Reliability Considerations of NDT by Probability of Detection (POD) Determination Using Ultrasound Phased Array – Results from a Project in Frame of the German Nuclear Safety Research Program

Reliable assessment procedures are an important aspect of maintenance concepts. Non-destructive testing (NDT) methods are an essential part of a variety of maintenance plans. Fracture mechanical assessments require knowledge of flaw dimensions, loads and material parameters. NDT methods are able to acquire information on all of these areas. However, it has to be considered that the level of detail information depends on the case investigated and therefore on the applicable methods. Reliability aspects of NDT methods are of importance if quantitative information is required. Different design concepts e.g. the damage tolerance approach in aerospace already include reliability criteria of NDT methods applied in maintenance plans. NDT is also an essential part during construction and maintenance of nuclear power plants. In Germany, type and extent of inspection are specified in Safety Standards of the Nuclear Safety Standards Commission (KTA). Only certified inspections are allowed in the nuclear industry. The qualification of NDT is carried out in form of performance demonstrations of the inspection teams and the equipment, witnessed by an authorized inspector. The results of these tests are mainly statements regarding the detection capabilities of certain artificial flaws. In other countries, e.g. the U.S., additional blind tests on test blocks with hidden and unknown flaws may be required, in which a certain percentage of these flaws has to be detected. The knowledge of the probability of detection (POD) curves of specific flaws in specific testing conditions is often not present. This paper shows the results of a research project designed for POD determination of ultrasound phased array inspections of real and artificial cracks. The continuative objective of this project was to generate quantitative POD results. The distribution of the crack sizes of the specimens and the inspection planning is discussed, and results of the ultrasound inspections are presented. In the context of the results, the remaining uncertainty of the inspections has to be taken into consideration for failure analysis.