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Advanced Nuclear Technology

2017-2018 Candidate Task List and Project Opportunity Forms (and 2019+ Projects)

Page Task ID Project Name

Engineering, Procurement & Construction (EPC)

EPC RFA #1: Increase Efficiency and Reduce Cost of New Nuclear Construction

2 EPC 2017-C Investigating Mechanical Splicing of Reinforcing Steel

5 EPC 2017-D Optimization of Concrete Placements

7 EPC 2017-E Feasibility Study of Using Existing Software for Flow Simulation of SCC

9 EPC 2018-B Field Guide for Reinforcing Steel Inspections

11 EPC 2018-C Image Processing for Data Development of Construction As-Builts and Inspection

EPC RFA #2: Development of Collaborative Engineering, Design Tools, and Processes

13 EPC 2017-A Vertical Response Motion Computation in SSI Analysis of Embedded Structures

16 EPC 2017-B Ground Motion Kappa Parameter Reassessment

19 EPC 2018-A Alternative Methods and Materials to Reinforce Concrete

EPC RFA #3: Improve Quality of Supply Chain for Nuclear

N/A No projects for prioritization

21 EPC 2019+ Quick Descriptions of Potential 2019+ EPC Projects

Modern Technology Application (MTA)

MTA RFA #1: Advanced Monitoring Technology and Data Management

25 MTA 2017-B Assessment of Automation Technologies to Reduce Chemistry and Radiochemistry O&M Costs

27 MTA 2017-E Gaps and Opportunities for Sensor Applications

29 MTA 2018-C Technical Evaluation of Using IPAWS Notification System

MTA RFA #2: Technologies to Improve Human Performance, Machine Interaction, and Operational Effect.

31 MTA 2018-A Alarm Prioritization and Filtering Methodology Improvement

33 MTA 2017-C Evaluation of Indoor Positioning Systems

36 MTA 2018-B Common Robotic Platforms

MTA RFA #3: Gaps for Use of Digital Systems Technologies in New Plants

39 MTA 2017-A Risk Informed Cyber Security Methods

41 MTA 2017-D I&C Obsolescence – Long Term Hardware Storage and Aging Mechanism

43 MTA 2019+ Quick Descriptions of Potential 2019+ MTA Projects

Materials & Components (M&C)

M&C RFA #1: Advanced Fabrication and Manufacturing Techniques

47 M&C 2017-C Additive Manufacturing Development

49 M&C 2018-D Evaluation of New Anti-Corrosion Surface Treatment Technologies for New Plants

51 M&C 2018-E Development of Adaptive Feedback Welding for Repair and Fabrication

M&C RFA #2: Material Performance and Inspection

53 M&C 2017-A Investigation of New Residual Stress Mitigation Techniques

56 M&C 2017-B Comprehensive Identification of New Plant NDE Needs

58 M&C 2017-D Guidance on the Application of HDPE Piping

60 M&C 2018-A Economic Evaluation of Upgrading Materials for New Plants

62 M&C 2018-B PWSCC Testing and Revision to Alloy 690 Tubing Specification

M&C RFA #3: New Materials Development

65 M&C 2018-C Support of Advanced 52 Weld Metal Development and Enhancement

68 M&C 2019+ Quick Descriptions of Potential 2019+ M&C Projects

71 M&C 2017 Qualification of Additive Manufacturing Components for Nuclear Applications (NEW)

EPRI ANT Project Opportunity Form *EPRI Internal Use Revision Date: 7/13/2016

UANT Project Title: EPC 2017-C Investigating Mechanical Splicing of Reinforcing Steel

UProject Leader: David B. Scott UPhone and Email: 704-595-2608, [email protected]

Target Start Date: January 2017 Planned Duration 12 Months

*EPRI WO Number: 1-****** *EPRI WO Title: tbd

Funding Plan (000 $s) 2017 2018 2019 2020 Future

Estimated Funding $120

Comments:

This was previously ANT Candidate Project 2016-T, which was a two-phased project that joined with the Rebar Field Guide project. The Rebar Field Guide project has now been separated and this POF includes only the mechanical splicing (quick connections) review of reinforcing steel.

Key Research Questions The usual placement of reinforcing steel includes overlapping and tying the steel and then moving the steel to its final location. The process can be time consuming and the overlapping of reinforcing steel increases the congestion of steel within concrete forms and reduces the effectiveness of consolidating the concrete around the reinforcing steel. Alternatively, reinforcing steel is sometimes joined using mechanical splices (sometimes these are created using what are called mechanical connections, couplers, or coupling sleeves). The mechanical splices can accelerate the steel placement process and reduce the congestion of steel within the forms. However, mechanical splices are not frequently used by the nuclear power industry though they have the potential of offering benefit.

Currently, design of reinforced concrete for nuclear safety-related structures is directed by ACI 349 which has developed Code Requirements for Nuclear Safety-Related Concrete Structures (the latest version being published in 2013). In this document, ACI 349 has deferred to ACI 318-08 for the use of mechanical couplers only in post-tensioning applications. More recently, ACI 318-11 has increased the use of mechanical couplers for anchorage systems in column bases and in-plane load transfer in walls. Additionally, the 2014 version specifically discusses the use of mechanical splices in special moment resisting frames and walls.

Some of the couplers which have reportedly been used require tapered threads which are machine cut or grout-filled units. They are sensitive to movement. Other systems which need to be explored include mechanical couplers which eliminate some of the limitations of other commonly used couplers (e.g., threaded couplers or grout-injected coupling systems). Namely, there are now epoxy-injected couplers which are less sensitive to movement of the bars after coupler placement. It is unknown if there are technical- or code-related hurdles for the use of these devices within the nuclear power industry.

Question(s): 1. What alternatives (material and methods) are available to structurally connect reinforcing steel?2. What types of mechanical couplers of reinforcing steel is available?3. Is the use of mechanical couplers advantageous at nuclear power plants and where do they provide the

largest benefit?4. What are the technical- and code-related hurdles that exist which restrict the use of these alternative

couplers for nuclear power construction?

mailto:[email protected]

Objectives The primary objectives of the project include the following items.

1. Investigate and inform about the use of mechanical splicing techniques and international standardsused for mechanical splicing.

2. Provide alternatives (e.g.; epoxy-injected coupling systems) to placing reinforcing steel to increaseconstruction efficiency and improve quality of concrete placements (as a result of less congestion).

3. List the recommended technologies for the use of coupling reinforcing steel for nuclear-power relatedconcrete structures and identify the current technical hurdles within ACI, ASME, and any other codesand standards.

Project Approach and Scope The project will predominantly consist of literature and technology review of mechanical splicing techniques and methods. It will identify the existing knowledge and state-of-the-art for mechanical splicing of reinforcing steel used in concrete structures for nuclear power plants. It will also include a review of existing codes and standards which deal with the use of mechanical splicing for reinforced concrete and the use of mechanical splices in nuclear power construction. This project is to:

1. Inform the end user about the availability and use of mechanical splicing options for reinforcing steelused in concrete.

2. Identify the current technical limitations of the current technologies and methods.3. Identify the current limitations of the current technologies and methods within codes, standards, and

regulatory requirements for nuclear power construction. Benefits which will be explored is efficiencyof steel placement, reduction in material and/or labor costs, and improvement in load transfer.Potential limitations may include stress risers developed at the coupler, inexperience with application,or inability to handle high temperatures as a result of a LOCA.

4. Identify a roadmap of needed activities, research, and development for the increased use ofmechanical couplers if the couplers are found to be beneficial for the nuclear industry.

Currently, the deliverable is expected to be a physical report for the end user.

Value and Benefit The value and benefit of the project will include the following items.

1. Additional options for structural designers to transfer strength of reinforcing steel2. Quicker placement and reduced congestion of reinforcing steel3. Improved quality of concrete placement and reinforced concrete members

Key Activities Key Activities and Milestones Due Date

1. Research the state-of-the-art of mechanical splices for reinforcing steel available to theinternational community 4/28/2017

2. Identify the benefits and limitations of the coupling technologies. 5/26/2017 3. Research the current technical hurdles for increased usage of mechanical coupling 7/28/2017 4. Identify code and regulatory acceptability of mechanical couplers and the path forward toincrease usage of mechanical coupling

9/29/2017

5. Publish EPRI report 12/22/2017

Anticipated Deliverables List of Proposed Deliverables

Deliverable 1: Advanced Nuclear Technology: Options for the Mechanical Splicing of Concrete Reinforcing Steel for Nuclear Power Plant Construction

Past EPRI Work on Topic Report Number and Title Description Date

3002005440; Advanced Nuclear Technology: Anchorage of High-Strength Reinforcing Bars with Standard Hooks

The deliverable provided an end user with the empirical results of reinforcing concrete using 80 to 120 ksi deformed bar steel. The testing was focused on standard hooks and structural member connections.

October, 2015

Related Research


ANT Project Title: EPC 2017-D Optimization of Concrete Placements

Project Leader: David B. Scott Phone and Email: 704-595-2608, [email protected]

Target Start Date: January 2017 Planned Duration 21 months

*EPRI WONumber: 1-****** *EPRI WO Title: tbd


Estimated Funding $100 $115 Comments:

Key Research Questions Concrete placements at NPPs are unique in that most of the other materials are qualified and in their final form prior to arrival at the site. Concrete components are shipped individually and then batched while onsite and placed in its final form while it cures. Concrete placement volumes are often limited for multiple reasons which include the capacity of the batch plant(s), availability of concrete pumps, QA/QC inspections, pour heights, allowable form pressures, and temperature limitations on mass concrete placements. These limitations on placement size result in schedule delays because of slower and smaller placements of concrete. There are opportunities to increase the magnitude of the pours to reduce the critical-path schedule of construction of NPPs. Given the vastness of concrete use as a structural material at NPPs, a reduction of the number and duration of concrete placements could save weeks and months of the total construction process at NPPs.

Question(s): 1. Are improved batching, inspection, and placement practices for NPP construction achievable?2. How can concrete placements used for NPP construction be optimized to reduce concrete pour

schedules for NPPs?3. What improvements can be made in the specifications to allow more efficient concrete placements at

NPPs?4. Are there needed changes and adjustments to current codes and specifications which prevent the

implementation of any of the findings from this research?

Objectives The primary objectives of the project are to:

1. Identify inefficiency and common delays of concrete placements for NPPs.2. Identify opportunities to better optimize concrete placements for NPPs.3. Identify areas for increased efficiency for concrete placements through the entire life cycle of the

concrete design and placement process – specifications, storage, batching, inspecting, placing, curing,and stripping.

4. Identify areas within concrete specifications and codes which restricts the implementation of theseoptimizing techniques and presents a plan to address and remove these restrictions.


Project Approach and Scope This project is intended to compile common best-practices used within the concrete industry. It will then compare those best-practices with the experiences of concrete placements in the nuclear power industry. The identified gaps will then be compiled and a guidance document will be developed. The primary area of focus will be on the mixture design and specification, batching processes, delivery mechanisms, and formwork requirements used at NPPs. Additionally, the results of the project should be implementable and accepted by regulators, code, and specification organizations. The project will identify any restrictions from implementation of these techniques and develop a roadmap for addressing and removing these hurdles. The document is intended to be an easy-to-use guide to have immediate impact on the schedule and processes used for concrete construction. Value and Benefit Millions of dollars are spent per day for and during the construction of NPPs. Batching and placing concrete is used for horizontal and vertical construction activities at a NPP and utilizes large amounts of resources in time and personnel. Shortening the amount of time needed to complete concrete pours has the potential of saving plants weeks and months of construction schedule and thereby reduce the cost and risk of NPP construction. More specifically, the benefits include:

1. Reduced concrete construction risks 2. Faster, more-efficient concrete placements 3. Reduced construction schedule and thereby increasing cost savings 4. Improved quality 5. Available alternatives to accelerate construction schedule to makeup other delays 6. Less material waste and loss of time

Proper implementation of best-practices for concrete placements will provide NPP sites with leveraged value that far exceeds the cost of the project. Key Activities

Key Activities and Milestones Due Date 1. Research best practices for the entire life cycle of concrete design and placement 5/31/2017 2. Identify inefficiencies of concrete placements at NPPs 6/30/2017 3. Identify gaps – best practices relative to concrete placements at NPPs 8/31/2017 4. Compile results of research 12/29/2017 5. Identify regulatory, code, and specification restrictions of these techniques 3/30/2018 6. Publish findings in EPRI report 9/28/2018 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Advanced Nuclear Technology: Optimization and Best Practices of Concrete Placements for Nuclear Power Plant Construction Past EPRI Work on Topic

Report Number and Title Description Date 3002000520, General Outline for Conducting Quality Inspections and Tests of Concrete Placement at Nuclear Facilities

This document is a concise and easy-to-use field guide for inspecting concrete placements at nuclear power plants. May, 2013

Related Research


ANT Project Title: EPC 2017-E Feasibility Study of Using Existing Software for Flow Simulation of Self-Consolidating Concrete





Estimated Funding $160 $170

Comments: This project has changed to a start of 2017 based on additional review of the multiyear plan and additional member feedback

Key Research Questions In 2015 and 2016, EPRI has been studying the plastic and mechanical properties of self-consolidating concrete (SCC). The use of SCC is continuing to increase in construction of nuclear power plants (NPPs) and is vital for increasing efficiency of concrete placements at NPPs. Regulation requires that SCC mixtures be reviewed to ensure adequate placement in the structural members of an NPP. The requirements include a significant number of large mockups to be constructed to test the use of the SCC. There is not widespread usage of modeling software (more specifically, computational fluid dynamics (CFD)) to predict the expected flow capabilities of SCC. Utilizing CFD could allow the sites to dramatically reduce the need to design and construct mockups and also inform the construction team on their concrete pour plan. Question(s):

1. Are there ways to reduce the number of mockups being required at NPP for self-consolidating concrete? 2. Can existing software (e.g., computational fluid dynamics (CFDs)) be used to simulate self-consolidating

concrete to indicate the plastic properties and adequacy of SCC placements (e.g.; filling ability, flow ability, passing ability)?

3. What barriers are preventing the use of existing CFDs for this purpose and can those barriers be overcome through EPRI development?


1. Identify the rheology requirements of SCC for typical structural members at NPPs. 2. Identify existing, off-the-shelf software used for computational fluid dynamics that could be used to

model SCC. 3. Demonstrate the use of the CFD software for predicting SCC flow. 4. Measure different SCC mixtures using the identified model and compare with mockups which are

consistent with structural members found at NPPs. 5. Determine what limitations there are in existing CFD software and what it would take to overcome

those barriers to produce a CFD capable of reducing the number of mockups needed at NPPs.


Project Approach and Scope This project is intended to demonstrate the use of CFD software for self-consolidating concrete placement. It will consist of two phases. The first phase will be to identify existing software used for CFD and determine which would be a good candidate to model the flow of self-consolidating concrete. The second phase would be to model self-consolidating concrete using the CFD model and compare the results of the CFD with that of the placement in the mockups. Phase two of the project will identify the limitations of using existing CFD to accurately model self-consolidating concrete and determine what would be required to circumvent the inadequacy of existing CFDs. This project is also planned to include a field trial of the CFD software on a scheduled concrete placement at a construction site (preferably a NPP site). Finally, the research results will be published by EPRI. Value and Benefit The value and benefit of the project will include the following.

1. Less mockups needed to receive approval of SCC mixtures for specific structural members 2. Improved quality in concrete placements 3. Identification of existing software which can be used for modeling SCC mixtures 4. Identification of areas of concern in structural members for placing SCC 5. Increased construction and constructability 6. Ability to quickly adjust concrete mixtures based on needed changes in rheology 7. Less restrictive regulatory requirements

This project will also provide the research team with additional uses of modeling for concrete placement. Computer-aided concrete placement is not performed except for a very limited amount for mass concrete placement. However, using computers to enhance design and planning of concrete pours is very reasonable and valuable. It should be explored. Key Activities

Key Activities and Milestones Due Date 1. Research existing CFDs with potential to be used to model SCC 2/15/2017 2. Identify the most suitable CFD for modeling SCC 3/15/2017 3. Model multiple SCC mixtures and develop mockups 8/31/2017 4. Compare CFD models with mockups and perform pilot study in the field 4/15/2018 5. Identify limitations of existing CFDs and needed R&D 6/15/2018 6. Publish findings in EPRI report 12/15/2018 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Advanced Nuclear Technology: Feasibility Study of Using Existing Software for Flow Simulation of Self-Consolidating Concrete Past EPRI Work on Topic

Report Number and Title Description Date

30020005228, Evaluation of Self-Consolidating Concrete Mixtures and Structural Members – Phase 1

This is a technical update of the on-going EPRI research on self-consolidating concrete. It provides the results of the testing indicating the plastic and hardened properties of SCC and comparing those properties with conventional concrete mixtures. It leads into Phase 2 of this project which consists of mockup testing of conventional and SCC mixtures.

December, 2015

Related Research


ANT Project Title: EPC 2018-B Field Guide for Reinforcing Steel Inspections





Estimated Funding $120

Comments:

This project was previously proposed as ANT Candidate Project 2016-T and was joined with the project related to mechanical splices. This and the other project have now been separated and this POF includes only the development of a field guide for inspection of reinforcing steel.

Key Research Questions The inspection of reinforcing steel is usually performed by site personnel responsible for visually assessing how well the material and placement of the reinforcing steel comports with that which was designed and specified. In some cases, other design and field engineers also review the placement of reinforcing steel prior to placement of the concrete around the steel. In 2013, EPRI published a document titled, General Outline for Conducting Quality Inspections and Tests of Concrete Placement at Nuclear Facilities (Product ID: 3002000520). As the title indicates, the document provided an easy-to-use field guide to assist engineers in providing quality inspections of concrete placements. Similarly, EPRI intends to publish a document to assist inspection of reinforcing steel. The project intends to utilize existing standards and specifications to provide the end user with information that will include bar details, typical sizes, strengths, deformation patterns, reasons to use smooth bars, mill test reports, applicable codes/standards, materials, coatings, development lengths, splicing, tie patterns, cutting, bending, supports, and ties. Reinforcement types to be included in the report include tendons, deformed bar, and smooth bar. Question(s):

1. What easy-to-use guide or tool is available for design and field engineers to investigate the placement of reinforcing steel prior to concrete placement?

2. Can visual inspection of reinforcing steel become more efficient through additional tools provided to the field engineer responsible for inspection of reinforcement?

3. What format is best used by inspectors and engineers to investigate reinforcing steel at a nuclear power plant (e.g.; hard copy, tablet, smartphone)?

Objectives The primary objectives of the project include the following items.

1. Provide easy-to-use field guide for inspection or reinforcing steel prior to concrete placement. 2. Simplify the inspections of reinforcing steel at nuclear power plants. 3. Improve the inspections of reinforcing steel at nuclear power plants.


Project Approach and Scope Based on similar projects produced by ANT in recent years, this project is expected to be a high-value, usable deliverable for the industry. The research will begin with collecting all of the applicable codes and standards used for the design, placement, and inspection of reinforcing steel. This includes nuclear regulation; ACI codes, standards, and guides; documents from the Concrete Reinforcing Steel Institute (CRSI), and international guidance. This information will be compiled and a concise field guide developed to better prepare a field engineer and/or design engineer to perform inspections on reinforcing steel. The field guide will consist of summaries of the different aspects of reinforcing steel and include complementary images to assist the end-user with performing inspection of steel reinforcement at an NPP. The images are expected to be copious in order to assist the end user with steel inspection. The guideline, at a minimum, will be formatted to be a handheld hardcopy document and suitable for a tablet-like device or smartphone. We expect the digital deliverable will also include a customizable and editable inspection template. Value and Benefit The value and benefit of the project will include the following.

1. Concise guidance for site representatives responsible for inspecting reinforcing steel 2. Increased consistency of inspection of reinforcing steel 3. Improved quality of concrete placement and reinforced concrete members

Key Activities

Key Activities and Milestones Due Date 1. Literature review (to include codes, standards, and guides for reinforcing steel) 2/15/2018 2. Compile abundant number images to support the guide 3/31/2018 3. Develop final outline for guide 3/31/2018 4. Draft guide (include abundant images to assist end user) 9/29/2018 5. Issue EPRI deliverable (potential formats: hard copy and/or tablet) 12/22/2018 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Advanced Nuclear Technology: Mechanical Splices of Concrete Reinforcing Steel for Nuclear Power Plant Construction Deliverable 2: Advanced Nuclear Technology: General Guidance for Performing Placement Inspections of Concrete Reinforcing Steel Past EPRI Work on Topic


3002000520; General Outline for Conducting Quality Inspections and Tests of Concrete Placement at Nuclear Facilities

The deliverable provided an end user with concise and easy-to-read guidance on performing field inspection of fresh concrete which included information about mixture development, batching, testing of concrete properties, conveyance, and curing of the concrete.

May, 2013

3002005440; Advanced Nuclear Technology: Anchorage of High-Strength Reinforcing Bars with Standard Hooks

The deliverable provided an end user with the empirical results of reinforcing concrete using 80 to 120 ksi deformed bar steel. The testing was focused on standard hooks and structural member connections.

October, 2015

Related Research


ANT Project Title: EPC 2018-C Image Processing for Data Development of Construction As-Builts and Inspection


Target Start Date: January 2018 Planned Duration 24




Key Research Questions Typical inspections of steel and concrete placement consists of a representative of the construction team to visually observe and test the location of the material and components. Similarly, as-built construction drawings are developed by visually identifying the location of materials and components and digitally transferring the information to drawings and documents. In addition to these uses, visual inspections are performed to measure tolerance and configuration compliance. On a limited basis, some construction sites will use lasers to develop as-built drawings. Alternatively, there are imaging and software techniques which use cameras, parallel processing, and machine learning to scan and identify components and materials, and then make comparisons and perform analysis. For example, EPRI is pursuing this technology for visual inspection of crack in metals. The imaging techniques are swift and may offer a valuable alternative and improvement to visual inspections for compliance, tolerance, configuration tolerance, and production of as-built drawings. Question(s):

1. What are the applications of parallel image processing for NPP construction? 2. Can parallel image processing improve and accelerate construction inspection of steel bars and concrete

placement and the production of as-built drawings? 3. What gaps need to be filled in order to utilize image processing techniques for the development of

construction as-built drawings and to improve inspections of reinforcing and concrete placement?


1. Demonstrate parallel image processing for construction inspections. 2. Compare the use of image processing with laser scanning and visual inspections. 3. Identify the barriers which are preventing the deployment of image parallel processing techniques for

the verification of reinforcing steel and concrete placement. 4. Identify other uses and methods of deployment of image processing to improve construction activities

(e.g.; site configuration development, module placement tolerances, drones, and EPRI’s concrete crawler).


Project Approach and Scope This project is intended to demonstrate the feasibility of using existing image processing techniques to develop as-built drawings and perform accelerated inspections of existing reinforcing steel and concrete placement. This will be tested by first developing the code which uses image processing to detect placement of reinforcing steel and concrete placement tolerances. Mockups will then be designed and constructed to determine the limitations of the software. The mockups will be intended to have varying layers and configurations of steel. Placement deviations from that which is specified will fall within and outside the ranges deemed acceptable by ACI 117. The testing is intended to indicate the current limitations of the technology. In addition to the testing using mockups, the team plans to travel to a site that is under construction and measure the placement of reinforcing steel and the placement of concrete to inspect for tolerance compliance and develop as-built drawings. A comparison is intended to be made with performing the inspections and as-built drawings using traditional techniques (i.e., visual) and non-traditional techniques (i.e., laser scanning). The research findings will also include other applications of this technology and other methods to deploy this technology. Other applications to be considered include module placement, site configuration, piping as-builts, conduit installation, and structural steel placement. Other methods of deployment to be considered are EPRI’s concrete crawler, drones, and augmented-reality systems. The research results will be published by EPRI. Value and Benefit The value and benefit of the project will include the following.

1. Reduce the time spent for the development of as-built drawings 2. Reduce the time needed to perform placement inspections 3. Automatically identify deviations in material placement which need correction 4. Automate inspection of compliance checks relative to specifications

Key Activities

Key Activities and Milestones Due Date 1. Research existing image processing and development techniques for as-built drawings 3/15/2018 2. Develop multiple reinforcing steel and concrete mockups or examples 6/30/2018 3. Perform scanning and image processing on mockups 12/15/2018 4. Perform pilot testing at a construction site (nuclear or non-nuclear site) 6/15/2019 5. Compare image processing of the techniques and identify limitations of the software 9/15/2019 6. Perform a study on other applications of this technology within nuclear power construction 11/15/2019 7. Publish findings in EPRI report 12/20/2019 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Advanced Nuclear Technology: Inspection and Development of Construction As-Built Drawings Using Parallel Image Processing for Nuclear Power Plants Past EPRI Work on Topic

Report Number and Title Description Date Related Research


ANT Project Title: EPC 2017-A Vertical Response Motion Computation in SSI Analysis of Embedded Structures





Estimated Funding $225 Comments:

Key Research Questions The current approach to developing vertical motion for structural design is based on ground motion models that provide the horizontal hard-rock motion and incorporates site amplification to develop horizontal design motion. For vertical design motion, the soil column analysis is no longer performed; instead, the applicable frequency-dependent spectral ratios of V/H are applied to obtain the vertical design motion.

Once the horizontal and vertical design motion are determined, the motions are specified at the foundation level of the structure in the soil column and soil-structure interaction (SSI) analysis is performed in order to develop seismic structural responses for design of structure and equipment. In the SSI analysis, the vertical motion in the soil column amplifies from the foundation level to the ground surface and the resulting V/H ratio typically exceeds the pre-determined value at the surface. As a result, the structure is subjected to higher vertical motion resulting in higher vertical seismic demand for the structure and equipment design.

Question(s):

1. Can vertical motion in SSI modeling be improved to maintain the appropriate spectral ratio of V/H in the soil column within the embedment depth of the building?

2. How conservative is the current industry practice for SSI analysis when vertical soil amplification is not constrained?

3. Is the degree of over amplification of vertical motion by current SSI approach a function of soil properties, depth of embedment, and the frequency contents of the design motion?

4. How does the soil stratigraphy (e.g., soil and rock sites) change the value of V/H ratios and the vertical ground motion?

5. How can the V/H constraints be imposed in the SSI formulation for nuclear power plants? 6. What are the technical- and regulatory-related hurdles that exist for implementation of more accurate

vertical-ground-motion estimations for nuclear power plant design?


1. Develop a more accurate vertical motion in the free-field for SSI analysis that maintains the currently accepted constraints of V/H spectral ratios as used for development of design motions.

2. Provide a discussion and summary of study results that provide V/H ratios depending on soil properties and ground motion intensity.

3. Based on the free-field vertical motion, provide an estimate of how the in-structure response spectra (ISRS) can be reduced as compared to the spectra developed using the current practice.


4. Determine how results can be applied to adjust seismic design response and in-structure response spectrums.

5. Develop an implementation plan to increase acceptability of government regulators to accept the more accurate ISRS.

Project Approach and Scope The project will begin with a literature review of EPRI and other industry-published technical papers that discuss the most recent developments for modeling vertical ground motion for nuclear structures at soil and rock sites.

Using appropriate site-dependent V/H ratios, SSI methods and computer models can be modified so that the free-field motion in SSI analysis maintains the appropriate V/H ratio within the soil column. The approach will be tested for both soil and rock sites using a modified SSI approach.

Additionally, the project will include reviewing and discussing with NRC representatives to learn their perspective of using the soil-column analysis approach for developing vertical-ground-motion estimates. If the discussions warrant it, a roadmap will be developed to ensure that implementation of the to-be-studied SSI analysis will be implementable by the sites.

The final deliverable will include an assessment of the current SSI practice which includes the use of vertical motion for both soil and rock sites; a discussion of the characterization of the differences between the constrained and unconstrained vertical motion for both rock and soil sites in SSI modeling; and, if in consensus, a discussion of the process to implement the updated SSI analysis for ISRS in NPP design.

Value and Benefit There are multiple opportunities for the sites to benefit from the results of this research depending on the findings of the study. The benefits include:

1. More accurate seismic margin for the SSI loads and ISRS.

2. A more accurate assessment of vertical seismic demand loads for stability analysis particularly for structures with high buoyancy forces.

3. A reduction of in-structure demands to resist vertical ground motions due to seismic events.

4. A reduction in vertical ISRS to reduce the expected motion of floors and the resulting anchorage requirements for equipment and components.

Depending on the results, this project can be expected to provide sites with leveraged value that far exceeds the cost of the project. Potentially, the results of this study could allow very timely implementation at those sites presently performing equipment evaluations.

Key Activities

Key Activities and Milestones Due Date 1. Literature review and summary of the approaches 1/20/2017 2. Implement modeling of the vertical ground motion with the selected approach for SSI

analysis and testing the program 3/17/2017

3. Perform parametric vertical SSI study of a typical nuclear structure with multiple embedment depths in soil and rock and describe the differences in the results comparing current and improved methods

4/28/2017

4. Provide a qualitative assessment of the vertical ISRS generated by the current methods considering the improved method

5/19/2017

5. Identify technical and regulatory hurdles for implementation of vertical ISRS 6/9/2017 6. Draft, review, and publish EPRI report 11/3/2017


Deliverable 1: Advanced Nuclear Technology: Vertical Response Motion Computation in SSI Analysis of Embedded Structures Past EPRI Work on Topic


1025287, Seismic Evaluation Guidance Provides guidance on screening, prioritization, and implementation for the resolution of Fukushima near-term task force recommendations

Feb., 2013

300200722, Soil Structure Interaction Effects on a Nuclear Safety- Related Structure in the Central Eastern United States

The project was to study the soil-structure interaction of nuclear safety-related structures in the central and eastern portion of the United States where there has been a remapping of the seismic hazard maps.

May, 2013

3002002997, High Frequency Program The report documents results of high-frequency dynamic testing of devices utilizing three-dimensional input motion. Sep., 2014

Related Research High Frequency Seismic Loading Next Generation Attenuation for Central and Eastern Portions of the United States


ANT Project Title: EPC 2017-B Reassessment of Kappa Parameter for Ground Motion





Estimated Funding $100 $105 $110

Comments: This project is being co-funded with EPRI’s Structural Reliability and Integrity group with commitments from PG&E, BC Hydro, SC Edison, and Swiss Nuclear.

Key Research Questions A previous EPRI report was instrumental in estimating the ground motion high-frequency content for nuclear power plants within the United States. In recent years the seismic hazard maps within the central and eastern portion of the United States have been revamped. Results from the more recent study has indicated that the current hazard estimates within the United States are indicating considerably high-frequency content. The models which have developed from this previous research has led to the high-frequency, ground-motion content of rock sites being scaled up well above that of soils sites. This is particularly the case for relatively shallow rock sites where the high-frequency content can propagate quickly to the near-foundation area of structures. One of the parameters used to increase estimates of the high-frequency ground motion at structures is the “kappa” parameter. Based on the more recent collection of ground motion data within the central and eastern portions of the United States (CEUS), there are indications that suggest the “kappa” parameter overestimates the high-frequency ground motion of rock sites. Question(s):

1. Are the estimates of high-frequency ground motion overestimated at soft and hard rock sites? 2. Are there opportunities to determine if a reduction of high-frequency ground motion is warranted? 3. Will updated ground motion data indicate a reduction in ground motion estimates and thereby reduce

the structural requirements resulting from soil-structure interaction, in-structure response spectra, and structure-equipment response spectra?

4. What are the regulatory hurdles for implementation of the findings if the results indicate that the kappa parameter should reduce the conservatism of ground motion of hard rock sites?


1. More accurately determine ground motion for high-frequency seismic activities for NPPs located at soft and hard rock sites.

2. Determine if empirical and recent data will warrant a change in the “kappa” parameter for ground motion at NPPs.

3. Identify the technical- and regulatory-related hurdles which prevent the implementation of the findings at NPPs.


Project Approach and Scope This project will begin with a literature review of EPRI and other industry-related documents that indicates the options for reassessing the original studies published in 1995 by EPRI. It will provide an investigation of the data gathered related to high-frequency ground motion within the United States and the kappa multiplier. Additionally, the newer data which has been developed for the to-be-completed Next Generation Attenuation East project will be reviewed. This project will investigate the NPP sites found within the United States and focus on those sites which are determined to be rock sites – soft and hard. Resulting from the investigation, the project team will estimate new values for “kappa” and update global ground motion data. This will also include updating empirical models and high-frequency scaling factors for hard rock sites. During the research activities, regulators within the United States will be informed of the findings and EPRI will interface to ensure that there is adequate technical justification for the acceptance of these findings by the NRC. Value and Benefit There are multiple opportunities for the sites to benefit from the results of this research depending of the findings of the study. The benefits include:

1. A reduction in seismic capacity requirements for structures by providing a more accurate estimate of “kappa” values.

2. Improved accuracy of licensing and seismic PRA evaluations. 3. Changes in onerous structural requirements for construction materials and members as a result of

reduced ground motion at rock sites. 4. A reduction in the ground motion will also adjust the in-structure response spectra and thereby

reduce anchoring requirements for equipment and components inside the plants. Depending on the results, this project is expected to be provide sites with leveraged value that exceeds the cost of the project and within a couple of years the results of this study could quickly allow implementation at sites under design. Key Activities

Key Activities and Milestones Due Date 1. Literature review of ground motion data and site conditions for rock sites throughout the world 8/31/2017

2. Compare results of literature review, 1995 research, and NGA research 12/29/2017 3. Develop an initial, updated model with new kappa factor and scaling of high-frequency ground motions for rock sites 12/12/2018

4. Develop a final model for soft and hard rock site factors 5/31/2019 5. Develop a roadmap of the necessary technical justification for the regulatory acceptance 8/30/2019 6. Publish EPRI report 10/31/2019 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Advanced Nuclear Technology: Reassessment of Kappa Parameter for Ground Motions at Rock Sites for Nuclear Power Plants

Past EPRI Work on Topic Report Number and Title Description Date

1025287, Seismic Evaluation Guidance

Provides guidance on screening, prioritization, and implementation for the resolution of Fukushima near-term task force recommendations

Feb., 2013

300200722, Soil Structure Interaction Effects on a Nuclear Safety- Related Structure in the Central Eastern United States

The project was to study the soil-structure interaction of nuclear safety-related structures in the central and eastern portion of the United States where there has been a remapping of the seismic hazard maps.

May, 2013

3002002997, High Frequency Program

The report documents results of high-frequency dynamic testing of devices utilizing three-dimensional input motion.

Sep., 2014

Related Research High Frequency Seismic Loading Next Generation Attenuation for Central and Eastern Portions of the United States

EPRI ANT Project Opportunity Form *EPRI Internal Use 7/13/2016

ANT Project Title: EPC 2018-A Overview of Alternative Concrete Reinforcement Materials and Methods



*EPRI WO Number: 1-XXXXXXXX *EPRI WO Title: WO Title



Comments:

This project was previously proposed as ANT candidate project 2016-T and was focused on the effects of alternative materials for reducing the likelihood of corrosion. The project scope has increased to include the benefits of alternative materials and methods for structural design, construction, repair, and durability.

Key Research Questions Traditional reinforcing steel consists of deformed bars made of carbon steel with yield strengths of 40 and 60 kips/in2. These steel bars come in standard shapes and sizes for both imperial and metric units and are specified according to ASTM A615. Traditional reinforcing steel is known to have limitations and hindrances related to design, constructability, and durability (e.g.; development length requirements, lap splices, congestion, and corrosion). There are alternative methods to reinforce concrete besides using traditional deformed-bar, carbon steel. The alternative methods include materials consisting of polymers, glass, carbon, enamels. The alternative methods are also provided in a variety of shapes and different purposes such as coatings, wraps, fibers, and bars. The alternatives provide the structural designers and construction specialists at a nuclear power plant (NPP) with increased and improved options for preventing some of the issues with reinforced concrete. Some of the potential benefits of using these alternative materials include reduced weight of the structural members, reduced steel congestion, additional repair options, increase durability of the reinforcement, reduced need for inspection and repair. Questions:

1. What alternative methods and materials of reinforcement are available for NPPs? 2. What are the uses, benefits, and limitations of these alternative types of reinforcement for concrete? 3. How can these alternative methods save money and increase efficiency of design and construction at

an NPP? 4. What are the technical obstacles for these materials being used and what is the path for increased

acceptance from regulators of these alternative materials? Objectives This project is intended to identify and disclose other methods to reinforce concrete at NPPs and to inform NPP personnel about the best uses of the alternative reinforcement methods and materials. Besides identifying the uses, the project is intended to show the technical benefits and limitations of alternative reinforcement and indicate where/when the use of the alternative reinforcement could help improve design and construction (e.g.; reduced cost, standardized design practices, and improved engineering and construction schedules). The research will also include reviewing code, specification, and regulatory requirements to learn what steps need to be taken to increase use and acceptability of these alternative materials if they are found to be significantly beneficial to the construction of NPPs. A path/roadmap will be laid out to determine what would be needed for increased acceptance and usage.


Project Approach and Scope A summary of the project approach includes:

1. Identifying and disclosing the existing alternative methods and materials used for reinforcing concrete. 2. Describing the uses, benefits, limitations, and practices associated with the existing alternative

methods/materials for concrete reinforcement. 3. Correlating the structural areas that could and/or should utilize alternative materials to reinforce

concrete. 4. Identifying how the materials could be used to reduce costs, improve efficiency, increase repair

options, shorten schedule, and improve quality of the design, construction, and structures. 5. Learning what technical and regulated-related hurdles prevent increased usage of alternative

materials to reinforce concrete. 6. Compiling and reporting the project findings in an EPRI publication.

Value and Benefit There are multiple opportunities for this project to provide value and benefit to design and construction of NPPs. They include the following list.

1. Reducing the schedule and cost of construction 2. Increasing awareness of design alternatives to improve structural designs of the NPPs 3. Increasing strength and toughness of reinforced concrete 4. Providing alternative methods to repair concrete 5. Preventing inspection of concrete of which there is concern of structural deficiency

Key Activities

Key Activities and Milestones Due Date 1. Investigate the different methods to reinforce concrete – construction and repair 4/30/2018 2. Identify the benefits and limitations of the alternative methods to reinforce concrete 7/27/2018 3. Identify areas of the NPP which could improve by using alternative methods to reinforce concrete

10/26/2018

4. Identify code, specification, and regulatory limitations of alternative reinforcement for concrete

1/25/2019

5. Develop roadmap for removing the code, specification, and regulatory limitation of alternative reinforcement for concrete if the changes are technically justifiable

2/15/2019

6. Generate and publish final EPRI report detailing research findings 9/1/2019 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Advanced Nuclear Technology: Alternate Methods for Reinforcing Concrete in Nuclear Construction Past EPRI Work on Topic

Report Number and Title Description Date Related Research

Quick Descriptions of Potential 2019+ EPC Projects

EPC RFA #1: Increase Efficiency and Reduce Cost of New Nuclear Construction

EPC 2019-# Alternative Methods to Install and Protect Electrical Cable • Issue: Traditional conduit installation is time consuming and costly. • Scope: This project evaluates potential alternative materials/methods for installing and protecting cable

including armored cable and will document benefits, cost, integrity validation, and effort required to bring promising installation methods through to code acceptance.

• Value: This project will improve cost and schedule for new nuclear and reduce the space required for electrical cables.

EPC 2019-# Updated Field Guide for Concrete Quality Inspection (Including SCC) • Issue: In May of 2013, EPRI published a field guide pertaining to the inspection of concrete quality for new-

nuclear construction (Product id: 3002000520) that needs updating due to new information from EPRI research and changes in germane to codes and standards.

• Scope: This project will update the existing field to reflect the changes in codes and standards related to concrete and the latest SCC research from EPRI.

• Value: This project will improve inspections and reduce time required to prepare for the inspection of concrete. EPC 2019-# Enhancements to Modular Construction Usage for Nuclear Power Plants

• Issue: The latest nuclear power plants (NPPs) being constructed around the world include an increased use of pre-fabricated modules which are being assembled on site and there are opportunities to improve the utilization of modular construction.

• Scope: This project will identify where modular construction is currently being used and where there are other locations which could utilize modular construction and will identify additional areas where modular construction can be used and the impact – positive or negative – of the use of the modular elements at other areas of the site.

• Value: This project is intended to improve schedule, reduce assembly time and cost, and increase leveraging of pre-fabrication of materials and components prior to shipment to site.

EPC 2020-# Real-Time Corrosion Monitoring of Steel Liners Embedded in Concrete • Issue: Steel containment barriers which are adjacent to and/or embedded in concrete is at risk of corrosion and

corrosion/damage inspections of the steel is difficult and sometimes impossible without major excavation. • Scope: This project will demonstrate online corrosion monitoring of the steel containment using sensors

embedded in concrete and adjacent to steel. • Value: This project will increase component quality and decrease inspection requirements and improve

longevity of steel containment. EPC 2020-# Best Practices for Soil Testing and Site Development

• Issue: Site development consist of a large amount of time and expense for new-nuclear construction activities. • Scope: This project will investigate the best practices for preparing a site and testing the soil for vertical

construction at a nuclear power plant. • Value: This project will develop consistency in site development and soil testing, improve schedule, reduce costs,

and improve quality of site stability and drainage. EPC 2020-# Best Practices for Using SCC for Mass Concrete

• Issue: Mass concrete is specifically defined within the American Concrete Institute and is utilized regularly in nuclear power plant construction and it is sometimes made using self-consolidating concrete (SCC) mixture designs.

• Scope: This project identifies the best practices for utilizing SCC for mass concrete pours. • Value: This project will reduce the risk of failed placements or deficient mass concrete pours, improve schedule,

and reduce the need for redesign and/or repair.

EPC RFA #2: Development of Collaborative Engineering, Design Tools, and Processes

EPC 2019-# Guidance on Construction Documents for Failure Management

• Issue: In some cases, repair of deficient design and construction of structures are not built into contract documents at sites, which causes delays.

• Scope: The project scope includes identifying common construction deficiencies and compile best practices for the needed repairs.

• Value: The project will provide consistency, improve quality, and reduce construction downtime of repairs. EPC 2019-# Foundation and Site Development – Design, Guidance, and Analysis for Wet Environments/Sites

• Issue: Wet conditions which exist during site development causes a significant amount of delay. • Scope: This project will include investigating the impact of wet conditions on the development of the site,

identifying best practices for mitigating wet site conditions, and developing guidance on current practices to mitigate wet conditions at a nuclear power plant site.

• Value: This project will increase awareness of the causes of a site being “wet”, provide guidance on troubleshooting a “wet” site, and improve ability to select mitigation techniques for site development and foundation design.

EPC 2019-# Alternative NDE of Steel-Concrete Debonding and Internal Voids

• Issue: Recent structural designs for nuclear-power containments uses steel-concrete shell construction; and, there is currently no viable technique to inspect concrete behind a steel liner or plate.

• Scope: This project is going to investigate and demonstrate if NDE techniques can detect the steel-concrete bond and internal voids inside the concrete when the only inspection surface is on the adjacent steel shell.

• Value: This project will satisfy the reported potential regulator concerns and increase the availability of useable techniques for S-C inspection of concrete voids.

EPC 2020-# Insulation Design and Thermal Cooling Changes for Passive Plant Relative to Active Plant Designs

• Issue: Updated plant designs utilize a passive cooling system as part of the response to a loss-of-coolant accident (LOCA) or main-steam line break (MSLB) and the passive design introduces additional stresses and impact onto insulation material in the plant.

• Scope: This project will assess the effect of passive cooling system on insulation and determine if development is needed to provide greater resistance to impact and stress while maintaining insulation of parts and components.

• Value: This project will improve insulation for parts and components and reduce the need for relief requests and design changes for insulation.

EPC 2021-# Revisit Siting Guide and URD Documents for Potential Revision

• Issue: The latest revision of ANTs siting guide was published in 2016 (3002005435) and is considered the standard for site selection in preparation of application for early site permits (ESP); revision 13 of ANTs utility requirements document (URD) was published in 2014. It was updated to include information for SMRs.

• Scope: Currently, this project concept is here as a placeholder and reminder that these two documents may need periodic updating.

• Value: These projects provide comprehensive documentation to support ESP applications and a set of expectations for all EPC activities at a site.

EPC RFA #3: Improve Quality of the Supply Chain for New Nuclear

EPC 2019-# Lessons Learned to Optimize Design and Construction

• Issue: Systemic cost and schedule overruns need to be and can be reduced and increased awareness of these issues may prevent future occurrence.

• Scope: This project will consist of surveying and interviewing ANT members about new-plant construction experience and then compiling and ranking the lessons learned, impacts, and root causes of successes and challenges.

• Value: This project will provide the plants with increased awareness of options to reinforce the concrete at the plants and improve the constructability of the reinforced concrete.

EPC 2019-# Best Practices for Prequalifying Suppliers and Vendors

• Issue: There have been instances during recent new construction of nuclear plants, when progress was stalled because suppliers and vendors of components and materials were not able to produce at sufficient capacity.

• Scope: This project will develop a set of best practices for prequalifying suppliers and vendors for new nuclear power plants.

• Value: This project will increase the ability to maintain construction schedule for the site and thereby reduce the risk of obsolescence and costs.

EPC 2019-# Development of Comparison Code Document • Issue: Procured components and items are subject to specification requirements for the products to be certified

according to a specific institution, organization, or code that is not always internationally recognized. • Scope: This project will research equivalency of international standards and they will be vetted and compared to

determine which international standards are equivalent, to disclose those which are equivalent, and to identify the gaps between international standards.

• Value: This project will provide opportunity to reduce time and cost spent on unnecessary quality control of procured items.

EPC 2019-# Proactive Obsolescence Management for New Plants • Issue: Suppliers sometimes cease production support of items for business reasons and replacement of these

obsolete items is typically on an emergent basis and is therefore inefficient, expensive (equivalency evaluation/modification), and sometimes nearly impossible.

• Scope: This project will review causes of and identify precursors to obsolescence; and, it will review existing software and develop purchasing requirements (product information) needed to better mitigate the impact of obsolescence.

• Value: This application of this project will improve ability to manage spare and replacement item supply chain and reduce expense and lead-time due to replacement of obsolete items.

EPC 2019-# Standard Templates for Original Procurement of Nuclear Components, Materials, and Services • Issue: Regulatory, technical, and quality assurance requirements are numerous and complex; and, procurement

documents are presented in a multitude of formats and ultimately result in the inability of suppliers to maintain the inventory to meet needs of nuclear customers.

• Scope: This project will develop standard component and material specification content and format and standard technical and quality assurance requirement templates for procurement of parts, components, and services.

• Value: Resulting from this research there will be a standardization of procured items, enhanced communication and error reduction, and enhanced ability of suppliers to support nuclear customers for life-of-plant without custom fabrication, QA program application, and certification for each order.

EPC 2020-# Supply Reduction Study of Supplementary Cementitious Materials and Alternatives

• Issue: The most common supplementary cementitious materials (SCM) is fly ash and there are reports that the supply of fly ash will begin to be dramatically reduced in the coming years as a result of regulatory restrictions on fly ash production and landfill storage.

• Scope: This project will assess the effects of a supply shortage of SCMs and determine if alternative SCMs should be developed if the existing supply is not available.

• Value: This project will continue reducing material cost (one of the benefits of SCMs is the cost savings incurred by replacing cement) and increase preparation in case SCM shortage does occur.

EPC 2021-# Technology Transfer of Procurement Processes/Tools from Other Industries

• Issue: There are a variety of industries with existing processes for procuring products, materials, and components; and, these processes would enhance the nuclear industries procurement abilities.

• Scope: This project will scour the methods used by other industries (e.g.; airline, military, aerospace, medical) and determine how these industries procure supplies and determine how these practices can benefit the nuclear power industry.

• Value: Results from this project will develop procurement which is more efficient, state-of-the-art, and autonomous.

EPC 2021-# Owners Requirements Document for a Coatings Program

• Issue: The development of a coatings program consists of a large amount of time and effort to ensure compliance with regulations and the new plant designs (e.g., AP1000 and SMRs) will need new coatings programs which will consist of a significant amount of updated provisions for the new designs.

• Scope: This project will review the technical requirements of owners for a nuclear coatings program and determine the adjustments needed for the new plant designs and document owner/operator requirements and expectations for nuclear related projects.

• Value: This project will streamline development of a coatings program for newer plant designs and create consistency for coatings programs at new-nuclear sites.


ANT Project Title: MTA 2017-B Assessment of Automation Technologies to Reduce Chemistry and Radiochemistry O&M Costs

Project Leader: Matt O’Connor Phone and Email: (650) 855-8523, [email protected]




Estimated Funding $100 Comments: Opportunity to collaborate with (and co-funding from) Chemistry program

Key Research Questions A key need for the economic viability of advanced nuclear plants is the ability to safely operate and maintain the plant with an optimized staff to minimize O&M costs. As noted in EPRI 3002007071, automation of plant chemistry and radiation protection (RP) activities such as chemical/radiological sampling and analysis has the potential to significantly reduce O&M costs. Further, automation of such activities could have other technical benefits, including improvements in plant chemistry stability (i.e., more steady control) and increased availability of chemical and radiological data. Automation of chemistry activities also has the potential to significantly benefit currently operating plants. In particular, automation of chemistry and RP activities could be especially beneficial at plants that load follow or conduct flexible power operations, since such operation entails more frequent changes to plant operation and accordingly, results in more frequent changes to plant chemistry and radiochemistry levels, requires more frequent chemical additions/removals, etc. Objectives The purpose of this project would be to evaluate the technical and economic feasibility of automating chemical/radiological sampling and to identify and evaluate other candidate plant chemistry and RP activities that would be enabled by automated chemical/radiological sampling and analysis. Project Approach and Scope The proposed work includes the following tasks:

Task 1: Functional Specification for Automated Chemical/Radiological Sampling & Analysis In this task, a functional specification will be developed for the control and diagnostic species identified in the EPRI Primary (BWR & PWR) and Secondary Chemistry Guidelines and the radiochemistry species identified in Technical Specifications. This functional specification will include parameters such as the required sampling frequency, accuracy, lower limit of detection (LLD), range of measurement, calibration needs, reporting needs, integration with laboratory information management systems (LIMS), etc. Further, the functional specification will identify the nature of the sampling requirement, e.g., technical specification, NEI 03-08 mandatory, etc.

Task 2: Review of Available Technologies for Automated Chemical/Radiological Sampling & Analysis In this task, currently available automatic chemical/radiological sampling and analysis technologies will be reviewed. This review will include an assessment of the technical capabilities of each technology and will include an evaluation of the capital, installation, and O&M costs for the equipment. Further, costs will be assessed for installation at a plant that is under construction and installation at an existing plant.

Task 3: Comparison & Analysis of Automated Sampling & Analysis Technologies In this task, the technologies identified in Task 2 will be evaluated to determine which technologies are able to meet the functional requirements identified in Task 1. Then, a cost/benefit analysis will be performed to determine which of the identified technologies will result in the greatest plant chemistry and RP O&M cost reductions. This evaluation will include analysis for the implementation of the automation technology at a plant that is under construction and at existing plants. For both scenarios, barriers to entry and key enabling technologies will be identified. It is anticipated that this task would include one trip to a currently operating plant to help determine the typical costs and manpower needs associated with chemical/radiological sampling.


Task 4: Assessment of Other Automated Chemistry Activities Based on the Automated Sampling/Analysis A number of other routine plant chemistry/RP activities could be automated based on a control scheme (e.g., feedback control) coupled to the automated sampling and analysis. In this task, automated chemistry and RP activities that will be enabled by the automated sampling/analysis will be identified and evaluated. To help identify candidate activities for automation, EDF operating experiences with automation for load following control and U.S. experiences with automation for flexible operations (e.g., at a few Exelon plants) will be reviewed. Then, a cost/benefit analysis will be performed to determine which automated chemistry/RP activities would result in the greatest plant O&M cost reductions. This evaluation will include analysis for the implementation of the automation technology at a plant that is under construction and at existing plants. For both scenarios, barriers to entry and key enabling technologies will be identified. Value and Benefit This project will identify currently available automation sampling/analysis technology that is technically capable of meeting nuclear plant chemical and radiological sampling needs and will identify other automated chemistry /radiation protection (RP) activities that would be enabled by the automated sampling/analysis. Further, this project will provide utilities with the inputs needed to determine whether implementation of certain automated chemistry and RP tasks would result in cost savings and/or other technical benefits (e.g., improved chemistry stability, increased availability of chemical and radiological data, etc.) at their plant. This work would be most applicable to new plants (SMRs, advanced light water reactors, etc.). However, this work would also be fully applicable to currently operating plants that want to operate more efficiently. Key Activities

Key Activities and Milestones Due Date Task 1: Functional Specification for Automated Chemical/Radiological Sampling & Analysis 3/31/2017 Task 2: Review of Available Technologies for Automated Chemical/Radiological Sampling & Analysis 6/30/2017 Task 3: Comparison & Analysis of Automated Sampling & Analysis Technologies 8/31/2017 Task 4: Assessment of Other Automated Chemistry Activities Based on the Automated Sampling/Analysis 9/1/2017

Draft Technical Report 10/1/2017 Final Technical Report 12/10/2017

Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Final Technical Report Past EPRI Work on Topic

Report Number and Title Description Date 3002007071, “Advanced Nuclear Technology: Using Technology for Small Modular Reactor Staff Optimization”

Provides a roadmap for development of technologies to optimize staff utilization in SMRs. IPS is identified as a key enabling technology.

March 2016

3002005325, “Intelligent Plant Configuration Management Using Wireless Sensors: Application to Nuclear Power Plant Valves”

Demonstration of using wireless technology for valve positioning and operation. July 2015

Related Research EPRI 3002007071, “Advanced Nuclear Technology: Using Technology for Small Modular Reactor Staff Optimization,” provides a technology development roadmap for improving staff efficiency in SMRs. While the focus of this report is on SMRs, many of the findings are also applicable to newly constructed plants in general. This report identifies automated chemical and radiological sampling and analysis as an area that could significantly reduce required staffing.


ANT Project Title: MTA 2017-E Gaps and Opportunities for Sensor Applications

Project Leader: Matt O’Connor Phone and Email: 650-855-8523, [email protected]




Estimated Funding $90 $50 Comments: Potential partnership/co-funding opportunities with prospective vendors exist

Key Research Questions Advanced monitoring hardware and technology continues to make dramatic improvements in capability and breadth of applications, both inside and outside of the nuclear industry. Many sensor solutions for nuclear applications are customizable in nature, which can be cost-inefficient and also limit their deployment to other applications within the plant. Moreover, enabling technology for extreme or harsh operating conditions (such as radiation, high temperature/pressure environments, etc.) are currently available but their widespread use, understanding, limitations, and standards remain unclear. There still remains an industry gap between the available enabling technologies, their applications, and the cost to develop and deploy these solutions for normal and extreme operating conditions. Generation IV nuclear reactor technologies are also beginning to look at monitoring solutions in as-yet defined operating environments. This and other situations present a unique opportunity to identify knowledge gaps toward broader industry implementation of sensors in a number of different applications. Objectives The objective of this project will seek to close the gaps that exist between industry use and understanding of sensors for various operating conditions, their applications (for ALWR, SMR, and GEN IV technologies), and the costs to develop and deploy solutions. Successful completion of the project will include an industry summary and evaluation, a cost evaluation for specific technologies and applications, identification of regulatory and standards gaps as well as gaps toward broader implementation, and a short pilot project that demonstrates application of sensor technology in a specified operating environment (real or simulated). Project Approach and Scope The project approach will establish an industry benchmark through a detailed scoping study of available technologies; identify potential applications for these technologies (for various types of plant technologies such as GEN IV reactors and SMRs); identify several use cases for matching technologies to potential applications; and then perform a short pilot project to demonstrate the technology, identify limitations, and summarize results. Task 1: Scoping study: identify enabling sensor technologies for various operating environments. Task 2: Investigate SMR and GEN IV reactor technology sensor needs, refine applications, and identify other sensor gaps and opportunities; cost evaluation. Task 3: Define use cases (real or assumed) for advanced reactor technology applications; identify any known or potential regulatory impacts. Task 4: Perform short pilot/demonstration project for specific use cases; summarize results. Value and Benefit SMR technologies as well as advanced Generation IV plants are beginning to explore more detailed evaluation of operation and the monitoring and diagnostics needs that will help these plants perform well. Understanding how advanced sensor technologies will benefit these reactor designs now will support a more cost-optimized approach to detailed design in the future. Furthermore, the lack of clarity of how some of the already-existing sensor and monitoring technologies are being deployed merits further investigation to support broader industry awareness.


Key Activities Key Activities and Milestones (assumes January start) Due Date

Task 1: Identify enabling technologies for operating conditions. 5/1/2017 Task 2: Identify advanced reactor sensor needs; gaps and opportunities for deployment; cost summary. 8/15/2017 Task 3: Define use cases for demonstration 12/15/2017 Task 4: Perform short pilot/demonstration project; summarize results. 6/1/2018 Task 5: Final Report 7/31/2018 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: EPRI Letter report of Tasks 1, 2, and 3 Deliverable 2: Final technical report of all tasks, including summary of pilot project Past EPRI Work on Topic

Report Number and Title Description Date Related Research On-going work in the Nuclear Sector on sensor research is exploring the downstream use of data from various types of sensors, specifically with a focus on data management and equipment health monitoring, diagnostics, and prognostics. Efforts from that corporate Research Imperative will provide insight into the types of sensor technologies currently being evaluated for various reactor technologies. Work and research at ORNL is also looking at advanced sensor applications, as well as some of the requirements and standards for custom solutions. This project will collaborate with that lab’s efforts, either directly or through EPRI’s working agreement. Research and work in the EPRI Generation Sector is also looking into an ‘integrated plant’ set of technology solutions, which include advanced monitoring and sensor technologies. Parallel efforts with this group have already yielded a better understanding of how some sensor technologies can be deployed in various environments, and how the information from these sensors can be used to support improved plant performance.


ANT Project Title: MTA 2018-C Technical Evaluation of Using IPAWS Notification System for Emergency Communication

Project Leader: Matt O’Connor Phone and Email: 650-855-8523





Key Research Questions Historically for large, light water commercial nuclear power plants, EPZs with boundaries of approximately 10 miles in radius have been developed using geographical and jurisdictional features in order to communicate the area at risk to the public. This approach allows public safety officials to identify specific areas within the EPZ where protective actions may be implemented, such as sheltering-in-place or evacuation. By regulation, the capability must exist to promptly alert and notify members of the public within the EPZ. The current methodology employed by the nuclear industry predominantly relies on outdoor warning sirens that meet regulatory requirements for promptly alerting the public during a nuclear plant emergency. Significant technological improvements have been realized since the original prompt alert methods were developed in the early 1980s. New and accepted technologies are currently in use that can be employed for new or operating sites to ensure the public is promptly alerted in a more precisely defined area. These state-of-the-art alert technologies do not involve the use of outdoor warning sirens as the primary means for alerting the public, but do ensure that members of the public within the EPZ can be alerted within timeframes required by NRC regulatory requirements. The approach negates the need for outdoor warning sirens and instead uses a combination of methods, devices, and technologies that are typically available to members of the public. The key research need is determining the effectiveness and reliability of these alternative technologies at reducing risk of exposure to the public while investigating the reasonable practicality of removing sirens as primary alerting mechanisms. Objectives This project would evaluate the requirements needed to implement such a system, and what technical changes may be needed to inform or alter the regulatory standard, which may also shrink the existing 10-mile EPZ. Project Approach and Scope The project would employ a risk-informed approach that would generate a value for public dose exposure based on certain initiating events for nuclear accidents. The public dose exposure estimates can then be used to determine whether the alternate notification systems can provide the public with the government-required level of protection in the event of an incident and at an equal or improved cost (based partly on the costs to maintain and operate the boundary-level siren systems). Overall approach: Assess the use of IPAWS and WEA (Wireless Emergency Alert) to replace existing siren and custom notification technologies.

• Define site-unique specifics necessary to justify use of IPAWS. • Determine the effectiveness and reliability of IPAWS and WEA relative to the current siren and text message

systems. • Conduct a pilot integration and demonstration with selected technology to validate reliability and usability

assumptions.

The project consists of the following tasks:

Task 1: Develop effectiveness value for alternate enabling technologies. The purpose of this task is to define a set of parameters for alternate technology in terms of effectiveness of meeting protection requirements. This might include a technology’s ability to alert the public in different weather and terrain conditions, audibility, range of notification, known bandwidth limitations, and other operating and performance criteria. An expected outcome is a comprehensive understanding of alternate technologies available, their benefits and limitations, and rough estimates of lifecycle costs (implementation, operation, maintenance, upgrades, etc.)

Task 2: Compare effectiveness of proposed and existing public warning systems. This task will take the outcome from Task 1 and compare performance effectiveness of existing warning and alert systems to the parameters and government-required protection requirements of alternate technologies. A thorough understanding of reliability of these alternate systems compared to sirens and other existing warning methods will be developed, along with the type of information communicated in various scenarios. Also during this task, engagement with the U.S. NRC (to understand the regulator’s position on alternate technologies and to inform them of this research and intended outcomes) can begin. The goal

Task 3: Develop approach for implementing at new and existing sites. Once performance, operating, and cost parameters are understood and compared to existing public warning systems, an understanding of knowledge gaps and steps to close them can begin. This task will include working with existing and new plant stakeholders to develop a plan to implement an alternate system in the future. A sample worked example or pilot demonstration is expected to be developed during this task. Value and Benefit Technological advances in public notification and warning systems have far outpaced the current state of technology at nuclear plants. Moreover, the cost to operate and maintain these networks of outdoor warning systems can range from $2M - $3M per year, in addition to human resources. In addition to significant cost savings, implementing an alternate public warning system includes other benefits including:

• Reduce risk of exposure to the public • Lessen environmental impact by using existing equipment around new plants instead of installing separate

warning systems • Modern alerting systems can provide detailed and refined information to the public that avoids the ambiguity

and potential confusion of the current alerting systems.

21st-century technology can provide these and other benefits to new and existing plants and support more efficient, long-term plant operation. Key Activities

Key Activities and Milestones Due Date Task 1: Identify new technologies, assess effectiveness and quantify added value 5/1/2018 Task 2: Compare effectiveness of proposed and existing public warning systems 10/1/2018 Task 3: Final Report 12/21/2018 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Final Technical Report detailing findings and describing methods of notification, effectiveness and any other value adds Past EPRI Work on Topic

Report Number and Title Description Date Related Research EPRI 3002007071, “Advanced Nuclear Technology: Using Technology for Small Modular Reactor Staff Optimization,” provides a technology development roadmap for improving staff efficiency in SMRs. While the focus of this report is on SMRs, many of the findings are also applicable to newly constructed plants in general. This report identifies IPAWS Public Notification System as a mature enabling technology to improve EPZ evacuation response

EPRI ANT Project Opportunity Form *EPRI Internal Use Revision Date: 7/13/2016 ANT Project Title: MTA 2018-A Alarm Prioritization and Filtering Methodology Improvement

Project Leader: Matt O’Connor Phone and Email: (650) 855-8523, [email protected]

Target Start Date: December 2017 Planned Duration 22 months



Estimated Funding $160 $155 External Leveraged Funding $40 $40

Comments: Tecnatom would cover the cost of the prototype software developments in the project. Recommendation is to move project start up to 2017, so that results are available sooner.

Key Research Questions Poor alarm system designs can contribute to alarm overload, which impacts the operator perceptive ability and could result in omission of important alarms, delays in alarm detection, and increased workload. Particularly sensitive to this issue are new plants with digital I&C, where the number of alarms per system is by design much higher than that for the analog systems. In addition, the presentation of the alarms to the operator has been modified as well, with less spatially dedicated space or fixed position alarms and alarm lists as a main way for the operator to monitor alarm conditions. Industry operating experience shows that alarms are not always assessed and prioritized according to their importance, which can potentially impact plant availability and safety. Sizewell B 1 (INPO #206712) ignored a significant alarm during a refueling outage in 2003 while taking the turbine off load, resulting in a failure to comply with a Technical Specification Action Statement. This is just an example of an event that could have been prevented with an improved Alarm Processing and Diagnostic System (APDS), allowing operators to focus on the most important alarms initially, and address later the previously suppressed alarms. Alarm systems that use dynamic priorities based only on operating modes can lead to inaccurate priority calculations. Evaluations with a first generation Alarm Processing and Diagnostic System (APDS) prototype determined that, on average, 30% of the alarms that were filtered should have been retained. A generic, improved methodology would provide new plant project stakeholders higher confidence in alarm management. Objectives The purpose of this project is to develop a new Alarm Processing and Diagnostic System (APDS) methodology that includes an event-based suppression module to make alarm processing more context-aware. The improved methodology will significantly reduce the alarm overload problem that is present in advanced alarm systems currently being installed in new plant project applications. APDS will be tested and validated to demonstrate the improvement of the operator´s awareness and understanding of alarm status. It will also reduce the likelihood of alarm overload and time for alarm diagnosis. Project Approach and Scope APDS is based on an advanced alarm processing concept that reduces the effects of cognitive overload by filtering alarms during periods of high activity. APDS uses combinations of static and dynamic priorities to automatically filter alarms and retain the most important ones, maintaining the alarm list close to the target of one screen full of user information. An existing prototype will serve as a basis for the development of the new system for alarm prioritization and filtering. This project will build and test the new system and will verify its functionality and benefits. Task 1: Analysis. Task 1 will focus on targeting the existing industry gaps in terms of alarm prioritization and filtering. It will also include an industry evaluation of current alarm prioritization and filtering approaches as well as brief overview of regulatory requirements in different global regions. A new approach will be defined, together with a set of recommendations for its implementation in operating and new power plants. This analysis will describe how static priorities are determined based on different static criteria to express the alarm condition seriousness: alarm hierarchy, time response urgency, and implications on system functions. It will also go through dynamic prioritization, which performs a ranking of systems for a given set of plant conditions (operating modes and plant events). APDS will use a combination of static and dynamic priorities to set different levels of filtering. As greater


numbers of alarms occur, alarms of lower rankings will be successively filtered out with the goal of maintaining the total number of alarms below a preset threshold. APDS will include new features such as discard/restores rules (when equal priority alarms are eligible to be discarded/restored), priority escalation (see EPRI 1010076) and manual suppression. Task 2: Implementation. An appropriate hardware and software implementation tool will be selected to build a new APDS prototype. This prototype can be tested in a host Plant as part of the project scope, as some of the information included in the previously developed prioritization matrices could be reused for this portion of the project. A support tool will be developed to assist the analysis and V&V tasks. Task 3: Validation and Verification. A validation process will assess the consistency of the new concepts implemented in the APDS. If available, MCR operators and instructors shall be interviewed to solicit comments about the features that would most benefit their operations. A key opportunity in this stage will be to collaborate with utilities or end users who could benefit from a demonstration of the prototype as users. The target collaborators include plant designers, utility operation personnel, etc., who will assess the benefits of the priority-based filtering process. The improved methodology will then be documented along with development of guidance for implementation in generic systems. Value and Benefit APDS prioritization and filtering methodology can significantly contribute to alarm reduction in different plant operating conditions, including major plant events. This increases operator performance and enhances the value of the alarm information (as evidenced in NUREG/CR-6691, EPRI 1003662). In addition, future consideration will be given to eventually updating the EPRI HFE Guidelines as well as evaluating the impact of the project’s results on other industry standards such as IEC 62241 Ed. 1 and NUREG 0700.

This project will provide the ANT members with a set of recommendations regarding the concept of alarm management and its implementation. The project will also develop and build a prototype system to demonstrate its effectiveness. This prototype will ease the future development and implementation of APDS generic commercial systems.

Some of the benefits of the application of this concept will be: • Consistent prioritization of alarms depending on the different plant operating conditions. • Limitation of the number alarms that are presented to the operator. • Reduction of distractions caused by alarm overload during major plant events. • Time reduction for diagnosis. • Increased ability of the operator to detect “maverick” alarms (secondary malfunctions) during transients. • Improved situational awareness and understanding of alarm status. • Increased plant safety through reduced operational risk.

Note: The prototype software is not a deliverable of this project. Key Activities

Key Activities and Milestones Due Date Task 1: State of the art analysis. 4/15/2018 Task 2: Alarm categorization support tool development. Alarm categorization. 9/1/2018 Task 3: Validation and verification. 3/1/2019 Task 4: Summarize results of test (Final Report) 11/1/2019 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Final report Past EPRI Work on Topic

Report Number and Title Description Date 1010076, Adv. Control Room Alarm System: Requirements and Implementation Guidance

Defines advanced requirements for an advanced control room alarm system for new or existing nuclear plants Dec. 2005

Related Research The EPRI HFE Guidelines Update (3002004310) provides basic and generic details about alarm processing methodologies for design and operator use.


ANT Project Title: MTA 2017-C Evaluation of Indoor Positioning Systems





Estimated Funding $136 $181 Comments: Opportunity to collaborate cross-sector with Generation Sector, including co-funding;

Key Research Questions The Global Positioning System (GPS) provides accurate location information throughout the world, and new applications for using this location information are continually being developed in both consumer and industrial markets. There are many applications where accurate location information is desired indoors, but GPS is unreliable or completely unavailable in most indoor locations due to interference from building structures. There are a variety of Indoor Positioning System (IPS) technologies available in the market or under development that may be used to provide indoor location services similar in functionality to GPS. These systems typically employ an array of beacons installed throughout a building combined with battery-powered tracking tags attached to the person or object being tracked. A variety of IPS solutions have been developed and deployed in the past for industrial applications, but adoption of the technology within the nuclear industry has been limited. The low level of adoption may be attributed to the following:

• High cost and complexity of deployment, due mainly to the large number of beacons that needed to be installed in the buildings to achieve the required level of accuracy.

• Insufficient accuracy and reliability limited the usefulness of the systems. Early IPS technology typically could not achieve accuracy better than 1 meter, and reliability of the systems could be significantly degraded in environments with significant obstructions from concrete and steel structures.

Recent technological innovations are beginning to address previous shortcomings and IPS is becoming more generally feasible in consumer markets. The following key improvements have recently emerged in the market:

• Recent advancements reduce the burden of installing beacons in buildings, which is likely to significantly reduce the cost and complexity of deploying these systems. Some systems are removing the requirement for installation of specialized beacons altogether with strategies such as utilizing existing wireless data infrastructure, use of inertial positioning sensors, and intelligent fusion of location data from multiple data sources.

• New sensing technologies are improving the achievable location accuracy and reliability. With the emergence of Ultra-wideband (UWB) technology, some vendors now offer location accuracy as good as 30 cm. New technologies such as UWB are also expected to be more robust in the presence of interfering structures.

• Improvements are also being made in the usability and interoperability of these systems. For example, some vendors now offer systems that interface with custom mobile apps installed on smartphones or tablets and require little to no additional external hardware carried by personnel to obtain location data.

IPS has been identified as a key enabling technology in the roadmap described in EPRI 3002007071, Advanced Nuclear Technology: Using Technology for Small Modular Reactor Staff Optimization. In this report, the authors identify the need for a general-purpose IPS solution that can interface with other plant information systems. By providing IPS as a building block integrated into a larger plant information system, it would be possible to build new solutions with broader applications using the existing IPS infrastructure. In order to achieve such a goal, further work is likely required to appropriately define the interface between IPS systems and future plant information systems. The feasibility of applying IPS in the nuclear industry will be driven heavily by the performance and cost of the technology, so the first step to applying IPS will be to perform a detailed technical review of the available solutions. Such a review would assist in identifying use cases that can be feasibly implemented in the near term. In addition to assessing the capability of the technology, another significant step toward adoption will be addressing regulatory compliance. Existing regulations and regulations under development should be reviewed to determine the administrative steps required to deploy IPS systems. Objectives


One of the highest-value uses for this technology in the nuclear industry could be the collection of geo-referenced dosimetry and radiological survey data. With such a system, data may be automatically collected from instrumentation worn or held by plant personnel (e.g., personnel dosimeters and hand-held gamma detectors) and associated with locations on a detailed indoor map of the plant. These data could be used to improve the accuracy and detail of radiological survey maps, facilitate ALARA planning, and assist in the assessment of contamination events. The following objectives would be addressed by this project:

• Identify high-value use cases for IPS in the nuclear power industry • Assess suitability of available IPS technologies for the identified use cases • Demonstrate effectiveness of IPS technologies with pilot testing • Identify next steps for implementation of IPS solutions in the field (e.g., further technology development,

resolution of regulatory issues) Project Approach and Scope This project would consist of the following primary tasks. It would be broken into two phases, with Phase 1 evaluating the IPS technologies and developing a proof of concept test plan and Phase 2 performing the proof of concept testing.

Phase 1 • Task 1: Develop functional specifications for IPS

In this task, key nuclear plant O&M tasks that would benefit greatly from incorporation of IPS technology will be identified and evaluated. It is anticipated that applications will be identified in the areas of radiation protection, aging management, plant security, and configuration management. For each identified O&M task, a functional specification will be developed to document the technical requirements for the incorporation of IPS technology. The functional specification will include parameters such as the required geospatial accuracy, repeatability, regulatory requirements, protection against RF interference, security requirements, and interfaces with other systems.

• Task 2: Assessment of available IPS technologies In this task, key nuclear plant O&M tasks that would benefit greatly from incorporation of IPS technology will be identified and evaluated. It is anticipated that applications will be identified in the areas of radiation protection, aging management, plant security, and configuration management. For each identified O&M task, a functional specification will be developed to document the technical requirements for the incorporation of IPS technology. The functional specification will include parameters such as the required geospatial accuracy, repeatability, regulatory requirements, protection against RF interference, security requirements, and interfaces with other systems.

• Task 3: Development of proof-of-concept testing plan for IPS Development of a proof of concept testing plan for the most promising IPS technology identified. The testing plan will define testing to be performed with the goal of evaluating the expected performance of the IPS technology in a nuclear plant environment. It is anticipated that this testing plan will define the following: • IPS technology to be tested • Environment used for testing • Size of monitored area used for testing • Performance characteristics of interest • Methods used to measure performance characteristics The results of this task will be used to define a testing scope and cost for the Phase 2 testing discussed below.

Phase 2 • Task 4: Proof-of-concept testing

The objective of this testing will be to evaluate the feasibility of the technology in conditions that are representative of nuclear plant conditions. The exact nature of the testing to be performed in this phase will be determined under Task 3 of Phase 1. The testing will be focused on assessing performance characteristics (e.g., accuracy and reliability), and will also provide insight into ease of installation and usability. For most IPS technologies, the amount of infrastructure that must be installed to achieve a desired level of accuracy is a function of the amount of interference caused by objects in the monitored area. Therefore, a key output from this testing will be an assessment of the required amount of infrastructure needed to achieve an acceptable level of performance. The option of testing the system at an operating plant will be explored, but this testing may be conducted at a comparable non-nuclear industrial facility to avoid obstructing normal plant operations while still accurately simulating the target environment. Value and Benefit It is anticipated that this project will further develop the industry’s understanding of the efficiency gains that could be provided through deployment of IPS for new plants, decommissioning plants, and currently operating plants. The information gathered about the available IPS technologies and the technical requirements for the identified high-value applications will aid utility members in making informed decisions about deployment of IPS-enabled solutions if they

choose to implement them in the future. This project will also provide input to future R&D efforts by identifying technical and administrative issues that would need to be addressed with further research. Key Activities

Key Activities and Milestones Due Date Task 1: Develop functional specifications for IPS 4/15/2017 Task 2: Assess available IPS technology 9/1/2017 Task 3: Testing plan for IPS 3/15/2018 Task 4: Conduct proof-of-concept testing 9/1/2018 Task 5: Final Report 12/22/2017 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Final technical report Past EPRI Work on Topic

Report Number and Title Description Date 3002007071, “Advanced Nuclear Technology: Using Technology for Small Modular Reactor Staff Optimization”

Provides a roadmap for development of technologies to optimize staff utilization in SMRs. IPS is identified as a key enabling technology.

March 2016

3002000268, “Evaluating Indoor Location Tracking Systems in a Nuclear Facility: Experimentation with Different Techniques in an Industrial Environment”

Provides an evaluation of the performance of four IPS technologies that were available in 2012: Zigbee, Wi-Fi, inertial, and Bluetooth low-energy. Each system was tested within the auxiliary steam generator building of the Tricastin French nuclear power plant.

April 2013

1023018, “Field Testing of Location Tracking Technologies for Radiation Management: Interim Report”

Documents the preliminary work performed by EPRI and EdF to conduct field tests of available location tracking technologies. This interim report includes functional requirements for the systems to be tested.

Dec. 2011

1021182, “Evaluation of Location Tracking Systems for Remote Monitoring of Radiation Protection Applications”

Evaluates the commercially available location and tracking systems that were available in 2010 for applicability in a nuclear power plant environment.

Sept. 2010

Related Research

Q-Track Corporation is a vendor that has developed indoor location solutions targeted specifically at the nuclear power market. They have successfully deployed a radiation worker training system that uses simulated dosimeters in combination with indoor location sensing to provide immersive training scenarios. They have also combined their indoor location system with remote monitoring dosimeters to perform real-time radiation mapping. A pilot demonstration of this radiation mapping solution was performed at the Oak Ridge National Laboratory (ORNL) Experimental Gas Cooled Reactor (EGCR) facility in 2008. EPRI began investigating the application of indoor location systems to nuclear power facilities in 2010, starting with a feasibility evaluation documented in EPRI 1021182, “Evaluation of Location Tracking Systems for Remote Monitoring of Radiation Protection Applications.” Following this evaluation, a field test was conducted in cooperation with EdF in the auxiliary steam generator building at Tricastin nuclear power plant in 2012. The field test evaluated the technical performance of four indoor positioning technologies available at the time: Zigbee, Wi-Fi, inertial, and Bluetooth low-energy. This study included a test that evaluated tracking of a robot traversing a rail as well as a test that evaluated sensor drift while tracking a stationary object. These tests provided a repeatable basis for comparing technologies, but they did not address the effect of body blockage or the effect of human gait when the sensors are attached to a person. A key conclusion of this testing was that accuracy below 1 meter was not possible with the tested technologies. EPRI 3002007071, “Advanced Nuclear Technology: Using Technology for Small Modular Reactor Staff Optimization,” provides a technology roadmap for improving staff efficiency in SMRs. While the focusing on SMRs, many of the findings are also applicable to all plants. This report identifies indoor location as one of the enabling technologies required for automation of radiation protection tasks, including: personnel monitoring and dosimetry, ALARA job reviews and RWP generation, and radiation monitoring and analysis.


ANT Project Title: MTA 2018-B Common Platform Robotics






Comments: Partnership/co-funding opportunities with prospective vendors exist; this will be clarified and defined once the project is approved.

Key Research Questions Over the years, robots have been used in various nuclear plant applications and for various purposes. These include performing jobs that reduces a plant worker’s exposure to dose or confined environments, installing tooling or hardware more effectively than plant workers on the refuel floor, or performing routine or advanced maintenance. The need for robotic technology to support new and operating plants continues to be strong and is expected to grow as plant operations evolve toward a more staff-optimized performance level. As robotic technology has evolved inside and external to the nuclear industry, so have the types of applications to which they can be used. These applications tend to be custom and specific solutions, which can often mean high implementation costs for only a single or limited use. A recent industry operating experience event revealed that for an emergent reactor internals hardware issue, there were only a limited number of tools and machines available to access, remove, and replace the hardware. Other plants experiencing the same hardware issue later during the outage season were forced to wait until the machines were available, causing significant plant downtime and lost revenue. This example illustrates the need to have readily available installation tools on-site and ready to deploy, or easily configurable for a range of applications. There is an increasing interest to explore whether common platform robotic solutions can benefit the industry. These platforms tend to support robotic applications that are small, configurable, inexpensive, and serve multiple environments for many applications (e.g., radiation resistance, small/tight spaces, high-temperature, other extreme environments, etc.). Understanding whether these solutions offer a cost-optimized approach to robotic solutions is the key research question that needs to be addressed. Objectives The objective of this project is several fold:

• Investigate the state of the industry with respect to common platform robotics; determine applications already employed in nuclear industry and other industries

• Evaluate common platforms that are configurable and inexpensive. Compare these platforms to custom, single-solution or single-purpose applications and develop cost-benefit evaluation for same application

• Evaluate what qualifications or standards are required for common platform applications • Identify gaps to broader implementation and steps toward solidifying the industry standards for common

platform robotics Project Approach and Scope The project will take a measured, prescriptive approach to fulfilling the main objectives. Task 1: Industry investigation/survey of common platform robotics. This task will take the pulse of the nuclear industry’s state of robotic solutions for new and operating plant applications. In addition to a broad survey of various robotic applications, a more specific benchmark will be performed that investigates the state of common and configurable robotic solutions and for which applications. The scope will include industry surveys (U.S. and non-U.S.), interviews with utilities and vendors, literature review, and standards benchmark. The outcome of this task will be a summary of the state of the industry with respect to common robotic platforms.


Task 2: Evaluation of common robotic platforms. Once the benchmark has been established and understood, this next task will delve into the details of common platform robotic systems. This task will look at specific vendor platform solutions (based on results from Task 1), their level of configurability and complexity to solve plant-specific challenges, baseline costs for implementing, storage and maintenance issues, and the types of applications where these types of platforms are best suited. Task 3: Comparison to custom solutions and cost-benefit evaluation. This task will use the information acquired in the first two tasks to develop a number of use cases for comparing custom, one-off solutions for these applications to using common platform robotics for the same applications. Examples of use cases might include:

• Installation of repair hardware (in RPV for reactor internals, for example) • Inspection of equipment in containment or in confined spaces • Inspection of piping (internal)

The primary driver will be a cost-benefit comparison that evaluates the costs of a custom solution to the total lifecycle cost of implementing a common platform robotic solution. The intended outcome of this task will be a summary of the comparison of these use cases and their associated total costs. Task 4: Standards and qualification evaluation. As part of Task 1 benchmarking exercises, identification of standards and qualification of robotics will be evaluated. In this subsequent task, these standards and qualification requirements will be evaluated for the use cases identified in Task 3. The purpose of this task is to identify the qualification plan necessary for nuclear-specific applications of these common platform solutions, as well as any commercial dedication required. Task 5: Identify gaps toward broader industry implementation, identification of demonstration, and standards development recommendations. This task will be the culmination of the effort that should include detailed results of the research as well as identification of gaps in industry toward use of common and configurable robotics. These gaps will also include specific recommendations to address the gaps, including any other technical R&D required. As a result of use cases identified in previous tasks, identification of a demonstration or pilot project will also be included as a recommendation for future work. Lastly, as part of long-term work identified in RFA roadmaps, this task will also include recommendations to enhance or contribute to qualification and standards requirements. Value and Benefit As robotic technology continues to evolve and provide more cost-effective application opportunities in different areas, the results of this project will have an impact on how plant operators manage maintenance, repair, and operations activities; provide a clear picture of how smaller and configurable robotic solutions can be beneficial to the industry; and lay the groundwork for any additional R&D required toward developing qualifications and standards for robotic applications in plants. Key Activities

Key Activities and Milestones (assumes January start) Due Date Task 1: Industry evaluation and benchmarking 4/1/2018 Task 2: Evaluation of common robotic platforms 9/15/2018

Task 3: Comparison to custom solutions and cost-benefit evaluation 12/15/2018

Task 4: Standards evaluation and gaps for wider implementation/use 2/1/2019 Task 5: Knowledge gaps summary, input to standards 4/15/2019 Task 6: Final Report 5/31/2019 Anticipated Deliverables

List of Proposed Deliverables Deliverable 2: Technical report of all tasks Past EPRI Work on Topic

Report Number and Title Description Date Product ID: 1009571 Application of Non-Nuclear Robotics to Nuclear Industry Decommissioning

Documents a first-of-a-kind robotics experience at plant going through decommissioning. Innovative use of robotic technology to perform specific tasks were evaluated.

August 2004

https://membercenter.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000000001009571


Product ID: NP-7456 Survey of Utility Robotic Applications

Presents the results of a survey to determine where utilities have found robotics to be most beneficial. May provide useful information about historical robotic applications and survey information.

August 1991

Product ID: 3002002036 Program on Technology Innovation: EPRI State of Robotics—Assessment and Proposed Strategic Program

Provides an overview of robotic technology projects in EPRI, their various applications to the power industry, and assess the need for engagement by sector, identifies technical gaps, and proposes additional research initiatives for robotics technology.

Sept. 2013

Related Research Previous work in the Plant Technology department, WRTC program, as well as the ANT program will support this project. On-going work in the Digital I&C Implementation program, such as the Severe Accident Mobile Investigator (SAMI) project, will provide a platform to understand whether additional robotic applications may be open for consideration. There are also non-Nuclear sector projects that have been performed in the past at EPRI, such as in the Power Delivery & Utilization (PDU) sector that will be benchmarked as part of this work. The project will also benchmark work outside of EPRI, such as through the DOE and any related non-nuclear industry applications.

https://membercenter.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=NP-7456






ANT Project Title: MTA 2017-A: Risk Informed and Enhanced Cyber Security Vulnerability Assessment Methods for New Plants

Project Leader: Matt O’Connor Matt Gibson Phone and Email: 650-855-8523 [email protected]

704-595-2951 [email protected]


*EPRI WO Numbers: 1-105861/1-107504 *EPRI WO Titles: Risk Informed Cyber Security Methods Technical Assessment Optimization



Comments: Significantly leveraged funding; ANT is a contributory partner to overall project with input to methodology use cases and active participation in Phase 3 and 4 pilots. Total Institute-wide project cost is roughly $6M (2014 – 2018).

Key Research Questions The Nuclear Industry has reported that they have spent between $700M and $1.2B on cyber security implementation to date. A significant portion of that is due to a lack of technical risk and prioritization processes to rationalize program expenditures with actual security benefits. These expenditures are predicted to escalate as utilities grapple with the regulatory mandated program implementation and ongoing sustainability along with the program deadline in 2018. Recently, the industry has reached a realization that a new approach is needed to integrate risk analysis into the cyber security process to allow graded approaches to be put in place that align with actual risk. A credible Risk Informed Cyber Methodology that includes an effective Vulnerability Assessment Methodology will help to rationalize the cyber security effort within the nuclear industry and can have significant impact on new nuclear designs by aligning cyber security requirements with good engineering practices and actual vulnerabilities. This will further allow certainty in the design and licensing process without resorting to prescriptive and ineffective “check list” processes. This multi-year, multi-focused project started in 2014 in the Digital I&C Implementation Group and is now at a point in its research cycle where new plant stakeholders can realize, and contribute to, significant value by participating with new plant-specific digital equipment cyber security issues. Objectives The objective of this project is to leverage the results from Phases 1 and 2 of the on-going effort and convert that research into meaningful cyber security guidance for new plant stakeholders. ANT funding and member pilot participation would also provide access to products produced to-date in the Digital I&C Implementation group developed under these two projects. Project Approach and Scope The ongoing research effort has investigated the application of hazard analysis methods as described in Hazard Analysis Methods for Digital Instrumentation and Control Systems, 3002000509, to cyber security vulnerability analysis. Specifically, the project is design around four phases: Phase 1- Methods Evaluation (Complete) Phase 2- Conceptual Application Guidance (Complete) Phase 3- Utility pilots to Refine and Validate Phase 4- Integration of Methods into Phoenix/CAFTA Starting in 2017, Phases 3 and 4 will continue with the results from Phases 1 and 2 providing input. ANT funding will support development of pilot projects, analysis of results, and development of methods and process for U.S. and non-U.S. new builds for a risk-informed cyber methodology as part of Phase 3. Commitment to the project would also include participation in Phase 4 with the new build-specific use cases. Phase 3 Scope and tasks: (2017) • Integrate the EPRI Technical Assessment Methodology with the Risk Informed Process. • Pen and Ink Pilots with ANT participants • Onsite workshops with ANT participants • Analysis of results after each workshop with iterative refinement and usability of the methods and process. • Develop final validated method and process and functional criteria to support Phoenix/CAFTA cyber security module



Phase 4 Scope and tasks: (2018) • Develop Detailed Phoenix/CAFTA specification • Develop companion process guidance based on Phase 3 methods. • Develop and implement a beta Phoenix module • Conduct onsite workshops with ANT participants to validate and refine • Deliver final Phoenix Cyber Security module to members. • Develop CBT/Training for technology transfer Three Products Produced to Date: • Phase 1- Interim Analysis of Hazard Models for Cyber Security, 3002003248 • Phase 1- Final Analysis of Hazard Models for Cyber Security-Phase 1, 3002004995 • Phase 2- Integration of Hazard Models into a Consequence Based Vulnerability Analysis Method- Phase 2, 3002004997 Note: Phase 4 will result in development of software managed under the EPRI RSM program. Many ANT funders have license to this software; for those that don’t, additional funding would be required if there is a desire for access. Value and Benefit Cyber security continues to be a resource drain on the nuclear industry with a difficult-to-quantify safety and security benefit. This project will align cyber security resources to the areas that can be demonstrated to have the highest safety and security benefit while allowing less critical areas to accept some appropriate risk. Key Activities

Key Activities and Milestones Due Date Task 1: Identify New Build Pilot Participants for Phase 3 and 4 1/20/2017 Task 2: Identify pilot project use cases 2/1/2017 Task 3: Identify Phase 4 participation requirements and parameters for new plants (U.S. and non-U.S.) 11/1/2017 Task 4: Final Risk-Informed Methods Guidance report 12/22/2017 Task 4: Integration of risk-based methodologies into Phoenix/CAFTA module (Software Deliverable) 11/30/2018 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Final Risk-Informed Methods Guidance report (2017) Deliverable 2: Final Phoenix/CAFTA module (2018) Past EPRI Work on Topic Report Number and Title Description Date Hazard Analysis Methods for Digital Instrumentation and Control Systems- 3002000509

This report documents an investigation of the use of various hazard and failure analysis methods to reveal potential vulnerabilities in digital instrumentation and control (I&C) systems before they are put into operation. The report looks at six approaches, ranging from well-established practices to novel methods still transitioning from academic demonstrations to practical, realistic applications. It includes step-by-step procedures and worked examples, applying each of the methods to sample problems based on actual cases to assess the methods for effectiveness, range of applicability and practicality of use by nuclear plant engineers and their suppliers.

7/2013

Related Research The Digital I&C Implementation Group continues to develop high-value research for cyber security of digital equipment for operating plant upgrade issues. This program is the primary leader in nuclear cyber-related research within the EPRI Nuclear Sector, and where and when appropriate, the ANT program has collaborated with that program when there is direct impact to new plant project stakeholders. Risk-informed cyber security methods have a near-term impact on new plant planning, design, and start-up activities, and this project will provide a near-term, high-value result that can be implemented quickly.


ANT Project Title: MTA 2017-D: Digital I&C Obsolescence – Hardware Storage and Aging Assessment




Funding Plan (000 $s) 2017 2018 2019 Future


Comments: Potential for co-funding from Digital I&C Working Group; June 20, 2016: Suggestion from MTA TAC is to move project start to January 2017 to support operating plant needs as well.

Key Research Questions Digital I&C obsolescence continues to be a topical area of interest for both new and operating plants as they install digital equipment. Recent research completed in the ANT program (2014) developed a framework and guidance to manage digital I&C obsolescence as part of a plant’s overall lifecycle management program. The objective of the guideline was to investigate existing and proposed methods for managing short digital-system obsolescence cycles, with an aim to control costs in applications that rely on digital technology but primarily use hardware with much longer obsolescence cycles. Although that guidance provides the user ample guidance and tools to proactively plan for digital I&C obsolescence and incorporate it into a strategic lifecycle planning process, there were additional research opportunities identified for future work. A primary hurdle for implementing digital I&C in safety related applications is the heavy cost and time burden on both licensing and engineering resources. Given the constant evolution and turnover in digital technology, the design and engineering cost burden will need to be revisited in one form or another to update these systems over the course of plant life. One potential means for reducing this engineering burden is to examine the basis of a new plant and determine the extent to which a digital-to-digital change can be performed. Another potential means to avoid this recurring design and engineering challenge is to acquire a substantial “stockpile” of the I&C hardware up front in the project to hedge against the likelihood of parts obsolescence 20 - 30 years into plant life. There is a need to understand the long-term storage capacity of I&C hardware, understanding the aging mechanisms of hardware, and developing a cost model to manage long-term hardware storage. Objectives The objective of this project is to address questions associated with performance and reliability of digital I&C hardware following long term shelf storage. Questions to be answered: What are the aging effects on microprocessors, highly integrated chip sets, and /or surface mount board technology? Can these aging effects be overcome with innovative storage approaches? Does the approach make sense from a general economic perspective? What percentage of the total I&C project cost is made up of hardware vs. design and engineering costs? What are the long term carrying charges associated with storage? Project Approach and Scope The project approach will consist of industry evaluation and benchmarking for storage of digital I&C hardware, component aging mechanisms, and engineering/design costs associated with upgrades of digital equipment. The next step will include addressing shelf life and storage experience of digital equipment, including identifying some pieces of digital equipment for performing a use case or demonstration. Lastly, the results will be included in a technical report that provides users guidance for long-term storage options of digital equipment. Task 1: Evaluate industry and non-industry (e.g., aerospace, automotive) practices for digital I&C storage Task 2: Identify common aging mechanisms for digital equipment, and determine typical storage timeframes. Include experience from digital upgrades at operating plants. Task 3: Identify 2 – 3 typical digital-to-digital upgrade projects and quantify the engineering and design costs. Perform cost-benefit assessment for these use cases.


Task 4: Develop industry guidance, best practices, and processes for long-term storage of digital I&C equipment. Include total system and part lifecycle costs as part of guidance for use cases. Value and Benefit New plant stakeholders will realize value from this research when long-term storage and aging mechanisms of critical equipment is quantified and obsolescence management plans can incorporate this information. Furthermore, a thorough understanding of design and engineering costs for replacement parts/components will enable new plants to better understand the obsolescence cost burden when developing long-term digital I&C obsolescence plans. A data point regarding recent digital I&C upgrade costs: For U.S. plants, the total cost for the Power Range Neutron Monitoring upgrade in BWRs has gone up by a factor of 5 in the last 20-years with a sizable portion of this cost being consumed by licensing and engineering. The current regulatory trajectory associated with digital I&C indicates that this cost component will not improve. The costs to accommodate the modification process associated with digital I&C upgrades are substantially greater than the cost of the hardware itself. Experience with a digital timer upgrade at a plant revealed the total design cost approached $40k for a $300 programmable logic control (PLC). Key Activities

Key Activities and Milestones Due Date Task 1: Research and develop approach, methods and annotated outline 3/15/2017 Task 2: Evaluate industry and non-industry practices 9/15/2017 Task 3: Identify common aging mechanisms and storage timeframes 12/15/2017 Task 4: Develop industry guidance, best practices 4/1/2018 Task 5: Final Report 7/1/2018 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Guideline for Reducing the Cost Impact of Digital Obsolescence Over the Life of a New Plant Past EPRI Work on Topic


3002002852: Advanced Nuclear Technology: Guidance and Methodologies for Managing Digital Instrumentation and Control Obsolescence

Provides detailed information about digital I&C obsolescence, life cycle management planning (LCMP) for equipment, the various risks associated with I&C obsolescence, and mitigating and defensive strategies to avoid future obsolescence costs. Also included user worksheets and checklists to aid in development of a proactive digital I&C mitigation strategy.

October 2014

Related Research Currently in the U.S., the most significant industry issues with respect to digital I&C are 1) common cause failure, and 2) cyber security and the burden of assessing thousands of CDAs against hundreds of security control requirements for each CDA. EPRI is currently developing methods and guidance for dealing with these issues. Both EPRI guidelines should enable new plant owners to deal with digital-to-digital changes with less cost burden than would otherwise be expected, and should help inform the guidance to be developed under this proposed project.

Quick Descriptions of Potential 2019+ MTA Projects

MTA RFA #1: Advanced Monitoring Technology and Data Management to Improve Plant Performance

MTA 2019-# Additional Automated Technology Applications and Pilots • Issue: After the completion of the investigation of automation technologies for water chemistry, this project will

investigate other enabling automation technologies for plants and/or potential pilot projects. • Scope: The project will identify additional automated technologies to which advanced plants, SMRs, and GEN IV

may apply. This will include a benchmark as well as identification of high-value use cases for demonstration and possible pilot applications.

• Value: In line with the results from the SMR Staff Optimization study in 2016, this project will continue research that would optimize plant staff efficiently and safely using a variety of technologies.

MTA 2019-# IPAWS Pilot Demonstration and MTA 2020-# Inform Regulatory Standard • Issue: After successful completion of the technical evaluation of using IPAWS and WEA for alerting the public,

there will still be a significant challenge toward acceptance by regulatory bodies. This challenge will need to be met with demonstration and proof that the technology can safely perform the task of alerting and evacuating the public should the need arise during a plant event.

• Scope: These projects will leverage the results from the Technical Evaluation performed in 2018 and develop a feasible demonstration protocol, perform a pilot/demonstration of the technology, harvest the results from the experience, and then use these results and guidance to work with regulators to inform them of the technology’s efficacy in meeting existing requirements.

• Value: These two projects will be the culmination of the prior technical evaluation research and show conclusively how newer technologies will meet notification requirements and are more cost-effective than sirens for performing the same tasks.

MTA 2019-# Data Management for Generation Risk Assessment • Issue: Can an analytical model based on a different risk based end state (safety system actuation (SSA) versus

core damage frequency) result in improved plant safety and availability through prioritization of activities and focused predictive monitoring?

• Scope: Develop a Safety System Actuation PRA model by modifying an at-power internal events PRA with two general changes: 1) adding initiator fault trees, and 2) changing the end state from core damage to safety system actuation.

• Value: Translate risk insights into cost savings, operating improvements, and focused digital solutions. Reducing the number of challenges to safety classified systems leads to reduced regulatory burden and increased generation capability. O&M activities can be optimized to reduce or eliminate resource allocations to non-critical SSCs and operator actions. This project can further define and place into practice some of the insights gained from previous generation risk assessment studies.

MTA 2019-# Configuration Management Optimization • Issue: Data-centric (intelligent) configuration management was identified in the SMR Staff Optimization study as

a common infrastructure that would significantly benefit plant and staff operations at a deployed SMR site. There continues to be a number of knowledge gaps among current practices and plans for system and component condition databases, real time plant configuration and status databases, and 3-D plant models and training qualification and future state.

• Scope: The project will springboard from the previous EPRI and ANT research in configuration management and seek to close these knowledge gaps or identify the type of fundamental research needed to close the gaps.

• Value: An intelligent configuration management system is considered a mandatory infrastructure to optimize plant staffing. This project would provide the necessary understanding and framework to develop the tools.

MTA 2019-# Assessment of Remote Technologies for Fleet Wide Use • Issue: With the prospect of fleets of similar, advanced plants connecting to the grid in the coming decade across

the globe, the ability to manage operations at these facilities simultaneously and remotely to save on staffing costs is an attractive concept. However, there remain many knowledge gaps toward implementing technologies for remote management of plant assets.

• Scope: With knowledge gained from other nuclear industry and fossil industry experiences, this project will take a closer look at the needs and requirements for managing plant assets remotely for a fleet of similarly constructed plants.

• Value: With nuclear operating costs continuing to be challenged in a low natural gas price environment (in the U.S. and globally), operating nuclear fleets efficiently and with an optimized staff is of paramount importance. ANT stakeholders will benefit from this research by using the guidance to make long-term decisions on integrating remote management technologies into their plants and systems.

MTA 2020-# Guidance for Sensor Applications • Issue: Once gaps and opportunities for advanced sensor applications is completed, additional research and work

is anticipated to develop useable industry guidance for how sensors. • Scope: Use results from Gaps and Opportunities research and work with cross-sector programs to develop

comprehensive guidance for use of sensors in advanced plants (SMRs, GEN IV) • Value: This project will provide the capstone of initial research efforts in understanding applications of sensors

for advanced plants. Guidance will provide users information to make decisions on sensor placement, data obtained, and how to use it effectively.

MTA 2020-# Investigation of Virtual Shift Technical Advisor (STA) • Issue: The development of SMRs will require a substantial reduction in plant staffing to accommodate the

reduced economics of scale associated with SMRs. A substantial staffing cost (aside from security) is operations. A current staff position within operations is the shift technical advisor (STA) that provides technical advice/guidance during off-normal, transient and accident conditions. One means of potential staff reduction could be achieved by “automating” the STA function via real time, digital assessment of plant conditions and automated feedback of recommended actions and/or procedural steps to follow in response to changing plant conditions.

• Scope: This project will investigate the needs and requirements for automating the STA and perhaps other operations staff positions in an effort to optimize SMR plant tasks.

• Value: Staff operations costs will continue to challenge the economics of SMRs once they are deployed. By investigating automation of specific roles and tasks, new plant stakeholders will have a better understanding of total staff lifecycle costs and whether certain activities can indeed be automated through the use of enabling technology.

MTA 2020-# Data Tools for Plant Siting Decisions • Issue: as data management tools continue to mature, their application to the nuclear industry will justifiably

widen. As more advanced plants are constructed and as their operating histories grow, data from these experiences can be used to support future plant siting decisions. However, there is a need to investigate how effective these data management tools would be for such a task.

• Scope: This project will look into application of various data management tools (available at the time) and determine their effectiveness at supporting plant siting decisions for future plants.

• Value: Data science and management is a burgeoning field and the applications of some of the available tools seems boundless. ANT stakeholders will benefit from this project by understanding how an application of data management tools to a specific issue can be realized.

MTA RFA #2: Technologies to Improve Human Performance, Machine Interaction, and Operational Effectiveness

MTA 2019-# Additional Use Cases for Standards Dev. and MTA 2020-# Finalize Utility Standards for AR Applications • Issue: As a follow-up to the completed work in 2017 and 2018 in augmented reality for nuclear plant

applications, these two projects are aimed at fulfilling the remaining work toward developing standards for industry for AR.

• Scope: These projects will use the results from the standards development process in the previous years and identify additional utility-focused use cases that will bring additional value to the overall process of incorporating AR into practice. The final step in the process is expected to be utility standards for AR applications

• Value: Incorporating augmented reality into broader use throughout the nuclear industry (but especially at the front end of plant activities) is expected to be a high-value growth area for technology development and cost savings.

MTA 2019-# Emerging Mobile Technologies for Power Generation • Issue: Mobile technologies will only continue to grow in variety, access, and use both from a consumer

perspective and in industrial settings. There will be an ongoing need in the industry to stay at the forefront of understanding how these technologies will impact nuclear plant stakeholders.

• Scope: Work cross-sector at EPRI will impact this project. The scope will include a benchmarking step that will evaluate state-of-the-industry with respect to mobile technologies and then identify cost-effective applications and use cases for deployment.

• Value: Advanced and modern technology will continue to present opportunities for ANT stakeholders to save money and operate more efficiently. By staying abreast of advancing mobile technologies for power generation, new plant stakeholders can make decisions on how to build these technologies into their future plants.

MTA 2019-# Technology-Based Training Methods • Issue: The ability to use technology to train personnel and operating staff continues to evolve and presents

opportunities for cost savings compared to more traditional training methods. • Scope: This project will take the results from the SMR Staff Optimization Study to determine how to harness

technology to better train staff for various tasks. • Value: This project is likely the first step in a multi-year effort to investigate and evaluate the various

technologies available (or to be developed) that will have a significant impact on staff optimization. Once demonstrated, the results can be used to make decisions on how to use technology to train staff to perform tasks effectively and efficiently.

MTA 2020-# Develop/Inform Standards for Robotics • Issue: As a follow-on to the expected completed work in common platform robotics, this project will use the

results of that research to inform changes to standards for robotic technology used in nuclear plants. • Scope: Develop guidance that can be used to inform existing standards for robotics in plant

activities/operations. • Value: Robotics will continue to be used in various capacities in plants. By having a set of standards available,

developers and end-users will have a common platform upon which to build solutions to problems using robots. MTA 2020-# Updates to HFE Guidelines

• Issue: The recently (2015) updated HFE Guidelines Document may benefit from a future update based on the advances in practices, regulations, and technologies impacting human performance and human factors engineering.

• Scope: Similar to the past, the guidelines document will go through a thorough and detailed review to determine what needs to be updated.

• Value: ANT and operating plant stakeholders will continue to glean tremendous value from this heavily-used and regulatory body-accepted document. Further updates will make the document more refined and valuable.

MTA 2020-# Advanced Security Technologies • Issue: Security staff at nuclear plants is a high cost element to operating the plant. There exist a number of

technologies that, if deployed, could reduce security staff and still meet the minimum security requirements. • Scope: The project will look at various types of security technologies (such as facial recognition, for example)

and determine the feasibility and cost of implementing such a system (including full lifecycle costs). In addition, understanding regulatory positions on these security issues will be developed.

• Value: As with other plant cost challenges, staffing is a major expense, especially security staff. If there are ways to minimize these costs with technology while still achieving the security objective, then there is a significant opportunity for new and SMR plant stakeholders to realize large cost savings.

MTA RFA #3: Addressing Gaps for Use of Digital Systems Technologies in New Plants

MTA 2019-#: Update Cyber Security Guidelines for New Plants • Issue: By 2019 and with the expected conclusion of a number of related cyber security research efforts, there

will be a need to revise the cyber security guidelines for new plant construction; this guidance will have an initial release in 2017.

• Scope: The process to revise the guidance will include input from the Technical Assessment Optimization and Risk-Informed Cyber Security projects.

• Value: As new research is performed and new information is gained through EPRI’s cyber security programs, relevant and contemporary guidance for ANT stakeholders will continue to be needed. This project will focus on providing that updated guidance in a timely manner.

MTA 2019-# Update Digital I&C Obsolescence Guidelines • Issue: With the completion of the initial I&C obsolescence guidelines in 2014, and with the expected completion

of additional research on aging mechanisms and long-term storage impacts on I&C hardware, there is a need to update the 2014 guidelines with more contemporary information.

• Scope: The project will go through the existing 2014 guidelines and identify specific sections with updated information.

• Value: Digital I&C obsolescence will continue to be a long-term cost concern for plant operators, especially with the short lifecycle of digital I&C equipment. Keeping the guidelines current with relevant information will deliver the highest value to ANT stakeholders for the foreseeable future.

MTA 2019-# Addressing Common Cause Failure in Digital Design • Issue: Currently in the U.S., the most significant industry issues with respect to digital I&C are common cause

failure and cyber security. The Digital I&C Working Group continues to develop valuable research results and guidance on common cause failure that benefits both operating and new plant stakeholders. However, as the various regulatory bodies continue to demand a higher burden on vendors and utilities to demonstrate how common cause failure is being addressed, there will be a need to research how some of these issues will directly impact new plant applicants.

• Scope: This project will work closely with the Digital I&C Working Group to develop meaningful guidance for new plant project stakeholders to deal with common cause failure.

• Value: Significant cost saving opportunities for new plant stakeholders who must deal with increasingly complex issues on common cause failure.

MTA 2020-# HFE Guidelines Training • Issue: In previous years, ANT has partnered with the Digital I&C Working Group to develop and deliver training

on the human factors engineering (HFE) guidelines. There has been emerging interest from industry to develop updated training sometime in the future.

• Scope: Update previous training with new HFE guidelines information and deliver the training, typically at a plant site.

• Value: A different way to transfer knowledge and technology from the HFE guidelines.


ANT Project Title: MC 2017-C Additive Manufacturing (AM) Development

Project Leader: Craig Stover David Gandy Phone and Email: 704-595-2990, [email protected]

704-595-2695, [email protected]


*EPRI WO Number: 1-XXXXXXXX *EPRI WO Title: N/A



Key Research Questions Additive Manufacturing is an exciting and novel fabrication technology that has generated significant interest in numerous industries. While polymer based AM is significantly more mature and developed, a significant effort is being carried out by OEMs and national labs to investigate and improve metal alloy AM technology. This ongoing research is focused on deposition rates, residual stresses, size limitations, inspectability, and generating material properties. For the nuclear industry, powder bed fusion AM (employing laser or electron beam melting) shows promise for small (less than 100lbs), intricate, complex RPV internals (i.e. parts that require significant amount of machining to achieve the final state). As AM technology develops for metal alloys, corresponding Standards or Specifications require updating to make the technology available to the nuclear industry. Thus far, ASTM specs for alloys 718 & 625 have been issued. It is anticipated that the spec for 316L will be issued in 2016. Furthermore, these alloys need to be demonstrated to assess “nuclear grade” feasibility and evaluated for material/mechanical properties, inspectability, and corrosion performance (SCC & IGSCC). Supporting specifications actions and generating test data for these alloys will help drive and encourage other nuclear relevant alloy specifications (304L, 600, & 690). Objectives The project will develop a roadmap for the implementation of additive manufacturing into the nuclear industry. This project will review, benchmark, and lay out steps for development of other codes and alloys to use AM. A follow up activity will be to generate guidance for implementing ASTM specs to meet nuclear quality requirements. Furthermore, this project will seek to demonstrate AM through mock-up fabrication and evaluation. Finally, this project will participate in the Oak Ridge National Laboratory Additive Manufacturing Consortium. Project Approach and Scope A roadmap will be developed such that a plan for the acceptance of components made by additive manufacturing in the nuclear industry can be established. To this end, the roadmap will be used to generate guidelines for how to implement the powder bed AM process so that the needed properties and performance criteria are met. ASTM specs already exists for AM of alloys 625 & 718, with 718 being heavily utilized by the aerospace industry. This project will document the current status, process qualifications, material requirements, powder handling/prep, etc… of ASTM, AWS, SAE, and any other relevant codes for nuclear relevant alloys (304L, 316L, 600, 625, 690, and 718). This effort is intended to provide a snapshot of the status of AM technology in Code & Standards bodies and provide recommendations on the path forward. This information will be fed into the technical basis supporting the roadmap. ANT will also work with member OEMs to identify two RPV internal components that are strong candidates for implementation of AM. The two mock-ups will be fabricated from alloys 316L & 718. This will, take advantage of readily available powders & industry expertise, address the data gap of nuclear grade chemistries & processes, and develop a host of valuable information in validating the AM process (material/mechanical properties, microstructure, dimensional accuracy, inspectability, residual stresses, corrosion data, deposition rates, size limitations, post heat treatment, etc.).



Value and Benefit A number of organizations are working to improve AM technology and develop the necessary material properties for technology approval and acceptance by relevant codes and the NRC. This project will provide momentum and needed guidance for the powder bed fusion AM technology for nuclear applications, while positioning ANT to further develop and support AM. AM has the potential to produce highly complex and intricate RPV internals at a reduced cost and schedule (reduced procurement times). Furthermore, it can dramatically the expand design options for small parts by eliminating traditional restrictions associated with machining. Key Activities

Key Activities and Milestones Due Date Task 1: Develop roadmap for AM 3/31/2017 Task 2: Document the status and approach of current industry standards and feed into roadmap technical basis 9/30/2017

Task 3: Fabricate mock-ups per ASTM specs 10/31/2017 Task 4: Characterize mock-ups for material/mechanical properties 6/31/2018 Task 5: Publish guidance for implementation of ASTM spec requirements for nuclear applications 6/31/2018 Task 6: Publish mock-up results in Technical Report 12/31/2018 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Technical Report on Nuclear Implementation Guidance Deliverable 2: Technical Report on Mock-up Demonstration & Characterization Past EPRI Work on Topic

Report Number and Title Description Date Related Research N/A


ANT Project Title: MC 2018-D Evaluation of New Anti-Corrosion Surface Treatment Technologies for New Plants

Project Leader: Craig Stover Phone and Email: 704-595-2990, [email protected]


*EPRI WO Number: 1-XXXXXXXX *EPRI WO Title: N/A Funding Plan (000 $s) 2017 2018 2019 2020 Future


Key Research Questions A number of materials-related issues in the current fleet are managed through time-consuming, labor intensive, and expensive operations and maintenance (O&M) programs. The scope or need for these O&M activities could be reduced by using new surface treatment techniques on affected components or systems during manufacturing. An example of one such surface treatment technology that has been successfully used is the electropolishing of the steam generator (SG) bowls of new SGs. This technique has successfully reduced activated corrosion product deposition in the SG bowls. Another surface treatment technology that shows promise is the prefilming of Alloy 690TT SG tubing to reduce corrosion rates during normal operation. This technology is currently being evaluated in other EPRI studies. Objectives The purpose of this project would be to assess the potential for O&M cost reductions at new plants by using new anti-corrosion or anti-abrasion surface treatment technologies on nuclear plant components during manufacturing. This will be accomplished by: (1) identifying nuclear plant components with materials-related issues that could benefit from anti-corrosion or anti-abrasion surface treatment during manufacture/installation, (2) identifying new surface treatment techniques that may mitigate these component-specific corrosion or wear issues, and (3) conducting tests to verify that the surface treatment technique results in the intended effect without any major issues. Project Approach and Scope Task 1: Conduct a literature review to identify new anti-corrosion or anti-abrasion surface treatment technologies/techniques for use in nuclear plants. This literature review will cover surface treatment technologies used in the nuclear industry, surface treatment technologies used in other industries, and new surface treatment technologies with limited or no application experience. Only surface treatment techniques that would be applied before plant operation will be considered in this task (e.g., online chemical addition techniques would not be considered in this task). The following are some categories of surface treatment technologies that would be considered in this task: • New cladding materials (including hardfacing materials) and new cladding application techniques • Chemical treatments • Electropolishing • Polymer coatings For each new technology identified in this task, the expected costs, benefits, and technical limitations will be identified. Task 2: Review nuclear plant components/systems with the objective of identifying components that would benefit most significantly from application of the new surface treatment technologies/techniques identified in Task 1. This task will leverage existing resources such as the EPRI URD, the EPRI Materials Degradation Matrix documents, the NRC Proactive Materials Degradation Assessment (NUREG/CR-6923), EPRI NMAC databases, etc. Note that this evaluation will specifically exclude steam generator tubing, which is covered by other EPRI projects. Task 3: Evaluate which new techniques identified in Task 1 could be successfully applied to the components identified in Task 2. Then new surface treatment technology-component pairings will be down selected to determine the technique that is expected to result in the greatest value to future plants if applied to a specific plant component. This down selection evaluation will consider the cost of applying the surface treatment technique and the expected cost savings from improved performance during nuclear plant operation. Task 4: Conduct testing of the surface treatment technology identified in Phase 1 that is expected to result in the greatest value if applied to a particular component. The purpose of this testing would be to demonstrate successful application of the new surface treatment technology. The exact nature of the testing to be performed in this task is not known at this

time since the candidate component and surface treatment technique are not yet known. However, it is anticipated that this testing would aim to: • Verify the surface treatment technique results in the intended benefit (e.g., reduced corrosion, reduced pickup of corrosion products, increased efficiency, etc., as applicable) • Ensure the surface treatment technique can be acceptably applied to the target component without major issues • Ensure the surface treatment technique does not interfere with non-destructive evaluation Value and Benefit The nuclear industry will benefit from the identification and development of surface treatment technologies that are less time-consuming to implement, do not require onerous amount of labor, and are cheaper to perform thereby resulting in the capability to reduce O&M costs. Moreover, the reduction of O&M costs is an important component of the industry’s Nuclear Promise initiative. Key Activities

Key Activities and Milestones Due Date Task 1: Identification of New Surface Technologies 6/1/2018 Task 2: Identification of Key Components for Surface Treatment 7/1/2018 Task 3: Complete Analysis and Down selection of New Surface Treatment and Key Components 2/28/2019 Task 4: Complete Testing of New Surface Treatment Technology 11/31/2019 Task 5: Complete Final Report 12/31/2019 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Technical Report with analysis and testing results Past EPRI Work on Topic

Report Description Date 1024567 EPRI Materials Management Matrix Project Gap and Opportunity Assessment: Revision 0 2011

1024568 EPRI Materials Management Matrix Project: KHNP Advanced Pressurized Water Reactor (APR1400) Materials Management Tables 2011

1022683 EPRI Materials Management Matrix Project: U.S.--Advanced Pressurized Water Reactor Materials Management Tables. 2011

1021089 EPRI Materials Management Matrix Project: AREVA U.S. EPR™ Materials Management Tables - Revision 0. 2010

1016751 EPRI Materials Management Matrix Project: AP1000 Materials Management Table 2008

1021088 EPRI Materials Management Matrix Project: Advanced Light-Water Reactor - Pressurized Water Reactor Degradation Matrix - Revision 1. 2010

1019611 Advanced Light Water Reactor - Boiling Water Reactor Degradation Matrix (ALWR BWR DM), Revision 0. 2009

1020488 Advanced Nuclear Technology: EPRI Materials Management Matrix Project—Toshiba Advanced Boiling Water Reactor Materials Management Table Report, Revision 0. 2010

1019210 EPRI Materials Management Matrix Project: General Electric - Hitachi Advanced Boiling Water Reactor (ABWR) Materials Management Table Report, Revision 0. 2009

1016334 Program on Technology Innovation: EPRI Materials Management Matrix Project. 2008

3002005332 Program on Technology Innovation: Polymers in Nuclear Power Plants, Current Status and Prospects for Expansion. 2015

1025297 Plant Engineering: Compilation of Lessons Learned on Buried and Underground Piping in Nuclear Power Plants. 2012

3002005470 Materials Handbook for Nuclear Plant Pressure Boundary Applications (2015) 2015 1016374 Austenitic Stainless Steel Handbook 2008 Related Research N/A


ANT Project Title: MC 2018-E Development of Adaptive Feedback Welding for Repair and Fabrication




*EPRI WO Number: N/A *EPRI WO Title: N/A


Estimated Funding $146 $116 Comments: ANT Funding would supplement WRTC funding that is already in place for this project.

Key Research Questions Current welding practices of RPV internals employ manual, semi-automatic, or orbital welding equipment to accomplish dozens of welds during shop assembly. High speed articulating arms that can perform such welds are available to industry, but often require considerable programming and dedication to effectively perform individual welds. Welding robotics and controls need to be developed/ demonstrated that can learn/recognize a specific weld joint (cavity) quickly via laser scanning. Once learned and processed, the information could be used repeatedly (via adaptive feedback) to perform complex welds such as those associated with building a new reactor (SMR or ALWR). Objectives This project would provide support to the ongoing WRTC project on Adaptive Feedback Welding that is in need of additional support to accelerate their schedule and make it to completion. Project Approach and Scope This project will be completed in two separate phases. The first phase of the project will concentrate on identification and development of welding robotics, automation, and controls to first recognize the welding joint (or cavity) via laser scanning, then rapidly select a welding procedure to perform the weld. The weld would then be performed automatically with computerized feedback and automation. There are several keys to this project including: • Identify and demonstrate the laser scanning equipment/technology to rapidly scan the weld joint (or cavity) on a pass-by-pass basis. • Identify and demonstrate the robotic equipment (automated articulating arms) necessary to complete the weld • Work with an equipment vendor to integrate the two technologies together such that adaptive feedback control can be accomplished. Once these key objectives of the project have been successfully accomplished and demonstrated, the second phase of the project will target assembly of the system into one platform such that the technology could be used within an RPV for assembly, repair or replacement. This would include installation of a welding track system such that the robotic articulating weld arm could work from one common platform to perform multiple welds. EPRI will work with one or more OEMs and selected welding equipment vendors to demonstrate the high speed robotic welding capability and cavity learning function. Examples of welds that could be performed with the system include: shroud support leg-, support plate-, and control rod drive penetration-welds, as well as nozzle overlays. Once the automated robotic welding equipment has been assembled, two RPV internals welding mockups (TBD) will be assembled to demonstrate the new capabilities. Value and Benefit The value of this project is similar to that experienced by other industries (automotive, appliance, etc.): Almost complete automation of welding fabrication within the reactor assembly will be achieved. Significant cost savings should be realized through reduction in required labor hours, improved and repeatable quality, and considerable increase in weld travel speed. From a utility standpoint, the improvement in weld quality and inspectability will be realized, and procurement costs should be reduced eventually. If successfully executed, the entire welding process could be placed into the hands of the welding engineer.



Key Activities

Key Activities and Milestones Due Date Task 1: Develop sensing concepts and integrate into demonstration welding robot 11/1/2018 Task 2: Complete demonstrations of technology 11/1/2019 Task 3: Publish Final Technical Report 12/22/2019 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Technical Report Past EPRI Work on Topic



ANT Project Title: MC 2017-A Investigation of New Residual Stress Mitigation Techniques





Estimated Funding $191 $285 $78 Comments:

Key Research Questions Stress corrosion cracking (SCC) of nuclear plant components is perhaps the most significant issue affecting nuclear plant availability and plant lifetime management. Management of SCC during plant lifetime entails significant costs associated with required inspections of susceptible components, evaluation of inspection data to demonstrate operability, and needed repairs/replacements of nuclear plant components. To reduce susceptibility to SCC and to permit reductions in the extent of examinations required, plants have applied in-situ residual stress mitigation techniques. For example, peening techniques have been demonstrated to improve residual stress and prevent the onset crack initiation in Alloy 600 reactor pressure vessel head penetration nozzles and for Alloy 82/182 dissimilar metal butt welds in primary system piping. Although Alloy 600 and Alloy 82/182, historically among the most problematic materials used in the current nuclear plant fleet, will not be used significantly in new nuclear plants, some nuclear plant components may still be susceptible to SCC in new nuclear plant designs. Therefore, residual stress mitigation is still expected to be an important tool for limiting the onset of SCC in new nuclear plant components. For new plants, it is expected that it would be advantageous to conduct such residual stress mitigation techniques during component manufacture/installation rather than in-situ after the plant has commenced operations. Specifically, it is expected that residual stress mitigation techniques applied during manufacture/installation could be more effective, less expensive, less technically challenging, and easier to validate than techniques applied in-situ after the plant has commenced operations. Further, it is expected that alternate residual stress mitigation techniques can be applied during manufacture/installation that are not practical to apply in-situ after the plant has commenced operations. In 2015 EPRI published 3002005402 - Guidance for Advanced Light Water Reactor Primary System Component Residual Stress Management. This report presents a methodology for proactively managing material degradation through the manipulation and control of residual stresses in the material. This approach highlights the highest-risk locations and provides guidance on available mitigation technologies to facilitate the procurement and fabrication of components with significantly reduced risk of long-term degradation. However, many of the currently available Residual Stress Mitigation (RSM) techniques are expensive, difficult to implement, or not as effective as desired. There are many residual stress mitigation techniques that have not been evaluated for nuclear applications that may address some of the shortcomings of the currently available techniques. Objectives The purpose of this project would be to identify nuclear plant components that would benefit from residual stress mitigation during manufacture/installation and to identify promising residual stress mitigation techniques for use during nuclear plant component manufacture/installation. After identifying the most promising technique for residual stress mitigation of a particular component in need of stress relief, testing would be conducted to demonstrate the technology and to begin the process of qualifying the technique for use in nuclear plants. Project Approach and Scope Task 1: Conduct a literature review to identify novel residual stress mitigation techniques appropriate for use during/after manufacturing or installation of nuclear plant components (i.e., before plant operation). This task will include a review of residual stress mitigation techniques used in non-nuclear industries and new techniques with limited or no application


experience. Further, this task will include a review of residual stress mitigation techniques that have been used during normal operation in the nuclear industry. These existing residual stress mitigation techniques will be reviewed for comparison with the new techniques and since these existing techniques could potentially be used in new manufacturing / installation applications. Candidate residual stress relief techniques that have already been used in the current nuclear fleet that will be considered in this task include: • Mechanical stress improvement • Induction heating stress improvement • Water jet (cavitation) peening • Laser peening • Abrasive water jet peening • Ultrasonic shot peening • Conventional shot peening • Rotary peening Task 2: Review nuclear plant applications with the objective of identifying specific geometries, thicknesses, or, components that would benefit most significantly from residual stress relief during/just after manufacturing or installation. Applications will be reviewed for the advanced light water reactor designs. Nuclear plant components assessed in this task will include major components that have been stress relieved in-situ in the current nuclear plant fleet, but will not be limited to such components, since some plant components in need of residual stress relief in the current fleet may have not been stress relieved due to the high costs / difficulty of performing the stress relief in-situ at an operating plant. Task 3: Evaluate which residual stress mitigation techniques identified in Task 1 could be successfully applied to the components in need of stress relief identified in Task 2. Then, downselect the residual stress mitigation technique / component pairings to determine the technique that would result in the greatest value to future plants if applied to a specific plant component. This downselection evaluation will consider factors such as the following: • Expected cost savings from reduced rates of degradation • Expected cost savings from reducing the extent of examinations needed (if applicable) • Expected cost to apply the technique • Market maturity of the technique (in terms of number of qualified vendors) • Technology readiness • Technology risk • Whether the technique is applicable for use in the field, in the manufacturing shop, or both • Whether a flooded water environment is needed to apply the technique (and how practical that is during construction) • Whether fabrication defects are mitigated or not • Effect on other construction activities • Effect on acceptance of the treated component for plant service (per ASME rules etc.) • Effect on pre-service non-destructive examination (NDE) • Effect on future in-service inspections Task 4: Develop a qualification plan for the most promising residual stress mitigation technique / component pairing identified in Task 3. This qualification plan will define the testing and analysis needed to support application of the identified residual stress mitigation technology in new nuclear plants. It is anticipated that this qualification plan could include the testing aspects listed below. The actual plan will depend on the current state of knowledge regarding the particular pairing evaluated. For existing technologies that have been applied in nuclear plants during operation, the plan would focus on resolving issues related to implementation of the technique during manufacturing / installation. • Mockup fabrication • Residual stress mitigation demonstration • Residual stress measurement • Corrosion testing • NDE Task 5: Conduct testing of the residual stress mitigation technique identified in task 1 that are expected to result in the greatest value to future plants if applied to a particular component. The objective of this testing will be demonstrate / evaluate the feasibility of the technology and to begin work to qualify the technology for use in nuclear plants. The exact nature of the testing to be performed in this task will be determined under Task 4.

Value and Benefit Identification and evaluation of new Residual Stress Mitigation (RSM) Techniques will benefit the nuclear industry by providing new techniques that are:

• more effective at addressing residual stresses • less expensive • available for difficult installations

Moreover, the development of new RSM techniques enables the procurement and fabrication of components with significantly reduced risk of long-term degradation. Key Activities

Key Activities and Milestones Due Date Task 1: Identify RSM techniques for evaluation 3/1/2017 Task 2: Identify key locations that are good candidates for new RSM techniques 6/1/2017 Task 3: Downselect RSM technique for further evaluation 8/1/2017 Task 4: Develop Qualification Plan 12/31/2017 Task 5: Conduct testing of RSM methods 12/31/2018 Task 6: Develop Technical Report 6/1/2019 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Final report containing results of evaluation and testing Past EPRI Work on Topic


3002005402 Advanced Nuclear Technology: Guidance for Advanced Light Water Reactor Primary System Component Residual Stress Management 2015

3002005498 Materials Reliability Program: Finite-Element Model Validation for Dissimilar Metal Butt-Welds 2015

3002003955 Materials Reliability Program: Prediction of Relaxation of Peening Residual Stresses in Alloy 600 (MRP-397) 2014

1019087 Materials Reliability Program: Validation of Welding Residual Stress Models for PWR Piping Dissimilar Metal Welds (MRP-271) 2009

1018056 Program on Technology Innovation: Nondestructive Evaluation and Measurement of Residual Stress 2008

Related Research


ANT Project Title: MC 2017-B Comprehensive Identification of New Plant NDE Needs






Key Research Questions New nuclear power plant designs have a number of unique characteristics that make Nondestructive Examination (NDE) inspections potentially challenging. Some of the challenges include accessibility to the components based on the tight physical geometries of the plant. Another challenge is the more rigorous inspection requirements that have been instituted in some new plant licenses such as 100% inspection of new components. For example, industry standards currently require ultrasonic (UT) examination on both sides of austenitic welds, an onerous task for many component configurations. In some cases, the component surface geometries make dual-side scans impossible, precipitating design license modifications, an expensive and time consuming process that may or may not be acceptable to the regulator. These issues and others present opportunities for the development of new technologies and techniques. However, the NDE needs for new plant have never been documented in a singular report. Objectives This work will develop a report that can be the comprehensive documentation of NDE needs for new nuclear plants. In this vein, the project will review new nuclear plant designs for the identification of inspection scenarios, commitments, and locations that are unique to the new plant designs. The identification of the NDE issues that are most important to new plants will enable the leverage of those ideas for further consideration in NDE committees. Project Approach and Scope

This project has a 1-year scope. It is anticipated that this document could be developed quickly to facilitate further research development.

The first part of the project would utilize interviews and meetings with utilities and plant OEMs to understand what NDE challenges and needs have already been identified through the design or construction of new plants.

The second part of this project would be a review of the plant design information for the identification of NDE challenges and gaps that were not identified in the first part of the project.

Finally, the third part of the project will be the development of a report that documents the results. Value and Benefit Members will benefit from having a comprehensive report that documents all known new plant needs, gaps, and challenges. The framework detailed in the report will make it clear what NDE research needs to be undertaken to support new nuclear. Moreover, the report can be used as a leverage mechanism to garner support for projects being proposed in NDE committees that could address issues identified herein. Key Activities

Key Activities and Milestones Due Date Task 1: Conduct interview and meetings 6/1/2017 Task 2: Complete review of plant design information 9/1/2017 Task 3: Complete report of findings 12/11/2017


Deliverable 1: Technical Report on new plant NDE needs Past EPRI Work on Topic



ANT Project Title: MC 2017-D Guidance on the Application of HDPE Piping

Project Leader: Craig Stover Doug Munson Phone and Email: 704-595-2990, [email protected]





Estimated Funding $66 $53 $XX $XX $XX Comments: 50/50 cost share with BOPC

Key Research Questions For a number of years EPRI has been researching the use of High Density Polyethylene (HDPE) pipe for nuclear power plant applications with the objective of supporting the development of ASME Code rules to allow its use in safety class 2 and 3 piping systems. A significant effort has been undertaken to develop the needed material properties and ASME Code rules to allow HDPE application in ASME Class 2 and 3 systems. EPRI has performed significant research on topics such as seismic, material properties, NDE, slow crack growth, creep, and fatigue. This work helped the development of ASME Code Case N-755-2 and Appendix XXVI to Section III to provide clear guidance on the application of HDPE. The development of ASME Code rules for HDPE are now nearly complete, and associated EPRI support are coming to a close. Based on utility experiences and R&D test results, there is a need to document lessons learned and develop guidelines for the procurement of HDPE pipe to better educate and guide utilities around potential issues. Objectives This report will support nuclear utilities in their efforts to install both non-safety and safety related HDPE by providing an overview of the major design, licensing, procurement, and installation issues to be considered. This report will not be intended to be a comprehensive guide on HDPE design. Rather, the report is intended to provide supplemental guidance to assist utility engineers involved with the design, modification, specification and installation of HDPE. The report will provide a compilation of lessons learned and operating experience applicable to the procurement and installation of HDPE. The information is intended to optimize the design and specification process. Project Approach and Scope This document will provide guidance for HDPE projects utilizing both safety and non-safety related HDPE. Furthermore, this report will cover procurement of pipe from a NQA qualified supplier as well as under the Owner’s QA program. This report is intended to address all issues associated with the procurement and installation of HDPE. Issues to be addressed include initial design considerations, bid evaluation, selection of a supplier, specification and procurement, NDE, shipping, storage, and installation. It is intended to implement a Technical Advisory Group (TAG) for the development of this work. The TAG will need utility members that have installed HDPE as well as myriad of technology suppliers from the HDPE industry. The first part of this project would be a TAG meeting(s) to obtain insight from utilities and technology suppliers on operating experience and potential improvements to purchase specifications/procurement documents to reduce incidents of problems. This phase of the project would also include benchmarking visits to sites that have installed HDPE to evaluate good practices as well as problems encountered during various phases of the project. The second part of the project would be a literature review of previous EPRI/Industry guidance and research to develop an outline of the report. The final part of the project would be the development of the technical report.



Value and Benefit This project will provide value to the membership by clearly documenting the elements of HDPE specification and procurement that are necessary to ensure an acceptable product is placed in service. Key Activities

Key Activities and Milestones Due Date Task 1: Conduct TAG meetings and benchmarking 4/1/2017 Task 2: Draft outline of guidance document complete 8/30/2017 Task 4: Complete Draft Final Report 2/28/2018 Task 3: Complete Final Report 5/30/2018 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Guidance on the Application of HDPE Technical Report Past EPRI Work on Topic

Report Number and Title Description Date 1016719 Fatigue testing of HDPE pipe and components 2008 1020438 Capacity testing of HDPE flanged joints 2010

1020439 Stress intensification and flexibility factors of common HDPE fittings 2010

1021094 Above ground design methods 2010 1022565 Slow crack growth testing, scratch criteria 2011 1023004 Fire testing of HDPE 2011

1021095 Seismic properties of PE4710: damping, seismic modulus, seismic qualification of vent & drain valves 2011

1025253 Preliminary crack growth curves of PE4710 2012 1025254 Tensile and modulus properties of PE4710 2012

1025296 Long Term Performance of PE4710 Materials in Disinfectant Treated Nuclear Raw Water Systems 2012

3002000592 An assessment of industry fusion data 2013 3002000524 Radiation effects on HDPE performance 2013 3002002748 Material Properties affecting butt fusion of HDPE 2014 3002003120 The Long-Term Oxidative Resistance of Butt Fusion Joints 2014 Related Research EPRI has published over 25 reports on the topic of HDPE. Many of the reports are referenced above.


ANT Project Title: MC 2018-A Economic Evaluation of Upgrading Materials for New Plants






Key Research Questions A number of materials-related issues in the current fleet are managed through expensive operations and maintenance (O&M) programs. Many of these materials-related issues could potentially be eliminated or substantially reduced by upgrading the materials of construction of the affected components or systems at the time of construction. Some material upgrades that would substantially reduce materials-related issues have already been identified in other documents such as the advanced light water reactor utility requirements documents (URDs). However, an economic analysis demonstrating why upgrading the materials of construction would reduce costs over the plant lifetime is needed to justify the (potentially) increased costs of the improved materials of construction. Objectives Conduct an economic assessment of the costs associated with the management of major materials-related issues) as compared to the costs to upgrade those materials at the time of plant construction to eliminate/reduce the issue. The ultimate objective of this work is to provide guidance on whether it is cost effective for utilities constructing new nuclear plants to upgrade the relevant plant components/systems to eliminate or reduce the identified issues. Project Approach and Scope Task 1: Review operating experience to identify the major materials-related issues in the current nuclear fleet. Issues identified will include those directly related to materials performance, such as increased rates of corrosion, cracking, wear, and component failure, and will also include issues that are indirectly related to materials performance, such as increased dose rates due to activation of corrosion products in the primary system, reduced equipment performance due to fouling, etc. The following are some issues that may be included among those identified in this task: • FAC of steam cycle piping • FAC of steam generator internals • Wear of CRDM guide cards • Boric acid corrosion of bolts • Pitting of condenser tubes • Corrosion product buildup in service water systems • CRUD formation in the primary system Task 2: Identify the major plant O&M costs associated with the top materials-related issues identified in Task 1. These costs will consider actual monetary costs associated with managing the issues (e.g., resulting from maintenance, inspections, analysis, repairs, replacements, program management, lost power, etc.), and will also consider more abstract costs, such as increased personnel safety risks and increased plant dose rates. It is anticipated that this task would include one trip to a currently operating plant to help determine the typical costs and manpower needs associated with managing the identified top materials-related issues. Task 3: Identify materials upgrades that would eliminate the materials-related issues identified in Task 1 and the costs to implement the material upgrades at the new plants, i.e., before operation. Finally, conduct a net present value (NPV) economic assessment to determine if it would be cost effective to implement the material upgrades at the new plants.

Value and Benefit Benefits of this project include: (1) identifying the major materials-related issues in current plants, (2) identifying materials improvements that would alleviate those issues, and (3) presenting an economic analysis that demonstrates whether utilities buying new nuclear plants should upgrade the materials of construction of the identified plant components/systems to alleviate the identified materials-related issues. Reducing the O&M costs associated with these materials issues is an important component of the industry’s Delivering the Nuclear Promise initiative. Key Activities

Key Activities and Milestones Due Date Task 1: Identification of Top Materials-Related Issues in Current Nuclear Plants 5/1/2017 Task 2: Identification of Plant Costs Associated with Management of the Top Materials-Related Issues 7/1/2017 Task 3: Draft report of Economic Assessment of Materials Upgrades to Eliminate Materials-Related Issues 10/1/2017 Task 4: Complete final report 12/22/2017 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Technical Report on Economic Evaluation of Upgrading Materials Past EPRI Work on Topic Report Number and Title Description Date

1024567 EPRI Materials Management Matrix Project Gap and Opportunity Assessment: Revision 0 2011

1024568 EPRI Materials Management Matrix Project: KHNP Advanced Pressurized Water Reactor (APR1400) Materials Management Tables 2011

1022683 EPRI Materials Management Matrix Project: U.S.--Advanced Pressurized Water Reactor Materials Management Tables. 2011

1021089 EPRI Materials Management Matrix Project: AREVA U.S. EPR™ Materials Management Tables - Revision 0. 2010

1016751 EPRI Materials Management Matrix Project: AP1000 Materials Management Table Report. 2008

1021088 EPRI Materials Management Matrix Project: Advanced Light-Water Reactor - Pressurized Water Reactor Degradation Matrix - Revision 1. 2010

1019611 Advanced Light Water Reactor - Boiling Water Reactor Degradation Matrix (ALWR BWR DM), Revision 0. 2009

1020488 Advanced Nuclear Technology: EPRI Materials Management Matrix Project—Toshiba Advanced Boiling Water Reactor Materials Management Table Report, Revision 0.

2010

1019210 EPRI Materials Management Matrix Project: General Electric - Hitachi Advanced Boiling Water Reactor (ABWR) Materials Management Table Report, Revision 0.

2009

1016334 Program on Technology Innovation: EPRI Materials Management Matrix Project. 2008

3002005332 Program on Technology Innovation: Polymers in Nuclear Power Plants, Current Status and Prospects for Expansion. 2015

1025297 Plant Engineering: Compilation of Lessons Learned on Buried and Underground Piping in Nuclear Power Plants. 2012

3002005470 Materials Handbook for Nuclear Plant Pressure Boundary Applications (2015) 2015

1016374 Austenitic Stainless Steel Handbook 2008 Related Research N/A

EPRI ANT Project Opportunity Form Revision Date: 7/13/2016

ANT Project Title: MC 2018-B PWSCC Testing and Revision to Alloy 690 Tubing Specification

Project Leader: Craig Stover Phone and Email: [email protected], (704) 595-2990




Estimated Funding $443 $83 Comments: NSSMC has committed to fund 50% of the specification rev. (an additional $83K in 2019)

Background and Key Research Questions Several relatively new processes for fabrication or pre-treatment of steam generator tubing are currently being evaluated for incorporation into the EPRI Alloy 690 Steam Generator Tubing Specification Sourcebook (hereafter the 690 Tubing Specification), including:

• NSSMC’s pre-filming process • EPRI’s stabilized chromium process (SCrP) • Continuous casting

NSSMC’s pre-filming process and EPRI’s SCrP were reviewed as part of the recent revision to the 690 Tubing Specification, but were not incorporated into this guidance document as acceptable processes due to several technical uncertainties that remained. To date, neither process has been used in the pre-treatment of SG tubing. In the case of NSSMC’s pre-filming process, overall the process appears potentially beneficial and the likelihood of detrimental material effects is judged to be low (based on the expected nature of the Cr-depletion layer). Nonetheless, plant trials using this process do not appear to be a viable option to confirm the effectiveness or harmlessness of this process because: (1) it is expected to take too long to determine if there is an effect on in-service PWSCC performance and (2) treating only a small population of SG tubes would not be expected to yield any meaningful data with respect to the expected benefits (reduced Ni release). The same can be said for EPRI’s SCrP, which has been applied to replacement components such as diaphragms, pump parts and valves, but not to SG tubing. Continuous casting was also reviewed as part of the recent revision to the 690 Tubing Specification, and was determined to be acceptable for use in fabricating Alloy 690 SG tubing as long as the material property requirements are fulfilled and purchaser approval is obtained in the same manner as other melting practices. Continuous casting has been used in other industries, such as oil and gas, and is economically favorable relative to ingot casting. As such, more widespread use of continuous casting could have economic benefits for utilities planning to replace SGs or build new nuclear plants. However, continuous casting has never been used to fabricate SG tubing, and it is anticipated that for the first few SG tubing orders produced using continuous casting, the possible economic benefits of continuous casting would be offset by additional sampling/analysis requirements and efforts by early-adopting utilities to gain acceptance. Further, like NSSMC’s pre-filming process and EPRI’s SCrP, it would take many years of in-service plant operation with continuously cast tubing to determine if there is any impact of this process on the in-service PWSCC performance of Alloy 690 SG tubing. Objectives The purpose of this project is to support an update of the 690 Tubing Specification by performing interrupted slow strain rate testing (SSRT) on Alloy 690 specimens that are exposed to or produced using NSSMC’s pre-filming process, EPRI’s SCrP process, and continuous casting methods. It is anticipated that this testing will: • Address key material integrity questions that will facilitate determining whether pre-filming processes, such as NSSMC’s pre-filming process and EPRI’s SCrP, can be incorporated in the 690 Tubing Specification. Incorporating these processes in this document would facilitate the use of pre-filming during production of commercial tubing lots for utilities seeking to minimize source term, radiation fields and worker exposure following SG replacement and/or new plant construction (relative to operation with untreated SG tubing). This is especially important in this case since, as described above, plant trials may be of limited value for evaluation of pre-filming processes.


• Provide increased confidence in relatively new processes that have already been incorporated into the 690 Tubing Specification, but that have not yet been applied to SG tubing. In particular, it is expected that this testing will increase confidence in continuous casting and reduce the burden on early-adopting utilities seeking to utilize continuous casting based on the longer term economic benefits to the industry. The results of this testing would then be used to support revision of the 690 Tubing Specification. Project Approach and Scope Task 1: Conduct interrupted SSRT on Alloy 690 specimens that are exposed to or produced using NSSMC’s prefilming process, EPRI’s SCrP process, and continuous casting methods. The performance of these specimens would be compared to reference specimens to determine if there is any impact on PWSCC initiation (beneficial, detrimental or neutral).The following specimens are anticipated for this testing:

• NSSMC Alloy 690 control specimen (ingot casting, untreated) • NSSMC Alloy 690 pre-filmed specimen (ingot cast, pre-filming process) • NSSMC Alloy 690 pre-filmed and descaled specimen (ingot cast, pre-filming process, plus descaling to exposed

underlying Cr-depleted layer) • NSSMC Alloy 690 continuously cast specimen (continuous casting, untreated) • EPRI Alloy 690 SCrP specimen (NSSMC control specimen, plus SCrP adapted for application to SG tubing) • EPRI Alloy 690 SCrP and “descaled” specimen (NSSMC control specimen, plus SCrP adapted for application to SG

tubing, then Cr-enriched layer removed) • Sandvik Alloy 690 control specimen (ingot casting, untreated) • Sandvik Alloy 690 continuously cast specimen (continuous casting, untreated) • Valinox Alloy 690 control specimen • Alloy 600MA control specimen

It is anticipated that this testing will be conducted at normal PWR primary system conditions (i.e., chemistry and temperature). Thus, unlike many PWSCC tests that are accelerated by using a more aggressive chemistry environment, the environment simulated in the proposed interrupted SSRT would be directly applicable to nominal PWR primary chemistry. Since the EPRI SCrP has not yet been applied to production lots of SG tubing, it will be useful to determine: (1) if this process can be adapted for application to production lots of SG tubing, and (2) if so, at what stage EPRI’s SCrP process would be applied during the SG fabrication sequence (e.g., integrated with tubing production sequence, performed after tubing production, etc.). After these details are determined, attempts will be made to prepare the SCrP test specimen for the interrupted SSRT mentioned above in a way that represents the expected method for applying EPRI’s SCrP to Alloy 690TT tubing during or after production of commercial SG tubing lots. Task 2: Revise the EPRI 690 Tubing Specification to address whether the pre-treatment techniques described in Task 1 above should be permitted and, if permitted, will identify any required conditions for implementation of these processes during manufacturing, including: • Process controls such as temperature, environment, duration, etc. to ensure processes are applied as intended. • Inspection activities (e.g., visual inspections of ID discoloration versus reference standards, metallurgical examinations such as the depth and nature of the chromium depletion layer, etc.) and/or destructive examinations to verify acceptable implementation of the process. • Required examination frequencies during both pre-production qualification and manufacturing of production lots. This revision will be based in part on the results of the Task 1 testing, but will also be based on previous EPRI work. Value and Benefit It is anticipated that this project will:

• Address key material integrity questions that will facilitate determining whether pre-filming processes, such as NSSMC’s pre-filming process and EPRI’s SCrP, can be incorporated in the 690 Tubing Specification. Formally accepting these processes in this document would facilitate the use of pre-filming during production of commercial tubing lots for utilities seeking to minimize source term, radiation fields and worker exposure following SG replacement and/or new plant construction (relative to operation with untreated SG tubing). This is especially important in this case since plant trials have been determined to be of limited value for evaluation of pre-filming processes

• Provide increased confidence in relatively new processes that have already been incorporated into the 690 Tubing Specification, but that have not yet been applied at SG tubing (i.e., continuous casting). In particular, it is expected that this testing will increase confidence in continuous casting and reduce the burden on early-adopting utilities seeking to utilize continuous casting based on the longer term economic benefits to the industry.

• Formally accepting these processes in specification would facilitate the use of pre-filming during production for utilities seeking to minimize source term, radiation fields and worker exposure following SG replacement and/or new plant construction.

Key Activities

Key Activities and Milestones Due Date Task 1: Perform testing and publish technical report (deliverable 1) 12/31/2018 Task 2: Publish Revised Alloy 690 specification (deliverable 2) 12/31/2019 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Technical report on testing Deliverable 2: Revised Alloy 690 specification Past EPRI Work on Topic

Report Number and Title Description Date 3002003124, “Advanced Nuclear Technology: Alloy 690 Steam Generator Tubing Specification Sourcebook”

Provides requirements and recommendations for procuring Alloy 690 steam generator tubing and sleeve material.

June 2014

TBD, “Advanced Nuclear Technology: Pre-Filming Steam Generator Tubing”

Evaluation of available pre-filming technologies and identify any potential knowledge gaps which need to be addressed for the technique to be made available on a wider scale for commercial use

Scheduled Aug. 2016

1013518, “Materials Reliability Program: Potential for Mitigation of Primary Water Stress Corrosion Cracking in Ni-Based Alloys by Using the EPRI Stabilized Chrome Process (MRP-194)”

Evaluated the ability of SCrP-treatment to delay cracking in reverse U-bend specimens made from a susceptible heat of Alloy 600

June 2006

Related Research The revised EPRI Alloy 690 Tubing Specification Sourcebook, prepared in 2014, provided updated information on requirements for procuring Alloy 690 tubing manufacturing and in-service performance, and ensured consistency with governing codes and standards, and reflected the latest tube manufacturing practices. Similarly, work performed in 2015 and 2016 examined the various processes of pre-filming steam generator tubing. These two works complement the research proposed in this project and it is anticipated that the results of this proposed work will determine if pre-filming steam generator tubing is a viable and economically sound option to reduce Ni release.


ANT Project Title: MC 2018-C Support of Advanced 52 Weld Metal Development

Project Leader: Craig Stover Steve McCracken Phone and Email: 704-595-2990, [email protected]



*EPRI WO Number: N/A *EPRI WO Title: N/A


Estimated Funding $183 $242 $80 Comments: Co-funded with WRTC.

Key Research Questions High chromium nickel-base weld metals such as 52 and 52M are used extensively in the nuclear industry for improved resistance to stress corrosion cracking. These weld metals are typically used in dissimilar metal weld joints in the reactor coolant system of nuclear power plants where weld quality is paramount. Unfortunately, the general weldability and susceptibility to various cracking mechanisms that occur during welding varies widely with minor variations of element composition within the ASME material specification limits for 52 and 52M type weld metals. Moreover, cracking susceptibility varies with weld dilution by the base material and welding process parameters. These issues have caused extensive in-process repair and rework of 52 and 52M welds costing manufacturers of nuclear power plant vessels and components millions of dollars. Therefore there is a need for both a 52M weldability screening test as well as a high-chromium nickel-base weld metal with excellent SCC performance and good resistance to both solidification cracking and DDC. Objectives This project would provide support to 2 ongoing projects (New Alternative High Chromium Nickel-base Weld Metal and 52M Weldability Screening Test) in WRTC that are in need of additional support to accelerate their schedule and make it to completion. Project Approach and Scope Task 1: Support of New Alternative High Chromium Nickel-base Weld Metal

EPRI will perform weld experiments with the new weld metal using gas tungsten arc welding (GTAW) typical for 52 and 52M. It is anticipated that the experiments for the new weld metal will be similar to those developed and used by EPRI to assess the cracking performance of 52, 52M and other high chromium nickel-base variants. If necessary, GTAW parameter development will be performed to optimize weldability of the new weld metal.

The second step will be to fabricate several mockups on austenitic stainless steel and low alloy steel base metals typical of dissimilar metal weld joints in a reactor coolant system. The mockup welds will be sectioned and characterized metallurgically and examined with typical nondestructive examination methods to access weld quality. Mechanical testing typical for qualification of a new weld metal (tensile testing, bends, hardness mapping, etc.) will also be performed to assess the weld quality.

The third step will be to perform limited weld experiments to access performance of the new weld metal with different welding processes such as GTAW-hot wire, gas metal arc welding (GMAW), sub arc welding (SAW), and laser bead welding (LBW). The purpose of this limited survey of other welding processes is to identify any issue unique to the new composition that is significantly different than other high chromium nickel-base weld metals. Task 2: Support of 52M Weldability Screening Test

EPRI will use knowledge of solidification cracking and ductility-dip cracking mechanisms to systematically develop a field deployable test for screening 52 and 52M weld metals. Welding experiments, material characterizations, and weld computer simulations will first be performed to evaluate different test geometries, variations in welding parameters, and material compositions that promote cracking in 52 and 52M weld metals. Testing and evaluations will include


solidification cracking that occurs when welding on stainless steels and ductility-dip cracking that occurs during reheating of previously deposited weld metal. Screening test concepts will be developed based on these results.

Initial screening test concepts will then be evaluated by investigating thresholds for cracking with various heats of 52, 52M, and other variants of high chromium nickel-base weld metals. Acceptance criteria for the screening test, such as bending, cross-section examination, NDE, etc. will be investigated to determine the most simple and straight forward option for field deployment. Finally, one or more welding vendors or nuclear component manufactures will be solicited to test the proposed weldability screening test. Value and Benefit Manufacturers, fabricators, and welding vendors are impacted by the susceptibility of 52 and 52M to cracking. A new high chromium nickel-base weld metal with improved crack resistance would eliminate costly rework and in-process weld repairs that often occur with 52, 52M or other similar variants. Finally, a high chromium nickel-base weld metal with the desired SCC performance and improved resistance to weld cracking will improve the overall quality of reactor coolant system dissimilar metal welds of high safety significance in nuclear power plants. Furthermore, A simplified weldability test will provide a means for manufactures and fabricators to screen heats of 52 and 52M for new nuclear components as well as replacement components. Use of a heat that is less susceptible to weld metal cracking will help reduce uncertainty associated with cracking susceptibility. For manufacturers with aggressive production schedules a simplified weldability screening test can provide confidence when using 52 or 52M. Finally, proper screening of high chromium nickel-base weld metals will improve the overall quality of reactor coolant system dissimilar metal welds of high safety significance in nuclear power plants. Key Activities

Key Activities and Milestones Due Date Task 1 Establish optimum gas tungsten arc welding (GTAW) parameters for the new weld metal. 4/31/2018

Complete weld experiments and mockup fabrication with GTAW. 9/28/2018 Complete metallurgical characterization, NDE, and mechanical testing of GTAW mockups. 12/30/2018 Survey and perform preliminary investigations of other welding processes such as gas metal arc welding (GMAW), laser bead welding (LBW), sub arc welding (SAW), etc. with the new weld metal. 9/30/2019

Develop Final Report (Deliverable 1) 6/30/2020 Task 2 Final concept for field deployable 52/52M weldability screening test

8/30/2019

Concept for 52/52M weldability screening test validated by nuclear component fabricator or welding vendor 4/30/2019

Task 3: Develop Final Report (Deliverable 2) 12/31/2019 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Final report of weldability and mockup results with the new weld metal Deliverable 2: Final report with field tested and validated weldability screening test for 52 and 52M Past EPRI Work on Topic


3002005527 WRTC: Welding and Repair Technology Center: Screening Test for High-Chromium Nickel-Base Weld Metals—Preliminary Studies.

This report describes mockup experiments designed to replicate the strain, strain rate, stresses, and thermal cycles expected in field welds and produces DDC in predicted weld regions. The data from this work will be used to assist in developing a simplified field test that will effectively screen for resistance to DDC and other common cracking mechanisms in high-chromium nickel-base weld metals.

September 2015

3002003140 WRTC: Measures to Minimize 52M Hot Cracking on Stainless Steel Base Materials – Update

This report details weld experiments performed to evaluate susceptibility of high chromium nickel-base weld metals to solidification cracking when welded on stainless steels. Practical solutions to manage and prevent cracking are presented.

December 2014

3002000412 WRTC: Development of Improved Weld Heat Input and Dilution Equations for Consumable Welding Processes

Improved heat input equations have been developed to better predict dilution of high-chromium nickel base weld metals. This knowledge can be used to manage solidification cracking.

November 2013

3002000641 WRTC: Evaluation of High-Chromium Nickel-Base Welding Alloys

This report provides results of laboratory weldability testing of high chromium nickel-base weld metals and indexes susceptibility of various high chromium nickel-base weld to weld metal cracking.

August 2013

3002005527 WRTC: Welding and Repair Technology Center: Screening Test for High-Chromium Nickel-Base Weld Metals—Preliminary Studies.

This report describes mockup experiments designed to replicate the strain, strain rate, stresses, and thermal cycles expected in field welds and produces DDC in predicted weld regions. The data from this work will be used to assist in developing a simplified field test that will effectively screen for resistance to DDC and other common cracking mechanisms in high-chromium nickel-base weld metals.

September 2015

3002003140 WRTC: Measures to Minimize 52M Hot Cracking on Stainless Steel Base Materials – Update

This report details weld experiments performed to evaluate susceptibility of high chromium nickel-base weld metals to solidification cracking when welded on stainless steels. Practical solutions to manage and prevent cracking are presented.

December 2014

3002000412 WRTC: Development of Improved Weld Heat Input and Dilution Equations for Consumable Welding Processes

Improved heat input equations have been developed to better predict dilution of high-chromium nickel base weld metals. This knowledge can be used to manage solidification cracking.

November 2013

3002000641 WRTC: Evaluation of High-Chromium Nickel-Base Welding Alloys

This report provides results of laboratory weldability testing of high chromium nickel-base weld metals and indexes susceptibility of various high chromium nickel-base alloys to weld metal cracking.

August 2013

Related Research

Compositional modeling and analysis in concert with newly developed small size laboratory testing techniques have been developed and deployed at the OSU Welding and Metallurgy department to identify two target compositions of high chromium nickel-base weld metals with improved weldability (e.g., resistance to both solidification cracking and DDC). This research and development work has been funded by EPRI Technology Innovation.

Small heats of target compositions are currently being manufactured for initial laboratory based weldability testing. This testing should be complete by the 3rd quarter of 2016 with intended outcome of identifying the optimum weld metal composition for larger scale mockup testing with standard arc welding processes. EPRI has worked with the OSU Welding and Metallurgy Department to understand the cracking mechanisms (i.e., solidification cracking and ductility-dip cracking) in high chromium nickel base weld metals for over seven years. Research and laboratory testing methods such as the strain-to-fracture (STF) test, cast pin tear test (CPTT), transverse varestraint test (TVT), button melting experiments, single sensor differential thermal analysis (SS-DTA), and thermal dynamic simulations have been applied to better understand cracking mechanisms. During this period of time the fundamental mechanism of solidification cracking and ductility-dip cracking in high chromium nickel-base weld metals has progressed and is better understood. In addition, EPRI has worked to develop weld simulations using SysWeld™ to predict ductility-dip cracking and also performed many weld experiments to understand dilution influence on solidification cracking. This large body of work and research will be leveraged to develop the simplified weldability screening test proposed in this project.

Quick Descriptions of Potential 2019+ M&C Projects

M&C RFA #1: Advanced Manufacturing & Fabrication

M&C 2019-# Additive Manufacturing Qualification and Code Acceptance

• Issue: The existing work on Additive Manufacturing will only partially complete the tasked required to gain acceptance of AM in the nuclear industry. Additional work will be required to gain complete code acceptance.

• Scope: This project will develop and support several code cases in multiple code bodies to gain the acceptance needed for significant implementation of AM in the nuclear industry.

• Value: AM has the potential to produce highly complex and intricate RPV internals at a reduced cost and schedule (reduced procurement times). Furthermore, it can dramatically the expand design options for small parts by eliminating traditional restrictions associated with machining.

M&C 2019-# Cost Comparison between Manufacturing Techniques

• Issue: There are many different manufacturing techniques available to manufacture the same components. It would be beneficial to gain an understanding of which techniques are more cost effective for a given component.

• Scope: This project would conduct and economic evaluation of the costs associated with manufacturing components using different techniques.

• Value: The resulting document produced in the project could be used as procurement tool to determine the best manufacturing method to enlist for a given component.

M&C 2020-# New Surface Treatment Technology Transfer

• Issue: There is a 2018 project proposed on the development of new surface treatment technologies to prevent component degradation. The identified and developed as part of the project will need to be transferred to the industry for use.

• Scope: The project will work with technology suppliers to demonstrate the use of selected surface treatments for the purpose of transferring the technology to industry.

• Value: The nuclear industry will benefit new surface treatment technologies that are less time-consuming to implement, do not require onerous amount of labor, and are cheaper to perform thereby resulting in the capability to reduce O&M costs.

M&C 2020-# Adaptive Feedback Welding (AFW) Technology Transfer

• Issue: There is a 2018 project proposed on the development of adaptive feedback welding for repair and fabrication. The identified and developed as part of the project will need to be transferred to the industry for use.

• Scope: The project will work with technology suppliers to demonstrate the use of adaptive feedback welding for the purpose of transferring the technology to industry.

• Value: Significant cost savings should be realized through reduction in required labor hours, improved and repeatable quality, and considerable increase in weld travel speed.

M&C 2020-# Repair of New Manufacturing Techniques

• Issue: Several new manufacturing technologies have been developed recently. However, little work has been completed to understand and develop repair processes for the techniques.

• Scope: This project would perform a gap analysis to identify the new manufacturing techniques requires unique repairs.

• Value: This would provide insight and provide the foundation to understanding where additional work would be required to develop new repair processes.

M&C 2020-# Identifying Applications for Bi-Metallics

• Issue: There are many different technologies available for producing components with multiple metallic surfacessuch as corrosion resistant cladding, bi-metallic extruded pipe, and PM-HIP. An analysis is needed to understandwhich bi-metallic technologies lend themselves to a give component.

• Scope: This project would compile and evaluate the existing bi-metallic technologies.• Value: The use of bi-metallic components has the ability to reduced manufacturing costs and extend component

life.

M&C RFA #2: Material Performance and Inspection

M&C 2019-# Expand Risk Informed Methods Applicability to SMR Designs

• Issue: The Risk Informed method of determining which components to inspect has not been completed for theSMR designs.

• Scope: This project would develop the basis document for various SMR designs to determine which componentswarrant inspection.

• Value: The Risk Informed approach has benefited the industry by significantly reducing the number of requiredinspections. This project would extend those benefits to SMR designs.

M&C 2019-# Risk Informed Methods Volume of Primary Interest Inspections

• Issue: Some new plants have identified welds that are not inspectable using ASME Section XI practices.• Scope: This project would develop a combination of risk-informed technical argument and an “inspection for

cause” (e.g. degradation dependent) inspection approach that will define the “volume of primary interest” forPSI purposes. It is envisioned that this smaller inspection volume will be achievable with current UT methods.

• Value: This work could be used new plants that have access issues to address a number unique inspectionchallenges.

M&C 2019-# Inspection Credit for Residual Stress Mitigation

• Issue: Plants are not currently able to reduce their inspections even if they have applied a RSM technique to acomponent.

• Scope: This project would provide the technical basis for obtaining regulator endorsement of reducedinspections for RSM treated components.

• Value: Tremendous time and costs can be saved from significantly reducing inspection volumes.

M&C 2019-# Opportunities for Enhanced Specifications

• Issue: Historically the nuclear industry has utilized procurement specifications that focus on referencing industrycodes and standards. Other industries such as aviation utilize procurement specifications that provide detailedand more restrictive material and manufacturing requirements.

• Scope: This project would evaluate the value and methodology of applying enhanced specification to nuclearcomponents.

• Value: Enhanced specifications provide the opportunity to procure components that have significantly improvedproperties resulting in improved performance and longevity.

M&C 2019-# Water Chemistry Guidelines for SMR’s

• Issue: Water chemistry guidelines have not yet been developed for SMR designs.• Scope: This project would develop water chemistry guidelines for multiple SMR designs.• Value: Ample water chemistry control is key to equipment performance, life, and reliability.

M&C 2020-# Residual Stress Mitigation Code Support

• Issue: Work has been planned to develop several new Residual Stress Mitigation techniques. Support is neededto push the new techniques through to code acceptance.

• Scope: This project would provide the support necessary to obtain code acceptance of new RSM techniques.• Value: Obtaining code approval for new RSM is an important step towards utilizing the new techniques in

nuclear plants.

M&C RFA #3: New Materials Development

M&C 2019-# New Material Scoping

• Issue: Materials are the fundamental limitation when designing and assessing performance, service life,operational limits, and degradation mechanisms of any nuclear component.

• Scope: This project will seek to identify new materials for nuclear applications that can provide improvedmaterial performance characteristics.

• Value: Identification of new materials with enhanced properties can have benefits such as extending theduration of operation, reducing inspections, cost reductions, and improved maintenance.

M&C 2020-# SMR Material Management Matrix

• Issue: A Material Management Matrix has not yet been developed for any of the SMR designs.• Scope: This project would develop a Material Management Matrix for multiple SMR designs.• Value: The information contained in the Material Management Matrix will provide the information necessary to

proactively identify and manage materials performance issues potentially reducing operating costs.

M&C 2021-# Gen IV Material Development

• Issue: New materials are needed to unlock the full potential of most advanced Generation IV nuclear reactorconcepts and designs. Materials for GEN IV applications will operate at temperatures/pressures and undercorrosive conditions never experienced for fossil or nuclear power applications.

• Scope: This project will identify and develop the alloys that can be used under these aggressive operatingconditions.

• Value: The development of new materials in required for Gen IV plants. The work conducted in this project willhelp to enable to new generation of plants.


ANT Project Title: Qualification of Additive Manufacturing Components for Nuclear Applications



Target Start Date: October 2016 Planned Duration 36



Estimated Funding $20 $80 $80 $60 $XX

Comments: The costs listed below represent EPRI’s portion of the DOE cost share. 2 other organizations are providing cost share as well. DOE is contributing $1M to this project.

Key Research Questions Nuclear power plant equipment manufacturers have realized the potential to deploy additive manufacturing (AM) methods to produce reactor internal components due to its unique capability to generate complex geometries rapidly with improved performance, while reducing the cost and time to market. At the same time, code and regulatory bodies are skeptical about adopting these components for real-life service due to the scatter in metallurgical and mechanical properties emanating from machine specific and process variations. Although current efforts to develop qualification standards (e.g. ASTM F42) are based on fabrication/testing of coupons, there is no clear, concise methodology for component process-based certification. For example, even when two identical parts are made with same processing equipment and powder composition, variations in properties are observed due to stochastic variations in laser energy interaction and associated effects leading inefficient melting and defect formation

Objectives This project will develop an innovative qualification strategy for complex nuclear components produced by laser powder bed AM which will be developed and demonstrated by leveraging relevant technology from recent welding developments, as well as, emerging process analytics, high- performance computation models, in-situ monitoring and big-data mining.

Project Approach and Scope The project scope involves six tasks involving design, processing with in-situ monitoring, deployment of high performance computational model, ex-situ characterization; scale up of components, and compilation of methodology and data package for standards organization approval. The project scope starts with design of a component with complex geometry, relevant to nuclear flow applications, with topology optimization methodologies for increased heat transfer efficiencies. Then, this component will be made in typical laser powder bed machines.

During the build process, in-situ process monitoring will be performed with state of the art sensors. Some of the sacrificial samples, built at the same time during component manufacturing, will also be characterized using destructive ex-situ characterization techniques including optical and electron microscopy. The ex-situ data is used to validate the computer algorithms for detection of defects from in-situ thermal and optical data and microstructures and residual stresses predicted by computational models. In the next step, all the defect and microstructural data with good spatial and temporal resolution can be used within existing finite element methods to evaluate the expected static and dynamic performance of structures under service conditions. Finally, all the data from process parameter log files, in-situ and ex-situ characterization have been spliced together within a 3-D data analyses framework. Although, each step of the objectives have been demonstrated individually, until now no one has integrated all the components to develop a live 3D data set that can be used as a qualification of additively manufactured components within the confines of ASME pressure vessel codes.

The systematic qualification approach, part qualification and certification will allow for realization of the potential of AM, while providing manufacturers and regulators with component-level certification data. During this research, a flexible business and operational model will be initiated to allow for different vendors with state-of-the art ICME models, in-situ sensors and ex-situ characterization to work together. The above objectives will be demonstrated in laser powder bed



process, also known as, selective laser melting (SLM) or direct metal laser sintering/melting (DMLS). The following section provide details of the technical tasks. Task 1. Demo Artifact Design and Baseline Properties Three demonstration components that have the required design complexity (e.g. fuel casting assembly or other) will be identified by each original equipment manufacturer (OEM). Potential areas for deployment of the results from this research will be related to steam separator inlet swirlers, nuclear fuel channels, fuel support bows and casings, inlet mixer assemblies, jet pump beams, shroud supporters and tube sheets. The baseline static (yield strength, tensile strength, elongation, and fracture toughness) and dynamic (Charpy energy and fatigue) properties will be measured and documented. The participating companies will initiate a manufacturing run of these components using the existing manufacturing technology, i.e., casting, forging and powder metallurgy and machining). All the relevant data during this processing will be collected and documented in as much as detail possible. The components will be evaluated and compared with similar component to be made by AM. Task 2. Process Design, Processing and In-situ Monitoring, Analyses and Validation The complex geometry from Task 1 will be scaled and appended with support structures to take care of overhangs. The part will be manufactured using a laser powder bed processing machine and other machines. The process variables including laser power, scanning speed, scanning strategy (continuous, island and chess) preheat temperature, and powder characteristics will be recorded and documented within Dream 3D architecture. Furthermore, all the in-situ process monitoring (time-resolved thermography) techniques will be deployed for the laser AM process. For example, some of the preliminary research pertaining to EBM process parameter data (e.g. chamber vacuum levels) analyses with Discrete Fast Fourier Transformation (DFFT) showed interesting results. The probability of build failure during manufacturing of Ti6Al4V correlated very well to the noisy spectrum with distinct higher order peaks at frequencies greater than 0.2 Hz. Similar analyses to correlate the same build failure and defect formation will be performed. Task 3. Deploy and Validate High Performance Computational Models Process parameter data and boundary conditions will be used as input to the high performance computational models (ICME) for heat and mass transfer. The model will predict the spatial variation of temperature, liquid metal flow, and liquid-solid interface velocity. The information will be used with phenomenological models to predict defect formation and columnar or equiaxed grain formation. Theories behind these phenomenological models have been developed. For example, using computational models based interface response function theories for weld solidification, the national laboratory researchers were able to control site-specific microstructure during electron beam powder melting process. These models will be extended to laser powder bed additive manufacturing. The predicted results will be validated with data from in-situ monitoring from Task 2. The predicted results (3D dataset) will be uploaded into Dream 3D framework. ICME performance models will then be used to predict the debit in the static and dynamic properties. Task 4. Ex-situ Non Destructive and Microstructure Characterization The components made by additive manufacturing will be non-destructively characterized using computer-aided X-ray tomography (CT scans). The spatial presence of defects like porosity, lack of fusion, and un-melted powders will be characterized and documented in 3-dimensional Cartesian coordinates. The data from CT scans will be used to evaluate the possible signature information from 3-D reconstruction of 2-D thermal image stacks. For example, such a correlation was obtained in samples by comparing CT images and also images obtained by in-situ infrared thermography. With such correlations, we envision that we can minimize the need for post process X-ray tomography for all AM samples. Furthermore, selected regions from the component will be extracted and microstructural distributions will be measured. The data will be compared and evaluated with thermo-mechanical cycles predicted in Task 3. The above data will also be populated into the Dream.3D. The samples will be subjected to loading conditions that is typical to the existing structure methodology outlined in Task 1. The mechanical properties will be correlated with results from analytics of data that is stored within Dream 3D architecture. Task 5. Scale Up to Full-Size Components Validation of qualification approach developed in Tasks 1-4 will be evaluated for scale-up at ORNL. On completion of addressing the scale-up issues, the methodology will be transferred to collaborating industries. Three full-size components will be fabricated using the methodologies developed in Tasks 2-4. Using the ICME modeling and processing methodology, in-situ monitoring, and characterization data, the performance metric and certification for these

components will be assigned. In the next step, the component fabricated by AM and traditional manufacturing (Task 1) will be tested mechanically. Efforts will be made to correlate the failure location to the in-situ data measured in Task 2. For example, recent work by collaborators of this proposal have confirmed the sensitivity of the fatigue life to the relative location of defects with reference to surface, within Ti6Al4V builds made by direct energy deposition. The results of this task will be the validation of the ICME process-based qualification versus traditional methodologies. Task 6. Develop ASME & Regulatory Acceptance & Project Management/Coordination If the ICME and in-situ process monitoring qualification methodology for AM components is proven accurate, these methodologies will be documented and will support the technical basis for ASME Code and NRC acceptance. Value and Benefit Laser-based power bed AM processes have the potential to develop an entirely new field for manufacturing nuclear internal components. This project will potentially determine if the laser powder bed additive manufacturing can indeed manufacture nuclear components with robust quality and performance. Several of the advanced geometric designs that could take advantage of increased heat transfer efficiencies (e.g., advanced reactor applications) can only be produced by additive manufacturing. By providing a pathway to qualify these components, the project may also contribute to increased performance of nuclear power generation. Key Activities

Key Activities and Milestones Due Date Task 1. Demo Artifact Design and Baseline Properties 7/31/2017 Task 2. Process Design, Processing and In-situ Monitoring, Analyses and Validation 2/28/2018 Task 3. Deploy and Validate High Performance Computational Models 10/15/2018 Task 4. Ex-situ Non Destructive and Microstructure Characterization 12/31/2018 Task 5. Scale Up to Full-Size Components 6/30/2019 Task 6. Develop ASME & Regulatory Acceptance & Project Management/Coordination 8/30/2019 Anticipated Deliverables

List of Proposed Deliverables Deliverable 1: Technical Update on Process Design and Validation Deliverable 2: Technical Update on Deployment and Validation of Computational Models Deliverable 3: Technical Report—Final Report Past EPRI Work on Topic

Report Number and Title Description Date N/A Related Research N/A