systems
 XRD based Residual Stress Measurements
for Life Assessment of Undercarriages of
Fighter Aircrafts
0 100

RESIDUAL STRESS, MPa

-100
RESIDUAL STRESS, MPa

-100
-200
-200
-300
-300
-400
-400

-500 Number of -500 Surface residual

Landings = 1050 stress
-600 -600
0 100 200 300 0 400 800 1200
DEPTH IN MICRONS NUMBER OF LANDINGS
The variation in residual stress The variation in surface residual
in the depth direction stress in landing gears experienced
different number of landings
In collaboration with IAF & HAL, Nasik
 M A IN LA N D IN G G E A R S T R U T

X-ray diffraction for life

K
1
assessment of landing gears of
V IE W -K

3 -F R O N T
MIG-21
4 -R E A R
10 MIG-21/23
7 -F R O N T
8 -R E A R

9
R E G IO N S O F R E SID U A L
5 -F R O N T
6 -R E A R STRESS MEASUREMENTS Micropores,
Stresses, impact
microstructures, damage, fibre
Remnant micro and macro breakage in
core in composites
defects through
turbine - through
Radiation based NDE micro focal
through
at IGCAR NDE
Neutron
Radiography-
KAMINI

Inclusions, Glue variations,

Quality Assurance of assemblies
–
LCA Conventional X-ray Mi-8/17
 The simulation paradigm

From: Kuivanen
Kuivanen,, ‘e
‘e--Engineering (Digital Manufacturing)’,
Manufacturing)’, VTT (Technical Research Centre of Finland), 2010.

www.monash.edu
 Courtesy,
CSIRO, Australia
 Courtesy,
CSIRO, Australia
 Factors Affecting Measurements in NDE
Fixed Factors Variable Factors

Sensor Operator
characteristics qualification
and training

Material Measurements
Properties in NDE Automation

Image and
Inherent Noise Signal
from sensor Processing
and electronics
Indicates significance

Automation
+
Defect Detection based on large defect database
Asset & Knowledge Six Sigma
+ Management
Heuristic Knowledge of Experienced Operators
 PERFORMANCE OF HIGH TECHNOLOGY
COMPONENTS AND SYSTEMS - MATURITY MAPPING
Production
Analysis Performance ISI
Technology evaluation
Code development NDE and Sensors
Operator
Model Modelling and Review
Simulation Integration
Interactions Analysis
Sensors and NDT Simulation
Materials POD
Quality Software
Microstructure Assurance Criteria
Hardware
Composition

Manufacturing Operation and

Design Health Monitoring
Technologies maintenance

 Excellence in Individual Domains

 Fractured Linkages

 Barriers of Disciplines and Management

 Lack of Integrated and holistic approaches

Challenging engineering and technological problems need…

Sensors
Electronics
Robust Measurements Statistics
Sciences
Systems
Galileo
Clear Convincing
Robust Analysis
+ even to concerned
non-specialists

Challenger Failure – Successful and

Well Appreciated Solution based upon
Holistic Analysis with robust
measurements and clear convincing

Richard Feynman
My Perspective of Missing Links …..

Measurements crucial for successful performance

Quality &
Safety in Life

High
Performance
Robust &
Health
System
Relevant
Measurements

Cultural
Environment Heritage

How well have we understood and translated …

A
V Small innovative ideas
A triggering research and
L application spanning
A disciplines and Kaiga Ring beam using
N organisations acoustic impact echo testing
C Acoustic Simulation of
H PE-16 (µm size
E precipitates) – Ph D
Thesis IzfP Germany

I
N Acoustic study of Humpy
musical pillars
N
Acoustic amplification based tests
O for dislocation studies (µm-nm)
V AE energy / load vs.
A normalized time
T Understanding curve
I Movement of
O Dislocations with Damage Micro-mechanisms in Ca Oxalate kidney stone
Acoustics Near Alpha Titanium Alloy acoustic microscopy
N Defence Lab (DMRL) (10 nm thick layers)
S
Ethical & Sustainable model