Safety-related considerations for reactor pressure vessels in consideration of hydrogen flaking

During non-destructive inspection of the reactor pressure vessels in the Belgian nuclear power plants Doel 3 and Tihange 2, a large number of crack-like indications located in the base metal of the core shells were found. As part of the evaluation of these indications, which were identified as flake-like separations (hydrogen flakes), questions arise as to their cause, possible operational growth and the impact on the continued safe operation of the plant. In addition to the operational load cases, possible accidental and beyond design load cases are also of importance. Within the scope of the ''Research Project Component Safety'' (Forschungsvorhaben Komponentensicherheit - FKS) in the time frame mid-1970s to mid-1990s, numerous R and D activities on the material mechanics behavior and qualification of RPV materials were performed at MPA University of Stuttgart. The objectives of these investigations were focused on material mechanical issues related to the integrity of components and included standard material testing as well as component-like large scale specimen tests. Another major objective was the evaluation of non-destructive testing (NDT) methods with respect to their detection capabilities for such defects which developed during the manufacturing process. The investigations also included a study of the conditions favorable for formation or prevention of hydrogen flaking. In the context of this paper, the results from these R and D activities are presented in view of the current issues and in relation to the integrity concept for German RPVs. Ultrasonic testing (UT) techniques applied during manufacturing and during in-service inspections of German RPVs will also be discussed.