[보고서]재료 열화손상 조기진단 신기술 개발

이덕현

재료 열화손상 조기진단 신기술 개발
Development of Advanced Technology for Early Diagnosis of Material Degradation and Damage 원문보기

보고서 정보
주관연구기관	한국원자력연구원 Korea Atomic Energy Research Institute
연구책임자	이덕현
참여연구자	최명식 , 정용무 , 박덕근 , 한정호 , 허도행 , 김경모 , 김홍표 , 정용환 , 심희상 , 임경수 , 박승규
보고서유형	2단계보고서
발행국가	대한민국
언어	한국어
발행년월	2017-04
과제시작연도	2016
주관부처	미래창조과학부 Ministry of Science, ICT and Future Planning
등록번호	TRKO201800005945
과제고유번호	1711035779
사업명	원자력기술개발사업
DB 구축일자	2018-05-12
키워드	증기발생기.전열관.배관.용접부.비파괴검사.조기진단.열화.손상.Steam Generator Tube.Pipe.Weld.Non-Destructive Test.Early Diagnosis.Degradation.Damage.
DOI	https://doi.org/10.23000/TRKO201800005945

초록 ▼

원전 설비의 구조재료는 가동기간이 경과함에 따라 열화에 의한 손상이 발생하며 이러한 열화 및 손상을 초기에 탐지하는 것은 기존의 비파괴 기술로는 매우 어려운 기술적 한계를 갖고 있다. 현재 수행되고 있는 원전 구조재료의 비파괴 진단기술은 이미 성장한 결함을 검출하고 크기를 평가하여 구조적 건전성을 입증하는데 치중되어있기 때문에 열화손상의 초기 상태를 조기에 진단할 수 있는 신기술의 개발이 시급한 실정이다. 최근에 국내 다수의 가동원전에서 발생한 증기발생기 전열관 대량 손상 및 원자로 관통관 손상으로 인한 기기의 조기 교체와 장기간 가동정지 등의 현장 사례에서 알 수 있듯이 원전 구조재료의 열화현상이 대량손상으로 발전되기 이전의 초기단계에 미리 손상을 진단할 수 있는 기술이 확보된다면 보수 및 대처기술을 적시에 사전 적용하여 효과를 극대화함으로써 원전 부품재료의 건전성과 수명을 증진시켜 안전성과 경제성을 혁신적으로 향상시킬 수 있음은 물론 원전의 안전성에 대한 국민의 신뢰도를 크게 높일 수 있다는 점에서 열화손상 조기진단 신기술 개발의 중요성이 더욱 강조된다. 본 연구에서는 가동원전 증기발생기 전열관 및 배관의 열화손상을 조기에 진단할 수 있는 와전류 및 초음파 검사 신기술을 개발하였으며 주요 내용은 다음과 같다.
● 증기발생기 전열관 곡관부 형상/결함 동시진단 신기술 개발
● 배관 및 용접부 비선형 초음파 진단기술 개발
● 매설배관용 장거리 유도초음파 진단장치 제작
● 결함평가 신뢰도 분석 및 검증DB 구축

(출처 : 서지정보양식 227p)

Abstract ▼

The structural materials in nuclear power plant are subject to degradation and damage with operation time, and it has technical limit to detect the degradation and damage in earlier stage using present non-destructive(NDE) techniques. NDE techniques of nowadays are focused on the detection and sizing of defects already grown to confirm the structural integrity and thus, the development of advanced techniques for earlier diagnosis of material degradation and damage are urgently needed. Recently, a number of domestic nuclear power plants suffered cracking in many steam generator tubes and reactor nozzles, resulting in the premature replacement of components and long term outage. The incidents tell us that if the defects could be detected earlier, the remedy for repair and mitigation could be applied timely to prevent the loss of safety, economy and public reliability of nuclear power plants. These lessons leaned also strengthen the importance of developing advanced techniques for earlier diagnosis of material degradation and damage. In this research project, various advanced techniques of eddy current and ultrasonic inspection were developed for earlier diagnosis of degradation and damage in steam generator tube, pipe and welds of operating power plant, as follows.
● Development of advanced technology for simultaneous diagnosis of geometry and defect in U-bend region of steam generator tube.
● Development of nonlinear ultrasonic diagnostic technology for pipe and welds.
● Development of guide wave diagnosis system for long range buried pipe.
● Analysis of reliability in defect evaluation and establishment of data base for verification.

(출처 : BIBLIOGRAPHIC INFORMATION SHEET 228p)

목차 Contents

표지 ... 1
제 출 문 ... 3
보고서 요약서 ... 5
요 약 문 ... 7
SUMMARY ... 16
CONTENTS ... 26
목차 ... 29
표목차 ... 34
그림목차 ... 35
제1장 연구개발과제의 개요 ... 43
제1절 연구개발의 목적 ... 45
제2절 연구개발의 필요성 ... 45
제3절 연구개발의 내용 및 범위 ... 46
제2장 국내외 기술개발 현황 ... 49
제1절 국내 기술개발 현황 ... 51
제2절 국외 기술개발 현황 ... 53
제3절 연구결과의 위치 및 수준 ... 55
제3장 연구개발수행 내용 및 결과 ... 57
제1절 증기발생기 전열관 곡관부 형상 및 결함 동시 진단 신기술 개발 ... 59
1. 곡관부 형상검사 코일 및 구조 상세설계 ... 59
2. 탐촉자 1차 시제품 제작 및 성능 평가 ... 64
3. 곡관부 결함 검출특성 향상 기술개발 ... 69
4. 곡관부 결함 검사 코일 및 구조 설계개선 ... 71
5. 탐촉자 2차 시제품 제작 및 성능 평가 ... 73
6. 형상/결함 동시 진단용 탐촉자 요건 최적화 ... 76
7. 최적화 탐촉자(U-Probe) 시제품 제작 ... 81
8. 신형 탐촉자 곡관부 형상측정 정밀도 및 결함 검출능 평가 ... 89
9. 신형 탐촉자 신호평가용 SW설계/Lab규모 시제품 제작 ... 93
10. 신형 탐촉자 신뢰도 및 제작/가동 원전 적용성 검증 ... 96
11. 신형 탐촉자 신호평가 SW 상용화 시제품 제작 ... 99
제2절 배관 및 용접부 비선형 초음파 진단기술 개발 ... 109
1. 비선형 초음파 신호처리 기술 개발 ... 109
2. 초음파 결함신호 영상화 기술 개발 ... 111
3. 비선형 초음파 미세결함 진단 시스템 구축 ... 119
4. 비선형 초음파 결함탐지 성능 평가 ... 123
5. 비선형 초음파 신호해석 SW 알고리즘 개발 ... 133
6. 비선형 초음파 신호해석 SW 성능검증 및 적용시험 ... 139
제3절 매설배관용 장거리 유도초음파 진단장치 제작 ... 144
1. 유도초음파 발생용 자기변형 밴드 시제품 제작 ... 144
2. 매설배관 결함탐지를 위한 유도초음파 모드 해석 ... 151
3. 자기변형 유도초음파 매설배관 적용기술 개발 ... 165
4. 매설배관 검사용 자기변형 유도초음파 성능 검증 ... 171
제4절 결함평가 신뢰도 분석 및 검증DB 구축 ... 182
1. 비파괴 결함평가 신뢰도 모델 개발 ... 182
2. 비파괴 결함평가 신뢰도 해석 및 시범적용 ... 187
제4장 목표 달성도 및 관련분야에의 기여도 ... 191
제1절 연구개발 목표의 달성도 ... 193
제2절 관련분야에의 기여도 ... 198
제5장 연구개발결과의 활용계획 ... 203
제6장 연구개발과정에서 수집한 해외과학기술정보 ... 207
제7장 연구개발성과의 보안등급 ... 211
제8장 연구장비의 구축 및 활용 결과 ... 215
제9장 연구개발과제 수행에 따른 연구실 등의 안전조치 이행 실적 ... 219
제10장 참고문헌 ... 223
서지정보양식 ... 227
BIBLIOGRAPHIC INFORMATION SHEET ... 228
끝페이지 ... 229

표/그림 (138)

표 Design diagram of eddy current test probe for U-bend ovality measurement.
표 Result of ovality measurement for row 1 U-tube of 3/4" OD with radius of 2.25"[4].
표 Design diagram of eddy current coil unit for inspection of low row U-tubes.
표 Design diagram of eddy current coil unit for inspection of high row U-tubes.
표 Photographs of prototype eddy current probes manufactured for the inspection of (a) low row U-tubes and (b) high row U-tubes.
표 Dimension of standard tube specimen for ovality measurement.
표 Calibration curve for conversion of signal amplitude to inner diameter.
표 Results of ovality measurement for straight tube region.
표 Results of ovality measurement for row 1 U-tube.
표 Results of ovality measurement for row >17 square type tube.
표 ECT c-scan of U-bend cracks.
표 Morphology of U-bend crack.
표 Sensitivity of +point coil amplitude on test frequency for EDM notches.
표 Optimized high frequency coils and test frequency characteristics, (a) +point and (b) pancake.
표 Prototype eddy current probes for U-bend.
표 +Point signals of (a) U-bend crack manufactured and (b) U-bend crack in US plant.
표 Vpp and signal to noise ratio of prototype eddy current probe for U-bend specimen with natural crack of small size.
표 Coil body size requirements.
표 Design diagram of 1-body eddy current probe.
표 Design diagram of 2-body eddy current probe.
표 Photograph of prototype eddy current probes.
표 EDM notch signals with test frequency.
표 Characteristics of Vpp amplitude on test frequency for various defect depth.
표 Normal signal of prototype probe for shape change.
표 Abnormal signal of prototype probe for shape change.
표 Zetec analysis results of prototype eddy current probe.
표 Driving performance of prototype eddy current probe.
표 Photograph of optimized prototype U-probe.
표 Accuracy of ovality measurement of prototype U-probe.
표 C-scan graph of eddy current signal from controlled U-bend ID crack.
표 Destructive examination of U-bend ID crack with different S/N ratio.
표 Detectability of U-bend ID crack in terms of S/N ratio.
표 Module for data conversion.
표 Graph from analysis of oval sections.
표 Noise distribution of U-bend specimens from 4 prototype U-probes.
표 Noise distribution of archive U-bend tube.
표 Noise distribution of U-bend specimen with defect.
표 Text format display of ZArchive binary file.
표 Signal profile and lissajous figure in MizVisualizer program.
표 C-scan data analysis figure with vertical and horizontal profile graph.
표 3D Surface plot of C-scan data.
표 Cylindrical modeling of C-scan data using PyQt and OpenGL modules.
표 The original signal represented on the time domain (left), and a wavelet transformed signal (right). The power of signal is represented as a function of time and frequency.
표 Schematic of nonlinear ultrasonic scanning system.
표 Photo of a nonlinear ultrasonic scanning system.
표 Fatigue test parameter.
표 Design diagram of 1/2T-1T CT specimens and pre-notches to make a trace for various shape of cracks.
표 Milling processing of both sides to make of nature crack and specimen photograph.
표 Manufactured nature cracking.
표 Comparison of harmonics between a) intact region and b) cracked region.
표 Normalized ultrasonic resonance pattern with respect to various exciting voltages.
표 Scanned image of cracked region a) photo of a crack, images of b) 1st fundamental frequency, c) 2nd harmonics, d) 3rd harmonics, e) 4th harmonics, f) 5th harmonics, g) 6th harmonics.
표 A setup for laser nonlinear resonant ultrasound spectroscopy.
표 A laser beam focused to a specimen to acquire a ultrasonic data.
표 Typical specimen assembly for nonlinear resonant ultrasound spectroscopy.
표 A setup for nonlinear ultrasonic resonance experiments.
표 Nonlinear resonance spectrum shows a more frequency shift when a specimen with longer crack length.
표 Block diagram for an impulse resonance acoustic spectroscopy.
표 Impulse resonance spectrum shows a frequency shift with increasing impact energy.
표 A drawing of specimen of PARENT open round robin test.
표 A typical nonlinear ultrasound spectrum of a specimen with crack.
표 Photo shows the controller and PC of LDV (Laser Doppler Vibrometer).
표 Photo of Laser with a tripod for a detector.
표 Photo shows a impact hammer with a ruler for measurement of impact hight or energy.
표 An example of specimen with a reflecting tape for laser.
표 Acoustic resonance spectrum with a various impact displacement for a CT specimen #1. color display shows vibration displacement measured by a piezo-sensor in the impact hammer.
표 Acoustic resonance spectrum with a various impact displacement for a CT specimen.
표 Acoustic resonance spectrum with a various impact displacement for a CT specimen #2. color display shows vibration displacement measured by a piezo-sensor in the impact hammer.
표 Acoustic resonance spectrum with a various impact displacement for a CT specimen.
표 Acoustic resonance spectrum with a various impact displacement for a CT specimen. color display shows vibration displacement or impact height measured by a piezo-sensor in the impact hammer.
표 Acoustic resonance spectrum with a various impact displacement for a CT specimen.
표 Algorithm for determination of effective resonance spectrum region using threshold analysis of peak values.
표 An example of ultrasonic resonance pattern(left) and converted bar code pattern(right). Frequence range: 0 ∼ 20 kHz.
표 An example of ultrasonic resonance pattern(left) and converted bar code pattern(right). Frequence range: 13 ∼ 15 kHz.
표 Drawing(top) and photos(bottom) for improved impact hammer device for acquisition of nonlinear ultrasonic resonance spectrum.
표 Extracted Results of nonlinear ultrasonic resonance spectrum for loose bonding.
표 Extracted Results of nonlinear ultrasonic resonance spectrum for loose bonding. (conti.)
표 Group velocity dispersion curve for a carbon steel pipe with diameter of 6 inch.
표 Photo of buried pipe mock-up (Dia. = 6 inch).
표 Photo of buried pipe mock-up (Dia. = 2.5 inch).
표 A ring type double magnetostrictive bands.
표 A spiral type double-layer coil(top) and single-layer coil(bottom) for generation and reception of guided wave.
표 A phot shows two magnetic bands bonded to 2.5 inch pipe for DC bias (left) and manually wound coil for AC magnetization (right).
표 A spiral coil for AC magnetization wound on a 6 inch pipe and terminals for connection to the magnetostrictive guided wave inspection system.
표 A plot of signal amplitude vs. DC bias current. (Dia. = 2.5 inch, signal from 40% circ. notch at 0.68 m from the sensor)
표 A plot of signal amplitude vs. frequency (Dia. = 2.5 inch, sensor = magnetic band + ribbon coil).
표 Phase velocity dispersion curve for a carbon steel pipe d = 63.5 mm, t = 7.0 mm.
표 Group velocity dispersion curve for a carbon steel pipe d = 63.5 mm, t = 7.0 mm.
표 Phase velocity dispersion curve (T(0, n) only) for a carbon steel pipe d = 9.5 mm, t = 1.24 mm.
표 Group velocity dispersion curve (T(0, n) only) for a carbon steel pipe d = 9.5 mm, t = 1.24 mm.
표 Wave structures (displacement vectors) of flexural vibration mode F(m, n) for a carbon steel pipe d = 9.5 mm, t = 1.24 mm.
표 Wave structures (displacement vectors) of torsional vibration mode F(m, n) for a carbon steel pipe d = 9.5 mm, t = 1.24 mm.
표 Magnetostrictive sensors for generation and reception of the T(0, 1) mode. Either a magnetic band with plate coil or a magnetostrictive strip with coil can be used.
표 Guided wave signal analysis of a pipe with diameter of 63.5 mm (2.5 inch) and wall thickness of 7.0 mm.
표 Guided wave signal analysis of a buried pipe mock-up with diameter of 63.5 mm (2.5 inch) and wall thickness of 7.0 mm.
표 Guided wave signal analysis of a buried pipe mock-up with diameter of 152.4 mm (6.0 inch) and wall thickness of 11 mm (Sch. No. 80).
표 Defect identification of a pipe mock-up with diameter of 152.4 mm (6.0 inch) and wall thickness of 11 mm (Sch. No. 80). (material: Carbon Steel, sensor: Fe-Co-V strip, pulse: 1 cycle)
표 Waveform analysis of a axial notch (top) and explanation of the wave propagation at an axial defect (bottom). (pipe diameter: 152.4 mm (6.0 inch), pipe wall thickness: 11 mm, material: Carbon Steel, magnetostrictive sensor: Fe-Co-V strip, pulse: 1 cycle)
표 Waveform analysis of two axial notches (top) and explanation of the wave propagation at two axial defects (bottom). (pipe diameter: 152.4 mm (6.0 inch), pipe wall thickness: 11 mm, material: Carbon Steel, magnetostrictive sensor: Fe-Co-V strip, pulse: 1 cycle).
표 Concept of GWSHM (Guided Wave Structural Health Monitoring) for a buried pipe inspection.
표 An example of comparison of GWSHM (guide waveform for structural health monitoring).
표 An example of waveform change at a different data acquisition condition.
표 An example of actual pipe diagram(left) and acquired guided wave signal(right).
표 Overlapped guided wave signals shows a little differences in time and phase. The signals were acquired at the same pipe same transducers with same parameter.
표 Simple subtraction of guided waves from the reference signals shows some residual signal components due to the differences of sound velocities and zero points.
표 Differences of guided wave signals due to the different sound wave velocities and zero points.
표 Different waveforms(left) are matched and show a coherent wave structures after the phase and time match program(right).
표 Comparison of the guided wave signals after signal elimination. The residue of geometrical signals(10% depth of wall thickness) after a phase-matched subtraction(bottom) shows a superior characteristics to those after simple subtraction(top).
표 Comparison of the guided wave signals after signal elimination. The residue of notch signals(10% depth of wall thickness) after a phase-matched subtraction (bottom) shows a superior characteristics to those after simple subtraction(top).
표 Comparison of the guided wave signals after signal elimination. The residue of notch signals(10% depth of wall thickness) after a phase-matched subtraction (bottom) were subtracted from the signals of 5% depth of wall thickness(top).
표 Comparison of the guided wave signals after signal elimination. The residue of notch signals(20% depth of wall thickness) after a phase-matched subtraction (bottom) were subtracted from the signals of 5% depth of wall thickness(top).
표 Comparison of the guided wave signals after signal elimination. The residue of notch signals(30% depth of wall thickness) after a phase-matched subtraction (bottom) were subtracted from the signals of 5% depth of wall thickness(top).
표 Location of coil sensor, PS(Pipe supports), and corrosion defect(top). A corrosion container with silicon gasket are fixed on the pipe(bottom).
표 Acquired guided wave signal(top) and the signal after processed with the phase-matched subtraction program(bottom). The right photo shows outer surface of pipe after a corrosion experiment with 10% nital solution for 24 hrs.
표 Acquired guided wave signal(top) and the signal after processed with the phase-matched subtraction program(bottom). The right photo shows outer surface of pipe after a corrosion experiment with 20% nital solution for 24 hrs.
표 Acquired guided wave signal(top) and the signal after processed with the phase-matched subtraction program(bottom). The right photo shows outer surface of pipe after a corrosion experiment with 40% nital solution for 24 hrs.
표 Acquired guided wave signal(top) and the signal after processed with the phase-matched subtraction program(bottom). The right photo shows outer surface of pipe after a corrosion experiment with 40% nital solution for 48 hrs.
표 Acquired guided wave signal(top) and the signal after processed with the phase-matched subtraction program(bottom). The right photo shows outer surface of pipe after a corrosion experiment with 40% nital solution for 72 hrs.
표 Dimensions of notches fabricated on the weld region of pipe.
표 Photo shows the pipe specimen used for the experiment(top) and schematic drawing shows the locations and dimensions of the weld and guided wave transducer in the pipe(bottom).
표 Baseline data acquired for the detection of the notch defect in the pipe weld.
표 RF signal (top) and video signal (bottom) after discrimination of the baseline signal(weld signal). The signals were acquired from the notch with a depth of 5% of pipe wall thickness, which equivalent to the 1.3% of CSA at the weld.
표 RF signal (top) and video signal (bottom) after discrimination of the baseline signal(weld signal). The signals were acquired from the notch with a depth of 10% of pipe wall thickness, which equivalent to the 2.3% of CSA at the weld.
표 RF signal (top) and video signal (bottom) after discrimination of the baseline signal(weld signal). The signals were acquired from the notch with a depth of 20% of pipe wall thickness, which equivalent to the 4.2% of CSA at the weld.
표 RF signal (top) and video signal (bottom) after discrimination of the baseline signal(weld signal). The signals were acquired from the notch with a depth of 30% of pipe wall thickness, which equivalent to the 6.6% of CSA at the weld.
표 Acquired guided wave signal(top) and the signal after processed with the phase-matched subtraction program(bottom). The signals were acquired from the corrosion defect with a depth of 0.25 mm, which equivalent to the 1.66% of CSA at the weld.
표 Acquired guided wave signal(top) and the signal after processed with the phase-matched subtraction program(bottom). The signals were acquired from the corrosion defect with a depth of 0.95 mm at weld region and 0.6 mm at the pipe region, which equivalent to the 2.55% of CSA at the weld.
표 Acquired guided wave signal(top) and the signal after processed with the phase-matched subtraction program(bottom). The signals were acquired from the corrosion defect with a depth of 1.86 mm at weld region and 1.14mm at the pipe region, which equivalent to the 3.46% of CSA at the weld.
표 C-scan graph of +Point coil signal from crack with S/N : 0.5.
표 Photographs of pressurization test on the U-bend specimen of Fig. 3.4.1.
표 C-scan graph of +Point coil signal from crack with S/N : 1.4.
표 Photographs of pressurization test on the U-bend specimen of Fig. 3.4.3
표 C-scan graph of +Point coil signal from crack with S/N : 1.7 and 1.0.
표 Photographs of pressurization test on the U-bend specimen of Fig. 3.4.5.
표 Reliability of crack signal analysis in U-bend region based upon structural integrity performance criteria.
표 History review of ISI data for crack indication in row-1 tube U-bend region of operating power plant.
표 C-scan graph of eddy current signal from small ID crack in U-bend specimen.
표 C-scan graph of eddy current signal from an operating power plant.

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