In-service Inspection and Structural Health Monitoring for Safe and Reliable Operation of NPPs

In nuclear power plants, continuous efforts are made to ensure that plants are operated in safe, reliable and economical manner. While utmost care is taken during design, construction and commissioning of the structures, systems& components (SSCs), continued healthiness has to be ensured during operation phase in accordance with the design intent. This is primarily achieved through the establishment of a comprehensive life management programme of surveillance, condition monitoring, periodic In-service inspections (ISI) and maintenance, the purpose of which is to ensure that required safety margins are maintained for all important SSCs throughout plant service life.In any industry, the important mechanisms which lead to SSCs degradation are general corrosion, Flow accelerated corrosion, erosion, thermal effects, fatigue and mechanical wear & fretting. In a Nuclear Power Plant, in addition to these, degradation also occurs due to irradiation and creep. Therefore SSCs need to be designed with due consideration of all such degradation mechanisms.During operation phase, the limiting conditions for operation and requirements of surveillance & condition monitoring for all components important to safety are documented in Technical Specification. A plant specific ISI manual defines and elaborates the ISI internal inspection methods and acceptance criteria. The ISI requirements are decided taking into account best industry practices and operational experience and meet the requirements of existing codes and standards. Both these documents are approved by AERB.In pressurized heavy water reactors, major components covered in ISI programme are coolant channels, feeder pipes, steam generators, heavy water heat exchangers, pressure boundary components, relief valves etc. The inspection methods adopted include use of UT, ECT, DPT and visual inspection. In addition to functional checks for some of the components, ferrography, vibration monitoring and thermography etc are also utilized for rotating equipment. The SSCs where unacceptable indications are revealed by ISI are repaired, replaced or isolated. The base line data generated during Pre-Service inspection is used for comparing and trending of observations. The observations made during ISI are subjected to thorough review and analysis by qualified experts to obtain assurance that unacceptable degradation in component quality is not occurring and it remains fit for service.The containment system of a NPP plays a crucial role in minimizing dose to the public in case of an accident situation. The integrity of Primary and Secondary Containment is assessed by conducting integrated leak rate tests in every Biannual Shut Down. The concrete structure is also subjected to NDT checks on a specified frequency to ensure continued healthiness.Indian nuclear power plants have accumulated an operating experience of more than 380 reactor years of operation. Over the years, the programmes for surveillance, condition monitoring and in-service inspections have been improved significantly and match with best in the industry. As a result, there has been no major age related failure in any of the important SSCs and thus continued safe and reliable operation of NPPs is assured.This paper brings out the ISI & health monitoring methodology adopted at Indian NPPs, to ensure safe and reliable operation.