TECHNICAL CENTER - Framatomede.areva.com/.../TechnicalCenter/...Materials_ · - Technical Center -...

Materials Consulting

Service Center for Materials Testing

Metallography/Component Metallography and Root Cause Analyses

In-Situ Metallography and Material Assessment

Welding Consulting

Corrosion Laboratory and Corrosion Consulting

High Temperature Potential Probe (HTPP)

Irradiation Behavior of Materials

Aging and Plant Life Management with COMSY 3.0

Degradation Assessment and Inspection Optimization with COMSY

COMSY - Flow Induced Corrosion (FIC) - Flow Accelerated Corrosion (FAC)

Numerical and Analytical Fracture Mechanics

FERESA (Finite Element Residual Stress Analysis)

Calibration

TECHNICAL CENTER Materials, Corrosion, Welding

AREVA GmbH - Technical Center - Materials, Corrosion, Welding

From concept developing, manufacturing and processing of semi-fi nished products up to the fi nished application: Custom-tailored materials consulting.

Materials Consulting Competence Center for Material Engineering

You are looking for an optimum material solution for a specifi c design or task? You need a reliable materials supplier having all relevant qualifi cations? You have already selected a material that needs to be qualifi ed or evaluated in terms of deviations?

In choosing AREVA, you have found a reliable partner with comprehensive expertise from a broad variety of successful projects who will support you in all material-related matters. We provide material consulting, support you in procuring semi-fi nished products and also develop qualifi cation concepts if required.

Based on our experience, we prepare material specifi cations addressing additional quality-related requirements not stated in codes and standards. Depending on the product, we develop manufacturing and inspection concepts in close cooperation with our customers.

Our material specifi cations are based on the following:• Codes and standards such as EN, ASME, RCC-M, KTA• Material approvals• European directives• Customer requirements

In case of deviations from the specifi ed material properties, these are evaluated with special regard to their eff ect on the fi tness-for-purpose. Rely on us in preparing the required non-conformance report (NCR) and defi ning the corrective actions, if necessary.

Comprehensive ServicesHow to benefi t from our know-how: Due to our experience gained over many years in the fi eld of materials technology we can provide you with comprehensive services. Benefi t from our extensive expertise in the fi eld of materials in nuclear technology. Beyond the scope of materials

Materials evaluation

Our Services at a Glance:

• Materials selection and procurement

• Codes and standards

• Fitness-for-purpose evaluation

• Preparation of material specifi cation

• Process qualifi cation (forming and manufacturing)

• Supporting mechanical acceptance testing

• Issuing of inspection certifi cate type 3.1 (DIN EN 10204)

• Creation of follow-up documents

• Heat treatment

consulting, our competence center off ers the following additional services:• Mechanical testing• Failure analysis• Corrosion• Metallography• Fracture mechanics


Your Benefi ts at a Glance

• A reliable partner with comprehensive experience in the fi eld of materials technology

• Short reaction times even for complex tasks

• Extensive laboratory infrastructure in associated disciplines

• Integrated solution competence from one single source

The Technical Center of AREVA Germany is generally considered to be center of competence in materials technology.

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Editor and Copyright 2015: AREVA GmbH – Paul-Gossen-Straße 100 – 91052 Erlangen, Germany. It is prohibited to reproduce the present publication in its entirety or partially in whatever form without prior written consent. Legal action may be taken against any infringer and/or any person breaching the aforementioned prohibitions.

Subject to change without notice, errors excepted. Illustrations may diff er from the original. The statements and information contained in this publication are for advertising purposes only and do not constitute an off er of contract. They shall neither be construed as a guarantee of quality or durability, nor as warranties of merchantability or fi tness for a particular purpose. These statements, even if they are future-orientated, are based on information that was available to us at the date of publication. Only the terms of individual contracts shall be authoritative for type, scope and characteristics of our products and services.


FailureAnalysis

Metallography(stationary & ambulant)

FractureMechanics

Materials TestingCorrosion Engineering

Integrated expert support

AREVA GmbHYour contact: [email protected]

Service Center of the Technical Center for Material Testing Material Properties are the Basis for a Reliable Design of Components

The service center for material testing has the objective to support you in the solution of prob-lems occurring in the operation of you plant or in the manufacturing of your products. We are a test laboratory accredited as per DIN EN ISO/IEC 17025 and thus qualifi ed for numerous tests.

You have a specifi c task regarding a component or an individual requirement regarding a mate-rial, and you have to qualify it or evaluate devia-tions? You need supplemental tests, support in the failure investigation or fracture mechanical properties?

The Technical Center off ers you the complete service from the preparation of material testing and sampling plans, to sample processing, testing and reporting, also with acceptance certifi cates 3.1 as per DIN EN 10204 or independent experts.

Material testing provides various test procedures for determining the behavior and the material properties of standardized specimens and fi nished components under mechanical and thermal stress.

A team of qualifi ed application engineers is avail-able for you. The tests are carried out on time and conforming to standards. The results are document-ed in the form of test certifi cates or comprehensive work reports.

Our service portfolio at a glance:

• Work preparation/CAD • Hardness tests, e.g. as per Vickers, Brinell, Rockwell• Tensile tests on standard and micro-specimens • Compression tests

Test laboratory of mechanical material testing

The following testing equipment is available for this purpose:

Universal testing machines:• Force measuring ranges: ± 250 N to ± 500 kN• Vertical test space: max. 1,600 mm• Temperature range: -196 °C to 1100 °C

Resonance pulsators:• Force measuring ranges: ± 250 N to ± 20 kN• Dynamic travel range: ± 4 mm• Frequency: 70 to 220 Hz• Oscillation mode: Sinus

Servohydraulic testing machine:• Force measuring ranges: ± 50 kN to ± 500 kN• Dynamic travel range: ± 125 mm• Frequency: ≤ 25 Hz• Oscillation mode: Sinus, triangle, single ramp, sawtooth

Impact testing machines:• 25 J and 50 J for micro-specimens• 150 J and 300 J (instrumented) for standard specimens

Hardness test equipment: • Vickers, Brinell and Rockwell hardness testing machines Pellini drop weight tester with max. 1600 J

• Notched bar impact tests on standard, micro and reconstituted specimens• Bend tests, fl attening tests, drift expanding tests• Pellini tests (drop-weight test)• Fracture mechanics tests• Fatigue tests• Customer-specifi c component tests• Manufacturing of irradiation capsules• Acceptance certifi cates 3.1 (DIN EN 10204)

Your Benefi ts at a Glance • Reliable partner with long-standing experience in the fi eld of mechanical material testing and experimental fracture mechanics

• Rapid response times even for complex test setups

• Qualifi ed personnel

Service Center of the Technical Center for Material Testing

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Comprehensive service

In material testing matters, we off er you a comprehensive service from sampling and sample

The Technical Center of AREVA Germany is considered to be a center of competence in the fi eld of mechanical ma-terial testing and experimental fracture mechanics.

Fracture Resistance Curve at T = 23°C; Material: 1

(see ASTM E 1820; page 28)

J=322,37*(Δ a)0,51

0

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400

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700

0 0,5 1 1,5 2 2,5 3

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J in

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/m2

Data points Points used for regression analysis Least-Square-Fit

construction line exclusion line (0,15 mm) exclusion line (1,5 mm)

offset line (0,2 mm) J_limit

J0.2BL = 201 kJ/m²

Methods for the determination of crack initiation values and crack resistance curves with regard to stable crack expansion in the elastic-plastic fracture mechanics

CT-25 specimen

Load vs. displacement

Specimen No. B2D.7; Temperature: 23°C

0

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Fracture-mechanical specimen CT-25

processing to testing and documentation.

You obtain a quality-assuring and timely service.




Metallography/Component Metallography and Root Cause AnalysesMaterial-related Testing

You are looking for comprehensive assistance for solving material-related problems regarding inspection, manufacturing, repair and alteration work?

AREVAs Technical Center off ers professional contact persons for the planning and execution of orders at any time, such as for example:• Long term or ad hoc deployment of on-site teams including material testing personnel and/or materials engineers for on-site evaluations• Organization of shipment of parts• Performance and documentation of failure analyses on contaminated parts • Development of interdisciplinary approaches and remedial actions• Presentation of results in the presence of an independent third party and/or licensing authority if required

We offer fast and competent support during operation and outage but also for individual problems regarding root cause analyses, material-related testing and

customized improvement process concepts.

Our Scope of Services at a Glance:

• Root cause analyses• Ambulant metallography• Positive material identifi cation (PMI)• Metallographic/ceramographic Investigation• Fracture surface investigations• Surface analyses (topography, roughness, contour)• Micro structure assessment (creep damage, aging, thermal heat treatment)• Analysis of deposits and particles• Phase and texture analyses• Issue 3.1/3.2 certifi cates• Assessement of production test coupons• Assistance for material-related and analytic problems• X-ray residual stress measurement

Transmission Electron Microscopy

X-ray Spectroscopy

Metallography

Scanning Electron MicroscopyFocused Ion Beam Technology

Analytical Transmission Electron Microscopy

Ambulant Metallography, Portable Emission Spectrometry etc.

Metallography/Component Metallography and Root Cause Analyses

Process and methods are certifi ed with DIN ISO 9001/200 and accredited to DIN EN ISO/ IEC 17025.

Your Benefi ts at a Glance:

• Fast response time and fl exible service possibilities because of the existing infrastructure

• Broad range of examination methods

• The availability of experienced nationally and internationally acknowledged experts in diff erent areas also ensure a competent back offi ce

• Integrated approach from the evaluation on-site to the defi nition and implementation of remedial actions based on long-time experience especially in the fi eld of power plant technology

The material technology of the Technical Center is a core competence of AREVA GmbH. (regarding several customer feedbacks)

Focused Ion Beam (FIB) plant

Scanning Electron Microscope

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In-Situ Metallographyand Material AssessmentInvestigation of Valve Seats & Hard Facings

Rapid and non-destructive examination for the evaluation of the current state of valve seats

Key Features

• Rapid execution

• Non-destructive approach

• In-Situ capabilities realized by replica techniques

• Independence from radiation level

• All materials covered

• Competent back offi ce support for the on-site teams

The Challenge

You want to obtain comprehensive knowledge about the current state of valve seats and hard facings for the defi nition of:

• sound operating conditions

• necessary mid- and long-term maintenance actions

• repair or replacement actions

You are challenged with:

• lack of information about your valve seats

• cost and time intensive replacements or repair actions

• the areas of interest cannot be examined by conventional methods because of dose rates and/or limited accessibility

• quality assurance after repairs

The Solution

AREVA developed tools and technologies to examine the current state of valve seats by non-destructive methods. The following examinations can be performed directly on-site:

• Determination of Hard-facing-/buff ering thickness

•Visualization of weld build up Hardness (indicator for important material properties)

•Chemical composition at the surface of the hard facing

•Geometrical details of the whole seat

•Characterization and assessment of defects

Investigation of a valve inaccessible with conventional methods

References

Germany E.ON, RWE, EnBW

Finland TVO

Sweden Forsmark Kraftgrupp AB

Switzerland BKW FMB Energie

In-Situ Metallography and Material Assessment

Investigation of small valves with special replica tools

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Your Benefi t at a Glance • Optimization of maintenance/repair/replacement actions regarding time and budget

• Detailed information concerning the current state and the integrity of valve seats

• Rapid and non-destructive method

• Wide range of valve types is covered

• Examination of the results directly on-site

• All material combinations

• 360° of the circumference of the valve seat

• Back office enables a competent and reliable assessment of the on-site results

Upper facing surface

Hardfacing

Innercylindricarea




Comprehensive welding consulting fromdesign, selection of the welding processes,preparation of welding procedurespecifi cations and their qualifi cation up to theevaluation of welded joints.

Welding Consulting Weldability, Selection of Welding Consumables, Procedure Qualifi cations

Your weld design is confronting you withquestions regarding general weldability,selection of appropriate fi ller metals andprocedure qualifi cation in compliance withcodes and standards?

According to your individual requirements we provide comprehensive welding consulting that covers:• Design evaluation regarding weldability and feasibility• Defi nition of the required weld quality (e.g. EN ISO 5817)• Assistance in selecting the optimal welding consumables • If necessary, we defi ne all kinds of post-weld treatments, e.g. machining and/or stress relief heat treatment.

Rely on us to support you with the preparation of welding procedure specifi cations (WPS) and their qualifi cation in compliance with national and international regulations such as EN ISO 15614-1 or ASME Section IX. The corresponding nondestructive- and destructive testing procedures can be performed in our readily available laboratories.

In case of deviations from the specifi ed weldproperties, these are analyzed with special regardto the fi tness-for-purpose of the welds in question.We establish the non-conformance report (NCR)for your intended application and defi ne correctiveactions as part of a comprehensive repair concept.

Infl uencing factors on the weldability of parts and components according to ISO/TR 581

Our Scope of Services at a Glance:

• Selection of welding process

• Selection of welding consumables

• Welding process optimization

• Establishment of welding procedure specifi cations (WPS)

• Welding procedure qualifi cations (WPQR)

• Evaluation of weld imperfections

• Fitness-for-purpose evaluation

• Evaluation of weld designs

• Preparation of follow-up documents

• Heat treatment

Welding Consulting


• Reliable partner with extensive experience in the fi eld of welding technology• Short reaction times even for complex tasks• Readily available laboratory infrastructure in associated disciplines• Integrated solution competence from one single source


Comprehensive Services

Benefi t from AREVA’s comprehensive welding services based on years of experience in the fi eld of welding technology known for highest quality and safety standards. Beyond the scope of welding consulting, our competence center off ers the following additional services: • Mechanical testing of welds• Failure analysis• Corrosion• Metallography• Fracture mechanics

Professional consulting for all kinds of welding-related tasks

On-site Shielded Metal Arc Welding (SMAW)

Dissimilar weld between ferritic tube sheet with austenitic weld overlay and austenitic bottom dome using nickel alloy fi ller metal (alloy 82)

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Corrosion Laboratory and Corrosion ConsultingCorrosion Tests and material-specifi c User Support

AREVAs Competence Center offers individ-ual laboratory testing for plant relevant corro-sion phenomena as well as the assessment and consultation of applications for material technology in gaseous and aqueous media.

You require support regarding corrosion technology, either for planning corrosion pro-tection, for selection of material, production, commissioning or during operation of parts and components? You would like to use the services of a well-equipped corrosion laboratory for the simulation of technical plant-relevant environ-mental conditions?

AREVAs internationally acknowledged corrosion experts and competent specialists will diligently support you in issues of corrosion:

• Assistance with material selection, taking into account your specifi c frame conditions and the material protection in corrosion tests at room temperatures of up to max. 400 °C• In addition to practice-oriented exposure tests, signifi cant corrosion technological parameters (e.g. current density, potential curves, imped- ance measurements, electrochemical noise) are identifi ed for you in the laboratory• Performance of online measurements of corrosion potential in the laboratory and in-situ during operation • Examination of mechanical and technical material behavior under actual operating conditions (e.g. high-temperature water)• Characterization of material conditions and proof of corrosion resistance during production based on short-term tests (e.g. Strauss-test as per ASTM G28 (DIN EN ISO 3651) for proving the intergranular corrosion resistance, comparable tests for PWSCC behavior, EPR-test, SSRT-test)• Simulation of damage cases in the laboratory, detection of factors and elaboration of problem- specifi c corrective measures for practical use• Creating material concepts focused on the requirements as well as the addition of experimental research when required

Methods and work equipment for compre-hensive service

• Consulting and assistance in all issues of material corrosion technology

• Comprehensive autoclave system (static operation/refreshing operation)

• Performance of tests under increased pressure (up to 220 bar) and increased temperatures (up to 400 °C)

• High-temperature reference electrode developed in-house

• Measurement of corrosion potentials during relevant operating conditions and test temperatures

• Numerous electrochemical test benches for corrosion tests

• Modern electrochemical methods for the determination of corrosion behavior

• Corrosion tests during simultaneous mechanical stress and simulated and controlled environmental conditions (e.g. pressurized water reactor and boiling water reactor conditions, boiler water as well as diff erent water chemistry)

• Practice-oriented exposure tests in the test solutions as well as under atmospheric stress for the detection of aging behavior (corrosion rate, kind of corrosion attack) under practice-oriented conditions

• Data bases for material use in accordance with standards and regulations

• Additionally: metallographic and analytical methods (SEM/EDX), examination of strength and ductility, various heat treatment processes, comprehensive chemical analytics

Your Benefi ts at a Glance: • Focused corrosion engineering in every phase of the project

• Well-equipped corrosion laboratories for the simulation of technically relevant environmental conditions

• Innovative test and measuring concepts for application relevant corrosion testing

• Performance of customized component tests

• Material-related competence from one source based on numerous interdisciplinary interfaces

Corrosion Laboratory and Corrosion Consulting

Material corrosion technology competence from one source:

AREVAs team is involved in the complete life cycle of nuclear power plants - ranging from the develop-ment, design, production and assembly monitoring to the operation and evaluation of damage cases. Our internationally acknowledged experts use their knowledge from resolving failure analyses and the defi nition of remedial actions as “lessons learned” in the fi eld of material selection as well as new material concepts. Our portfolio includes conversa-tions with inspectors and third parties as well as the cooperation in relevant expert groups and the performance of customized laboratory testing. This results in a high competence in the fi eld of materials and their corrosion as an integrated and focused approach.

Crack initiating attempt at notched bend test specimen under medium conditions

Performance of a tensile test under medium conditions

Corrosion protection is the more effi cient the better the failure mechanisms are known. It starts with the evaluation of the corrosion system.

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High-Temperature Potential Probe (HTPP)Online Measurement of Corrosion and Redox Potential up to 300 °C and 120 bar

The knowledge of the electro chemical potential (corrosion potential) indicates whether reducing or oxidizing water conditions exist in the water circuits observed, which is decisive for avoiding corrosion and optimizing process fl ows.

You want to monitor water circuits and optimize process fl ows, whether in the lab or in industrial plants? Use the benefi ts of the AREVA-developed high-temperature potential probe for online measurement of corrosion and redox potential up to 300 °C and 120 bar. The corrosion poten-tial of a material as well as the redox potential of the medium are signifi cant in every respect for assessing the electrochemical behavior of a material within its environmental conditions.

The description of the corrosion system – consisting of material, environment and mechanical stress – represents the basis for every corrosion protection. Especially the environmental conditions in the water circuit may greatly vary in practice depending on the process status.

Laboratory version of the high-temperature reference electrode

AREVAs internationally acknowledged corrosion experts and competent spe-cialist staff will diligently support you in issues of corrosion and redox potential measurement.

The service portfolio at a glance:

• The HTPP system consists of an externally cooled reference electrode (Ag/AgCl) with an electrolyte bridge and a platinum electrode for measuring the redox potential.

• The electrolyte bridge serves as electrolyte contact (ionic bridge) between the measuring electrodes and the reference electrode.

• For defi ning the corrosion potential, the relevant component in the system itself is used. However, it is also possible to integrate special electrodes made of the appropriate material within the probe.

• In addition, the temperature (thermocouple NiCr/Ni) can be measured at the measuring point.

• Since the reference electrode itself is not exposed to the high-temperature water, it exhibits a very stable reference potential and a long service life.

With the application of the high-temperature potential probe, AREVA off ers you the online measurement of corrosion potential in the relevant conditions of use and test temperatures. Based on the measured values achieved with the high-temperature reference electrode, oxygen can thus be induced directly into a system section to form a protective coating on surfaces with medium contact.

Your Benefi ts at a Glance: • Measurement of the corrosion potential under increased temperature and pressure conditions• Long-life, stable high-temperature reference electrode that has been well proven for more than 20 years in power plant and laboratory use• Description of the actual environmental conditions of material in the water circuit of technical installations• If necessary, targeted optimization of system parameters for avoiding corrosion in practice• Using our experts‘ know-how in material and corrosion technology in the assessment of your corrosion system • Material-related competence from one source based on numerous interdisciplinary interfaces

High-temperature potential probe (HTPP)

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Material corrosion technology competence from one sourceAREVAs team is involved in the complete life cycle of nuclear power plants - ranging from the development, design, production and assembly monitoring to the operation and failure evaluation. The experience of our internationally acknowledged corrosion experts gathered from failure analyses and defi ning remedial actions is integrated in the selection of materials and in new material concepts as “lessons learned”. Our portfolio includes discussions with inspectors and third parties as well as the cooperation in relevant expert groups and the performance of customized laboratory testing. This results in a high competence in the fi eld of materials and their corrosion as an integrated targeted approach.

The description of a corro-sion system begins with the measurement of the corrosion potential. This enables an eff ective corrosion protection.

Flange version of the high-temperature reference electrode

Schematic representation of the measuring principle

data transfer

reference electrodes(Ag/AgCI)

reassurement of medium temperature

monitoring of cooling temperature

coolingin

outfl ange

tube

platinium electrode

data aquisition




Comprehensive assessment of materials behavior depending on time of operation and neutron irradiation in power and research reactors

Irradiation Behavior of MaterialsMonitoring and Assessment of Irradiation Behavior of Materials

Plant lifetime management requires qualifi ed monitoring and assessment of the aging behavior of irradiated nuclear components. This implies the need for conceptual planning, coordination, technical execution and fi nal evaluation of irradiation surveillance programs in close collaboration with inspection bodies and nuclear authorities.

AREVA provides the full scope of irradiation surveillance programs for reactor pressure vessels in light water reactors (LWR). We support you with specific services such as conceptual consulting for plant life extension measures, theoretical and experimental determination of neutron fluence and qualified manufacturing of reconstituted specimens from irradiated specimen materials. State-of-the-art facilities and highly skilled and experienced staff are always at your service.

RPV: Change of material behavior under irradiation

Our Scope of Services at a Glance

Turnkey irradiation surveillance programs for reactor pressure vessels (RPV) in LWRs:• Consultation, planning, coordination and execution• Close collaboration with independent experts and authorities• Manufacturing of specimens and capsules • Baseline testing • Delivery of capsules to the power plant• Withdrawal of capsules from the RPV• Post-examination of irradiation capsules - Transport to the hot cells test lab - Dismantling of capsules and specimen testing - Examination of temperature and fl uence monitors - Fluence calculations - Final assessment of results, documentation of the entire project, compilation of the necessary documents for license applications

Specifi c services such as:• Removal and examination of scraping samples from the austenitic RPV cladding• Conceptual consulting for plant life extension and mitigation measures• Qualifi ed manufacturing of reconstituted specimens from irradiated specimen materials

Monitoring and assessment of irradiation behavior of other nuclear components:• Irradiation surveillance programs for research reactors• Assessment of irradiation behavior of Al-Mg alloys and of austenitic materials

Beyond this scope of services our competence center off ers the following additional services:• Mechanical testing of unirradiated material• Structural integrity assessment of the components concerned in terms of fracture mechanics in terms of fracture mechanics (pressure-temperature limit, pressurized thermal shock, fl aw assessment)

Irradiation Behavior of Materials


• Strong partner with extensive experience in the fi eld of ageing management of nuclear components

• Short reaction times even for complex tasks

• Integrated solution competence from one single source

• State-of-the-art facilities and highly skilled and experienced staff are always at your service

• All manufacturing and testing activities can be performed on site in certifi cated

and accredited laboratories including material testing, hot cells and radiochemistry.

• Good knowledge of requirements of inspection bodies and nuclear authorities

Comprehensive Services for Many Decades

Benefi t from AREVAs comprehensive services for the management of the irradiation surveillance of materials is based on long-term experiences and the proper use of national and international safety standards in this fi eld. We provide services from small conceptual studies to big irradiation surveillance programs for our customers worldwide.

Qualifi ed assessment of irradiation behavior of nuclear components by professional and cost eff ective services in high quality

References for German Plants

• Biblis A,B (KWB-A,B)• Brunsbüttel (KKB)• Philippsburg 1,2 (KKP-1,2)• Neckarwestheim (GKN-1,2)• Isar 1,2 (KKI-1,2)• Unterweser (KKU)• Krümmel (KKK)• Grafenrheinfeld (KKG)• Gundremmingen B,C (KRB-B,C)• Grohnde (KWG)• Brokdorf (KBR)• Emsland (KKE)• Karlsruhe (MZFR)• Obrigheim (KWO)• Würgassen (KWW)• Stade (KKS)• München (FRM II) *)• Berlin (BER II) *)

*) Research reactors

References for Plants Worldwide (excluding Germany)

• Atucha (CNA 1) (Argentina)• Angra 2 (Brazil)• Beznau, Leibstadt, Mühleberg, Gösgen (Switzerland)• Borssele (Netherlands)• Ringhals (Sweden)• Santa Maria de Garoña, Trillo (Spain)


Subject to change without notice, errors excepted. Illustrations may diff er from the original. The statements and information contained in this publication are for advertising purposes only and do not constitute an off er of contract. They shall neither be construed as a guarantee of quality or durability, nor as warranties of merchantability or fi tness for a particular purpose. These statements, even if they are future-orientated, are based on information that was available to us at the date of publication. Only the terms of individual contracts shall be authoritative for type, scope and characteristics of our products and services. G-051-V3-13-ENGPB


Software-supported knowledge base for effi cient long-term monitoring of power plant systems

Aging and Plant Life Management with COMSY 3.0 Condition-Oriented Aging and Plant Life Management SYstem

Plant-wide and systematic Aging Management (AM) is essential for the safe operation of nuclear power plants. This complex task and the continuous data maintenance required can be handled reliably with a qualifi ed software tool.

COMSY is an effi cient system by which power plant operators can implement the individual process of managing aging and plant life eff ectively. The program with its integrated AM modules enables the design and setup of a knowledge-based power plant model compatible to the requirements of international and national rules (e.g. IAEA recommendations, KTA 1403).

In this process, a key task is to identify and monitor degradation mechanisms. Since 1998 COMSY has been applied successfully in more than fi fty reactor units in this fi eld. The current version 3.0 was revised completely and off ers additional AM functions.

All aging-relevant component data are compiled and allocated via an integrated power plant model. Owing to existing interfaces to other software

COMSY – Condition-Oriented Aging and Plant Life Management SYstem

solutions and fl exible import functions, COMSY is highly compatible with already existing data bases in the plant.

Its functions and modules include

• Flexible power plant model• Materials library• Graphical water-steam cycle model for determining local water chemistry parameters • Identifying and evaluating degradation mechanisms • Recommending points in time for inspection / maintenance • Inspection management• Evaluating inspection and maintenance reports• Events from nuclear reporting systems• Integrated document management • Interfaces and import functions• Automatic reports

Documentationand reports

Validation of inspection and maintenance

strategy

Evaluation of degradation

mechanisms in components

Aging-relevant information

Inspection and maintenance program

Safety and availability requirements

Internal/external messages or eventsC

OM

SY

Aging Management as a core competence of AREVA

As a nuclear power plant manufacturer with global expertise, AREVA off ers you comprehensive know-how and highest competence in the fi eld of aging management. The calculation models integrated in COMSY are based on our more than 30 years of experience in the evaluation of degradation eff ects and numerous experimental studies.

Aging and Plant Life Management with COMSY 3.0

Benefi ts at a Glance

• Identifying and evaluating 14 degradation mechanisms

• Effi cient design and set-up of a comprehensive knowledge base via intelligent import and interface solutions

• Retaining the know-how by means of the integrated document management system

• Validating the inspection and maintenance strategy

• Yearly status report on the state of the plant


The calculation models are frequently improved and validated by means of latest insights. Our expert team develops and updates the COMSY software continuously so that it will always comply with the latest technical standards.

Future-oriented and effi cient aging management for safe power plant operation

Process engineering model of the water-steam cycle of a plant with COMSY



Degradation Assessment and Inspection Optimization with COMSYCondition-Oriented Aging and Plant Life Management System

Plant-wide degradation prognosis allows for a optimized and cost effective maintenance and inspection strategy and supports risk based inspection concepts

Lifetime predictions for degradation mechanism:

• General corrosion, shallow pitting

• Pitting and crevice corrosion

• Microbiologically induced corrosion

• Stress induced corrosion cracking (IGSCC, TGSCC, Ni-SCC)

• Thermal transient fatigue

• Corrosion fatigue

• Thermal cycling and stratifi cation fatigue

• Creep

• Flow-accelerated corrosion (FAC)

• Cavitation erosion

• Droplet impingement erosion

• Solid particle erosion

The evaluation of maintenance feedback utilizes statistical information to optimize the eff ort accord-ing to economic criteria considering availability and safety requirements. This includes probabilistic approaches to determine updated MTBF (mean time between failures) values for the components considered using the Weibull approach to resemble aging eff ects.

Changing energy markets require power plants to operate with more fl exible loads. In addition, pressure is increasing to keep costs down by optimizing maintenance and inspection activi-ties for the realistic needs.

The COMSY software solution is an effi cient predic-tive system which is capable to provide life cycle management and realistic condition assessment for power plant components based on the individual operation conditions. The program with its integrat-ed degradation assessment modules enables the design and setup of a living program with optimized maintenance and inspection concepts. System areas sensitive to creep, fatigue, fl ow-accelerated corro-sion (FAC), pitting, crevice and other degradation mechanisms can easily be identifi ed and evaluated. The software integrates degradation analysis and trending techniques to optimize the inspection, maintenance and repair strategy. Furthermore, case studies can be carried out to investigate the eff ect of e.g. higher start up gradients.

Maintenance needs for active components (e.g. valves, pumps, etc.) can be assessed based on industry experience regarding symptoms and root causes of system malfunctions. The active components evaluation with COMSY provides the technological basis for predictive/prognostics capabilities by providing a range of reliability per-formance indices for key power plant components.

COMSY Software Modules

Degradation Assessment and Inspection Optimization with COMSY

From an economic perspective, proactive life cycle management with an optimized inspection program is essential for an effi cient plant operation with high availability.


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Your Benefi t at a Glance • Predictive calculation of degradation progress for piping and components

• Determination of the remaining lifetime based on design criteria

• Determination of individual inspection dates for all components at risk with the support of Risk informed prioritization methodology

• Identification and evaluation of operation modes margins

• Design studies for new plants or power uprates regarding the optimization of material selection and geometry



Main objectiveThe main objective is to generate a dependable ranking of components or locations to be inspected based on the insights from the consequence as-sessment and degradation potential evaluations.

AREVA methodologyThe methodology to optimize inspection programs uses reliable condition based degradation assess-ment. The predictive models integrated in COMSY are based on our more than 30 years of experience in the evaluation of degradation eff ects and numer-ous experimental studies. The software assisted approach for risk based inspection (RBI) planning allows for a comprehensive, cost reducing and safety increasing maintenance strategy for a large stock of systems and components.

AREVA methodology on degradation assess-ment and inspection optimization

Determination and evaluation of damaged system areas, piping elements and components

COMSY Flow Induced Corrosion (FIC) Flow Accelerated Corrosion (FAC)Software for Aging and Plant Life Management

Flow-Induced Corrosion (FIC) mechanisms (fl ow-accelerated corrosion, cavitation erosion and liquid droplet impingement erosion) are hard-to-control degradation mechanisms. Their occurrence depends on a series of system-related, material-related and water-chemical conditions. We have performed laboratory tests as well as damage analyses for over 30 years. Our experience and results are incorporated in analytical and semi-empirical corrosion models. The software tool COMSY uses them to carry out specifi c weak-point analyses in power plants.

AREVA has developed a special screening procedure to reliably locate system areas which could be aff ected by e.g. Flow Accelerated Corrosion. In this procedure, the detailed heat balance diagram of the power plant is modeled using graphical tools, and the thermal-hydraulic parameters are specifi ed. This model enables an analytical calculation of the water-chemical conditions in the water/steam cycle. The result shows which piping systems are at risk. Detailed analyses for the localization of each component are carried out for areas where a potential risk could not be excluded.

For this purpose, every single component of an examined piping system is additionally specifi ed with material and design data sets.

Its functions and modules include

• Flexible and comprehensive power plant model• Material libraries for diff erent international standards• Graphical water-steam cycle model for determining local water chemistry parameters• Identifi cation of system areas aff ected by degradation eff ects • Lifetime calculation for piping components, vessels, heat exchangers and weld joints• Recommendation of inspection deadlines• Evaluation and calibration of inspection results• Visualization of inspection results• Integrated document management

This procedure enables the• Calculation of wall thinning rates for single piping elements and components• Determination of the remaining lifetime based on design criteria• Recommendation of individual inspection dates for all components at risk

CO

MS

Y

H2 Fe2+

H2

FeOH

Fe(OH)2

Velocity profi le

Flow coreTurbulentboundary layer

Base Metal

WaterFlowOxide

COMSY – Condition Oriented Aging and Plant Life Management SYstem

COMSY Flow Induced Corrosion (FIC) Flow Accelerated Corrosion (FAC)


• Targeted identifi cation and localization of endangered systems (screening analysis)• Conservative lifetime evaluation and weak-point analyses for components aff ected by FIC/FAC• Simple creation / optimization of the inspection program• Design studies for new plants or power uprates regarding the optimization of material selection and geometry• Quantifi cation of the iron ingress into the steam generator


Aging Management as a core competence of AREVAThe objective of a systematic lifetime management is to predictably shape the service life of the systems and components of a plant and/or to reliably indicate that the technical lifetime limit has been reached prior to the possible occurrence of a component failure. Another goal of the lifetime management is to particularly maintain the availability of the plant on a high level despite the aging and to enable an economically and technically targeted maintenance strategy.

A future-oriented and effi cient aging and plant life management

COMSY Workfl ow

• Heat balance diagram• Thermal hydraulic conditions• Water chemistry cycle calculation• Material properties

SCREENING

RelevantSystem-

Properties

Operation

Material

Chemistry

No Risk

Detailed Analysis



Numerical and Analytical Fracture MechanicsStructure Mechanical Calculation on the Basis of the Finite Element Method

Precise fracture mechanical calculation of complex structure and load confi guration by means of numerical methods which are inaccessible to an analytical approach

Safety-relevant components whose integrity has to be proven fracture mechanically often have complex geometrical shape or are subject to a combined load. Analytical calculation methods are only applicable to a certain extent. Numeri-cal calculations based on the fi nite element method can realistically depict very complex scenarios with corresponding eff ort and can produce precise results.

AREVA has long-time experience in modeling structure and fracture mechanical problems. Powerful computing capacities are available to effi -ciently calculate even large-scale and sophisticated models. This for example enables the application

Simulation of a reactor pressure vessel during a coolant loss incident

We give advice, we carry out structure mechanical calculations focused on fracture mechanical problems and we evaluate them.

• Calculation for the targeted preparation of fracture mechanical tests

• Calculations for the safety-related evaluations of fi ndings detected in components

• Calculations of crack growth for lifetime evaluation

• Consultation regarding fracture mechanical aspects in engineering and manufacturing issues

• Execution of all necessary experimental work in in-house laboratories

• Application of advanced calculation and simulation systems in the fi eld of brittle and ductile fracture

• fl aw analysis (ASME/KTA)

• Leak-before-break analysis

• Support to qualifi cation of non-destructive examination by calculation of component specifi c allowable crack size at the beginning of the inspection interval

of computationally intensive damage models which help to simulate the crack growth in a component.

Besides numerical fracture mechanics, we also off er services in analytical (deterministic and probabilistic) and experimental fracture mechanics. This allows challenging and extensive problems to be solved effi ciently and “from one source”.

Your Benefi ts at a Glance • Long-time experience in terms of numerical, analytical and experimental fracture mechanics

• Substantial knowledge as a result of numerous successfully performed fracture-mechanical safety analyses

• Well-equipped modern laboratories available in the Technical Center when required

Numerical and Analytical Fracture Mechanics

AREVAs competences in nuclear and non-nuclear plant engineering as well as the knowledge in the fi eld of fracture mechanical methods are constantly being developed in the context of national and in-ternational research and development projects. The performance of complex numerical calculations is being enabled by a powerful infrastructure. Various specialist departments closely cooperate in interdis-ciplinary issues. Furthermore, there is a substantial experimental data base as well as comprehensively equipped laboratories available for safety-related evaluations.

Simulation of ductile crack growth compared to a real CCT sample (center cracked tension)

Simulation of a CT sample (compact tension) as the basis for probabilistic analyses

Your reliable partner for numerical calculations with focus on fracture mechanics

G-013-V4-13-ENGPB




FERESASimulation of Weld Residual Stresses – FERESA (Finite Element Residual Stress Analysis)

The numerical simulation of welding processes is an effective tool for detailed planning and optimizing of welding.

Residual stresses and distortion of components due to welding can signifi cantly infl uence the components’ functionality and life time. The stresses aff ect the calculation of the static strength of the structure as well as the as-sessment of fatigue, wearing and crack corro-sion behavior. Therefore, the determination of residual welding stresses as well as respective process optimizations are an essential step for ensuring the components’ safety and stability.

Residual stress and distortion in structures caused by welding can be calculated by means of nu-merical simulation based on the fi nite element (FE) method. The team of AREVA proceeds as follows:

• Determination of the relevant process parameters and material properties• FE modeling of the examined structure (2D or 3D)• Calculation of the temperature distribution in the component during welding• Calculating the residual stresses and distortion of the component based on the temperature distribution• Application of loads occurring during operation• Evaluating the calculations

The impact of welding on the residual stresses of the component can be determined fast and cost-effi ciently compared to experimental test ar-rangements. Consequently, FE calculations are the perfect tool for optimizing pending welding as well as for evaluating already performed welding.

Simulation of a dissimilar weld on a reactor pressure vessel nozzle

Consulting, conducting and evaluating welding simulations according to the guidelines:

• Preprocessing simulation of (repair) welds and their optimization with regard to residual stress and distortion

• Assessing of welded in service components with regard to stresses

• Determination of the required mechanical properties in our in-house laboratories

• Parameter studies

• Interpretation of results

Your Benefi ts at a Glance • Long-time experience with the FE method

• Cost saving compared to experimental methods for residual welding stress determination

• Short response times even for complex tasks

• Extensive laboratory infrastructure in associated disciplines

• Integrated solution competence from one source

FERESA (Finite Element Residual Stress Analysis)

Comprehensive Services

AREVA off ers comprehensive services for the deter-mination of residual welding stress and distortion by numerical simulation. Benefi t from our extensive expertise in the fi eld of nuclear and non-nuclear plant construction. Beyond the scope of the calculation of residual welding stresses, our competence center off ers the follow-ing additional services:

• Welding consulting• Fracture mechanics• Failure analysis• Metallography• Mechanical testing• Corrosion

Stress distribution of a reactor pressure vessel to nozzle dissimilar metal weld (cross section)

Stress distribution of a reactor pressure vessel to nozzle dissimilar metal weld (cross section)

Your reliable partner for numerical calculations with focus on weld residual stress

G-014-V3-13-ENGPB




Calibration Calibration and Management of Measuring and Testing Equipment

Calibrated measuring and testing equipment shall be used in quality-assured production and assembly. The technical requirements and functions are reviewed and documented through the calibration.

The reliable function of a component depends upon its precise manufacturing. This requires the use of calibrated measuring and testing equipment. Hence, the calibration of measur-ing and testing equipment for geometric and mechanical parameters in certain time intervals is indispensable.

Calibration of measuring and testing equipment:

AREVA ensures the quality assurance of the meas-uring and testing equipment through calibration in well equipped laboratories. The calibration can be performed either in the temperate measuring rooms or, for stationary devices, on site.

The procedures are in compliance with require-ments and standards (e.g. DAkkS, VDI, DKD, DIN) or, in special cases, internal requirements monitored by a quality management system.

The calibration status of each measuring instru-ment is documented in a calibration certifi cate and additionally with a calibration sticker on the device. The results are kept by the calibration service and are accesable at any time.

Calibration of a thread plug gauge

Calibration of mechanical, geometrical and thermal measuring and testing equipment for the measuring variables:• Length: 1 μm to 670 mm

• Force: from 1 cN to 600 kN

• Tightening torque: from 1 dNm to 1,000 Nm

• Temperature: -196 °C to 1000 °C

Application examples:• Distance

• Radius

• Straightness

• Evenness

• Angle

• Diameter

• Parameter of thread

• Rotation-symmetric parts (roundness, radial runout, axial runout)

Example for dimensional control of components and workpieces:• Artifi cial refl ectors (calibration phantoms) for ultrasonic and eddy current inspection

With the registration of your measuring and testing equipment in a special database, you will be auto-matically informed on a monthly basis if a calibra-tion is due, ensuring a timely notifi cation before the validity expires.

Your Benefi ts at a Glance • Competent consulting in calibration tasks

• More than 20 years of experience in calibration

• Short distances to the customer

• High fl exibility in urgent orders

• Monitoring and calibration of testing equipment from one source

• Automatic reminder service before calibration due dates

Calibration and Management of Measuring and Testing Equipment

G-120-V3-13-ENGPB

Comprehensive calibration service at AREVA

A team of specialists is available to support you in the calibration of your measuring and testing equipment. Both standard calibrations and calibra-tions tailored to your special application can be performed.

AREVAs long-standing experience in the area of metrology makes a comprehensive range of calibration procedures available to you. They are performed in-house or if necessary by externally assigned specialists.

“The qualifi ed and correct cali-bration of your measuring and testing equipment infl uences the quality of each measurement”

Calibration with length measurement equipment

Contour measuring system




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