Samuel W. Glass

This document describes the adaptation of a clamshell inductive current coupler for online reflectometry testing (both frequency domain reflectometry and spread spectrum time domain reflectometry) to evaluate cable anomalies. The life span of safety-critical nuclear power plant cables are initially qualified for 40 years in accordance with IEEE 383 without additional testing. As plants extend their operating licenses to 60 and 80 years, justification for continued safe operation includes cable test and condition monitoring programs. Test programs traditionally involve manual interventions to disconnect the cables, perform one or several tests, then reconnect the systems, usually during refueling outages occurring only every 2 years. Offline testing poses an operational burden that can be minimized by online testing. This work investigates the adaptation of a clamshell inductive current coupler to inject a signal onto a cable conductor and listen for a reflected signal indicative of a damage condition. The coupler provides >60 dB of protection, thereby allowing tests on cables up to 10 kV or more. Although the clamshell coupler is a known commercial product for cable performance testing, it’s use for energized cable condition monitoring constitutes a novel use case.

One approach for mitigation of stainless steel (SS) spent fuel canisters (SFCs) is to coat the welds or even the entire SFC with a cold-sprayed nickel coating. The coating can serve as a magnetostrictive interface between an electromagnetic acoustic transducer (EMAT) and the SS plate material. The EMAT can send ultrasound into the canister and “listen” for reflections caused by chloride-initiated stress corrosion cracking (CISCC) or other damage mechanisms that may lead to leaks if undetected and unmitigated. This project outlines an approach for monitoring the integrity of SFCs using magnetostrictive EMAT sensors, which emit and detect discontinuity-initiated reflections indicative of pits or cracks likely arising from CISCC. Flat 13 mm SS plates with welds similar to actual canister welds were prepared, with flat-bottom holes 3 mm and 6 mm deep and 6 mm in diameter placed within the weld heat-affected zone (HAZ). The most effective sensor configurations were able to detect critical discontinuities more than 2 m away. Although a single sensor could be robotically deployed, the large volume covered by each sensor could support a small number of permanently mounted sensors, equipped with an external connector for periodic interrogation. The HAZ of a hypothetical SFC cylindrical surface could be effectively monitored with just 16 sensors.

Planar capacitor sensors have been proposed to measure the aging related dielectric constant variation of the jacket or insulation materials of cables. Although capacitor sensors have been used to monitor the aging of cable insulation by removing the jacket, through the jacket measurement of cable insulation dielectric constant variation is difficult because once the sensor is placed on the jacket it would either measure the aging of the jacket or that of the jacket and insulation together. A reconfigurable sensor along with innovative cable specific models could be used to determine the jacket and insulation aging using the same sensor. For the proposed novel reconfigurable sensor, the electric field penetration depth is changed by activating and deactivating PIN diode switches. In one instance, the sensor measures the dielectric constant variation of the jacket, while in the next it measures the dielectric constant variation of both the jacket and the insulation. By leveraging previously developed capacitance estimation models from large scale finite element simulations for a specific cable these two sets of measurement data are used to evaluate the aging related dielectric constant variation of the insulation. Experimental data from aged cable specimens are presented to demonstrate the operation of the sensor.

This letter introduces the study and application of a conformal surface wave launcher array to detect miniature insulation and/or jacket damage on unshielded cables. Simulation and experimental results are presented that demonstrate that with the proposed concept very small instances of damage at various distances along power cables can be detected. Effects of damage detection feasibility in the presence of other cables in proximity and for cables containing semiconducting screen are also presented.

This paper presents a non-conductor-contact surface wave-based reflectometry technique to detect and locate missing or damaged insulation and/or jacket of electrical cables. The described sensor may be uniquely and practically implemented on live cables as a non-destructive evaluation (NDE) method since it may be applied to the outer insulation/jacket of a cable and requires no direct contact to the conductor. The innovation lies in a high-frequency surface wave launcher that can introduce broadband signals in the GHz frequencies that insure maximum electromagnetic (EM) energy localization within the insulation and/or jacket material. By further processing the reflection data in the frequency domain, the location and severity of insulation damage is detected. Simulated results of thin, thick, short, and long cables show the results expected from small, medium, and large damage regions. For example, the detection of 40 mm-long damage region at 40 m distance on a 50 m long cable (2.44 cm diameter) is demonstrated. Experimental results are presented that validate simulation findings.

The U.S. Department of Energy's Office of Scientific and Technical Information

Online structural health corrosion monitoring in advanced molten salt reactor heat exchangers is desirable for detecting tube degradation prior to leaks that would either cause mixing of heat exchanger fluids or release of radiologically contaminated fluids beyond the design containment boundary. This program seeks to demonstrate the feasibility for a torsional wave mode sensor to attach to the outside of a long (30-m) heat exchanger tube in the stagnant flow area where the tube joins the heat exchanger plenum and where it is possible to protect a sensor cable from high-force flow connecting through a heat exchanger shell to a monitoring instrument. The envisioned sensor and cable management approach will be impractical to implement on existing heat exchangers; rather, sensors must be installed in conjunction with the heat exchanger fabrication. Initially, flaw surrogates of interest (50% notch and 50% flat-bottom hole) have been detected in a 3-m tube using low-temperature PZT piezoelectric crystals. The transducer consisted of multiple shear elements placed circumferentially around a tube. The program will continue to investigate higher temperature piezoelectric ceramics, long-term performance of high-temperature adhesives, and flaw sensitivity on long (30-m +) tubes.

This paper describes a technology review of nondestructive evaluation (NDE) methods that can be applied to cold spray coatings. Cold spray is a process for depositing metal powder at high velocity so that it bonds to the substrate metal without significant heating that would be likely to cause additional residual tensile stresses. Coatings in the range from millimeters to centimeters are possible at relatively high deposition rates. Cold spray coatings that may be used for hydroelectric components that are subject to erosion, corrosion, wear, and cavitation damage are of interest. The topic of cold spray NDE is treated generally, however, but may be considered applicable to virtually any cold spray application except where there are constraints of the hydroelectric component application that bear special consideration. Optical profilometry, eddy current, ultrasound, and hardness tests are shown for one set of good, fair, and poor nickel-chrome (NiCr) on 304 stainless steel (304SS) cold spray samples to demonstrate inspection possibilities. The primary indicator of cold spray quality is the cold spray porosity that is most directly measured with witness-sample destructive examinations (DE)—mostly photo-micrographs. These DE-generated porosity values are correlated with optical profilometry, eddy current, ultrasound, and hardness test NDE methods to infer the porosity and other information of interest. These parameters of interest primarily include: • Porosity primarily caused by improper process conditions (temperature, gas velocity, spray standoff, spray angle, powder size, condition, surface cleanliness, surface oxide, etc.) • Presence/absence of the cold spray coating including possible over-sprayed voids • Coating thickness Porosity primarily caused by improper process conditions (temperature, gas velocity, spray standoff, spray angle, powder size, condition, surface cleanliness, surface oxide, etc.) Presence/absence of the cold spray coating including possible over-sprayed voids Coating thickness Optical profilometry measurements of surface roughness trended with porosity plus, if compared with a reference measurement or reference drawing, would provide information on the coating thickness. Ultrasound could provide similar surface profile information plus attenuation measurements trended with porosity. The ultrasound measurements, however, may be limited to geometries where the substrate back-wall is normal to the cold spray surface and not too thick. Eddy current showed a strong correlation with porosity. Eddy currents can also be sensitive to cracks and do not need fluid coupling to make measurements, but are not sensitive to coating thicknesses in most cases. Vickers hardness measurements also tracked well with porosity; however, these types of hardness measurements are also not sensitive to coating thickness. An NDE program may include multiple measurements.

Cable insulation polymers are among the more susceptible materials to age-related degradation within a nuclear power plant. This is recognized by both regulators and utilities, so all plants have developed cable aging management programs to detect damage before critical component failure in compliance with regulatory guidelines. Although a wide range of tools are available to evaluate cables and cable systems, cable aging management programs vary in how condition monitoring and nondestructive examinations are conducted as utilities search for the most reliable and cost-effective ways to assess cable system condition. Frequency domain reflectometry (FDR) is emerging as one valuable tool to locate and assess damaged portions of a cable system with minimal cost and only requires access in most cases to one of the cable terminal ends. Since laboratory studies to evaluate the use of FDR for inspection of aged cables can be expensive and data interpretation may be confounded by multiple factors which influence results, a model-based approach is desired to parametrically investigate the effect of insulation material damage in a controlled manner. This work describes development of a physics-based FDR model which uses finite element simulations of cable segments in conjunction with cascaded circuit element simulations to efficiently study a cable system. One or more segments of the cable system model have altered physical or electrical properties which represent the degree of damage and the location of the damage in the system. This circuit model is then subjected to a simulated FDR examination. The modeling approach is verified using several experimental cases and by comparing it to a commercial simulator suitable for simulation of some cable configurations. The model is used to examine a broad range of parameters including defect length, defect profile, degree of degradation, number and location of defects, FDR bandwidth, and addition of impedance-matched extensions to minimize the end-shadow effect.