Inspection during

Manufacture in shop

Jan. 16, 2013

Nuclear Energy Systems

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Summary of In-process Inspection

There are various requirements for nuclear related components such as
laws and regulations, standards, contracted specifications and design
requirements, etc.
For In-process Inspection in a factory, tests and inspections shall be
planned and implemented in such a way as to meet these requirements.
In order to implement tests and inspections as planned, management of
these tests and inspections are very important and rules shall be
established clearly and a system shall also be established to comply with
these rules.
Pressurizer

Steam Generator

Primary Coolant Pump

Primary
Coolant
Circuit
Reactor
Vessel

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Regulations for Inspections in shop

Regulation system for manufacturing and inspection of

nuclear power plant in Japan

Laws and Regulations

Safety
Review
Guideline
etc.

Electricity
Business Act
Technical Standard
of Facilities for
Nuclear Power Generation

Ministerial
Order

Interpretation of Ordinance in
relation to the Technical Standard of
Facilities for Nuclear Power Generation

Announcement

Technical provision for

electrical engineering and
guideline, etc.

JSME S NC1
Code for Nuclear Power Generation Facilities
Rules on Design and Construction for Nuclear Power Plants
JSME S NB1

Code for Nuclear Power Generation Facilities

Rules on Welding for Nuclear Power Plants

JIS (Japanese Industrial

Standards)
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Plan for Tests and Inspections

Requirements for product shall be clarified and develop a plan for tests and
inspections.

Inspection Plan

Inspection requirements of laws and

regulations
Legal Inspection related to nuclear related components
Electricity Business Act (Operator's Inspection on Welding ,
Pre-Service Inspection) etc.
Japanese Industrial Standards
Material verification Inspection, Dimensional Inspection,
Non- destructive Testing, etc.
Contracted specifications
requirements

Degree for witness of inspection

Extent for submittal of inspection records
Special inspection requirements
Receiving inspection, etc.
Design requirements

Requirement for Manufacturers Internal-inspection

Dimensional inspection, Cleanliness inspection, etc.
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Management of Tests and Inspections

Tests and Inspections shall be managed to satisfy the requirements of laws and
regulations, standards, contracted specifications and design requirements, etc.
Control of Tests and Inspections
Procedure
Quality Control Grade List(Degree of importance for QC, Degree for
witness of inspection, Extent for submittal of inspection records)
Tests and Examinations Procedure (Regulations, Standards,
Inspection process and procedure, Acceptance Criteria)
Control of Inspectors skill
Management of
Tests and
Inspections

Control of Inspectors skill in the company, Qualification of NDE

Control of in-process
Identification
Control of Identification for product (Identification for accepted

product, rejected product)

Control of tests and inspection

facilities
Control of measuring apparatus, Control of tests and Inspection
facilities
Control of QC records
Retention period for inspection records and documents,
coordinate procedure
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In-process inspection in shop

Typical Legal Inspection and Manufacturers Internal inspection for nuclear related
components
In-process
inspection
in shop

Legal
Inspection

Operator's Inspection
on Welding (welds)

Material Verification

Electricity Business
Act 52

Welding Inspection

Fit-up Inspection
PWHT Inspection
Non-destructive testing
Mechanical testing
Hydrostatic Test, Leak Test

Pre-Service Inspection
(Base Material)
Electricity Business
Act 49
Internal
inspection

Material Verification
Dimensional Inspection
Hydrostatic Test, Leak Test

Foreign Material Inspection

Cleanliness Inspection
Shipping Inspection

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Type of Inspection 1/2

There are many types of inspections based on their purposes.

Material Verification
CMTR(Certified Material Test Record) shall be examined.
In addition, identification on the product shall
be verified with the ID number in CMTR.
Fit-up Inspection
Groove surface shall be examined whether
blemishes or harmful foreign materials are
observed prior to start welding.
Welding Inspection
Welding record shall be examined.
Fit-up Inspection
Welding conditions and qualification of welder, etc.)
Non-destructive Testing
Part to be examined is inspected without destruction by NDT
method.

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Type of Inspection 2/2

Post weld heat treatment inspection
Heat treatment chart shall be examined.
heating /cooling rate, holding time, temperature, etc.
Mechanical Test tensile testing, bending test, impact testing
Strength of welded part shall be verified by these test.
Hydrostatic Test / Leak Test
It is verified that there is no deformation and leak
under specified pressure.
Visual Inspection
It is verified that there is no harmful defect on
the surface.
Dimensional Inspection
Product shall be measured and verified those
Hydrostatic Test / Leak Test
values shall be conform with required dimensions and tolerances.
Others
Cleanliness inspection, Foreign material inspection, Packing
inspection, Shipping inspection, etc.
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Inspection flow for pipe in-process Inspection

in a factory
Pipe
M

Cut

QCR( Quality Control Release)

Di
Welding
A

Pipe Cut
M
Di

UT

RT

PT

Vi

PWHT

Di

Packing
F
Shipping

Packing/Shipping inspection
M Material Verification , A: Fit-Up Inspection, W Welding Record Check,
PWHT: Post weld heat treatment inspection, UT: Ultrasonic Testing ,
RT: Radiographic Testing, PT: Liquid Penetrant Testing, Vi: Visual inspection ,
Di: Dimensional Inspection, P: Hydrostatic Testing ,F: Final Visual Inspection
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Internal-inspection,
inspection
legal
Internal-inspection

Examples for application of NDT technique

Digital RT
Digital RT is applied partially on pipe welds as Internal inspection.
Digital RT technique enable to filmless inspection and simplifying every aspect of
control through electronic database of radiographic films.
Dark room and processing of film are not necessary.
Signal processing and image processing can be applied on digital imaged RT.
Radiographic image is digitally processed and enable defect to be
easily visible and analysis the defect automatically.

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Examples for application of NDT technique

PC

Automated piping UT system

High-speed automated inspection
using automatic tool
Applicable Part : Weld of Straight
pipe and elbow

Flaw Detector

Applicable Size : 4B 14B

All UT signal data can be recorded
Highly precise data analysis by UT
analysis system
Color map 3D model

Control panel

Scanner

Automatic UT system
Flaw echo

Shape echo

3D model

UT analysis system
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11

Manufacturing flow for Steam Generator

SG in a factory
Material Verification, NDT, Dimensional Inspection etc.
Upper Head

Upper
Portion

Insertion
of the
Internal

Upper Shell

Conical Shell

Lower Shell
Tube Sheet

Channel
Head

Tube
Hole
Drilling

Helium Leak Test

RT ECT
Tube Hole DI

Cladding on
primary side

Final
Welding

Hydrostatic Test
As-built DI

Shipping

Lower
Portion

Middle Shell

Assembling of
Wrapper, TSP, Tube
and AVB

Channel
Head
Welding

Channel Head

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In-process Inspection for Steam Generator

SG in a factory
Inspection technique for Steam Generator SG
<General inspection>
Material Verification / Dimensional Inspection / Visual Inspection
/ Fit-Up Inspection / Hydrostatic Test/
Cleanliness Inspection Foreign Material Inspection
NDE(MT/PT/UT/RT)

< Special inspection >

Measurement system for heat exchanger tube holes diameter

RT/ECT for seal welds of heat exchanger tubes
Helium leak test for seal welds of heat exchanger tubes
Profilometry measurement of tube expanded area measurement by ECT
Measurement system for the gap between heat exchanger tubes
As-built 3D dimensional inspection

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NDT for
Following NDT is required for each type weld.
Weld Type

NDT (Based on Japanese nuclear code requirement)

VI

PT or MT

UT

RT

Butt Weld

(MHI Internal)

Full Penetration Weld

(Every 3 Layer
instead of UT or
RT)

Partial Penetration
Weld

Buttering

Cladding

(MHI Internal)

Seal Weld
(Tube to Tube Sheet
Weld)

Sample
inspection

Helium Leak
Test

(MHI internal)

For seal welds, ECT may be implemented.

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14

RT for circumferential welds of SG

SG is large component with thick wall.
For implementation of RT, high-energy source is required then RT is
implemented with LINAC.
LINAC(Linear accelerator)
High-Powered X-Rays generating machine

Specification
Maximum X-Ray Voltage: 12 MeV
X-Ray Output:32,130,520mC/Kg/min at 1 m
Maximum X-Ray Voltage: 7 MeV
X-Ray Output:8,320,130mC/Kg/min at 1 m
Focal Spot:1mm
Radiation field 300 mm at 1 m
Photographable
mm

thickness

50

500

steel

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15

Measurement system for heat exchanger

tube holes diameter
For heat exchanger tube holes diameter, laser technique is applied for
measurement.

Holding guide
Laser
Sensor
Encoder

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RT for seal welds of heat exchanger tubes

RT is applied for seal welds of heat exchanger tubes on SG to
verify the soundness of welding.
Center of tube hole

Film
Tube plate

Seal weld

Radiation
source

Image of radiographic film of

seal welds

Numbers of seal welds: 10000/SG

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17

ECT for seal welds of heat exchanger tubes

Application of ECT technique for seal welds of heat exchanger tube of SG

MHI has succeeded in developing of ECT technique for seal welds of

heat exchanger tube to verify the soundness of welds.
ECT technique is possible to apply not only detection of surface flow but
also flow in underneath the surface.
ECT SYSTEM
Control PC

Probe 1

Signal Cable

Probe 2

PC for Tester
Probe 3
Probe 4
Tester

Display of control software

Encoder cable
Controller

Probe
4 tubes simultaneous data
acquisition

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Controller
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Helium leak test for seal welds of heat

exchanger tubes
Leak test are required on seal welds of heat exchanger tubes (Tube-to-tubesheet
welds). Therefore, He-leak test is applied on this welds.
Lower Portion

Seal Weld
Suction Apparatus

Tube

He
Tube Sheet

Helium Atmosphere
Detector
He

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19

As-built 3D dimensional inspection

As-built 3D dimensional inspection by photogrammetry and laser tracker
are implemented before shipping.
Photogrammetry

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Laser tracker

20

In-process Inspection flow for Containment Vessel in

shop

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21

In-process Inspection flow for Containment Vessel

in shop
Top Dome Plate
M

Cutting Bending

Thickness
i

Pad Plate
M

Back Chipping
Welding

(Front Side)

Top Dome Plate

Cutting Bending

Package and Paint Check

Cutting

Machining Edge

Over Coat
Welding

B
(Back Side)

RT

Welding

Machining Edge

Back Chipping
Welding

A
(Front Side)

Machining Edge

MT

Di

Shipping
Pad Plate

Thickness
Machining Edge

Package and Paint Check

Over Coat
Welding

B
W
(Back Side)

RT

QCR Shipping

Di

Transport
by Sea
Internal-inspection,
Legal inspection
Internal-inspection

M Material Verification Test, A: Fit-Up Inspection, B: Back chipping Inspection, W Welding Record
inspection,
RT: Radiographic Examination, MT: Magnetic Particle Testing, Vi: Visual Inspection,
F: Visual Inspection of completion, T: Mechanical Testing (Impact test) ,Di: Dimensional inspection,

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Examples for application of NDT technique

Omnidirectional MT system
Omnidirectional MT system is applied on the
welds of bottom plate for CV.
This MT system enable to detect all round flow
at the same time because of application of
omnidirectional magnetic field.
This MT system enable to implement scanning
in constantly moving and improve efficiency of
the work.

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