In-service inspection as an aid to steel pressure vessel reliability

In-service inspection has played an important role in non-nuclear pressure vessel technology, being a legal requirement in many countries. Evidence from surveys of reliability of non-nuclear plant has suggested that such inspections can be effective in reducing the risk of subsequent failures. Recent requirements of the ASME XI code which will be summarised have important implications on the techniques to be used for in-service inspection, and so on design and fabrication aspects. Moreover, in-service inspection can only be an effective procedure if its possible weaknesses are recognised. The first problem is to ensure that an ultrasonic technique is used which is capable of detecting defects of an order of magnitude smaller than the critical size for each particular situation, in whatever defect orientation is important. The potential of different ultrasonic techniques will be compared. Next it is necessary to ensure coverage of all the relevant material. In this respect machine operation is superior to manual scanning, so that manipulation and scanning devices have to be developed. Problems of local geometry and of deviations in geometry have to be discussed with designer and fabricator; plate and clad quality have to be controlled (with respect to surface contour, metallurgical condition and freedom from interfering defects) to ensure inspectability in depth. The reliability of the mechanical and electronic equipment has to be assessed and designed to meet high requirements. Some presentational aids to detection and interpretation will be discussed. Having located a potential defect, the application of fracture mechanics treatments requires knowledge of size, shape and orientation. Some of the problems will be discussed together with possible solutions. (author)