STATE ENTERISE “KOLORAN”

REVIEW OF ELABORATIONS, EXECUTED FOR INDUSTRY’S
ENTERPRISES BY STATE ENTERISE “KOLORAN”
OF INSTITUTE OF PHYSICAL CHEMISTRY
NAMED BY L.V. PISARZHEVSKIY, ACADEMY OF SCIENCES
OF UKRAINE
Institute of physical chemistry named by L.V. Pisarzhevskiy has a large experience of works
on an atomic subject. Already in 1939 under the guidance of academic A.I. Brodskiy technology of
receipt of heavy water was developed. The results and specimen of D2O were successfully used at
creation of domestic nuclear industry.
Continueing these traditions SE “KOLORAN”, from 1984 executes works on creation and
production of facilities and technologies of non-destructive control, repair and defence of NPP
equipment.
1. Non-destructive control and diagnostics.
1.1. Elaboration and organization of ecologically clean material’s production for the
“dye” penetrant control.
Work is executed by order “Prometheus” Institute in connection with the necessity of
leadthrough of non-destructive control of the weld-fabricated connections into the compartments of
atomic submarine boats and high toxicness of applied penetrants.
As a result we synthesized dye “basic raspberry”, unique properties of which allowed to develop
a gamut of fully harmless, easily reutilizable “penetrants”. These materials are entered in the
“Compatible methodic of control of basic materials, weld-fabricated connections of equipment and
pipelines of NPP. Capillary control (PNAE G-7-018-89) (fig.2)”
Государственный комитет СССР
по надзору за безопасным ведением работ
в атомной энергетике
УНИФИЦИРОВАННА МЕТОДИКА КОНТРОЛЯ
ОСНОВНЫХМАТЕРИАЛОВ (ПОЛУФАБРИКАТОВ)
СВАРНЫХ СОЕДИНЕНИЙ И НАПЛАВКИ ОБОРУДОВАНИЯ
И ТРУБОПРОВОДОВ АЭУ
КАПИЛЛЯРНЫЙ КОНТРОЛЬ
ПНАЭ Г-7-018-89
Москва 1990
ПЕРЕЧЕНЬ РЕАКТИВОВ И МАТЕРИАЛОВ,
ПРИМЕНЯЕМЫХ ДЛЯ КАПИЛЛЯРНОГО КОНТРОЛЯ
Материал (реактив) Нормативный
документ
Керосин осветительный из сернистых нефтей
Бензин Б-70 для промышленно-технических целей.
Технические условия.
Бензин “Нефрас-050/170”
Скипидар живичный.
Ксилол
Ацетон
Спирт этиловый реактификованный
Спирт этиловый реактификованный, технический
Спирт этиловый технический
Масло трансформаторное
Каолин, обогащенный для парфюмерной
промышленности, сорт 1
Каолин для фарфоровой промышленности
Краситель жирорастворимый темно-красный 5С
Краситель жирорастворимый темно-красный “Ж”
Люминофор “Нориол А”
Краска “М” проявляющая белая
Жидкость “К” красная проникающая
Натрия карбонат безводный
Сода кальцинированная
Ткани хлопчатобумажные бязевой группы
Марля медицинская
Перчатки резиновые хирургические
Набор дефектоскопических материалов
ИФХ-КОЛОР-4
АК - 2Ц
ДАК – 3Ц
ГОСТ 11128-65
ТУ 38-101913-82
ГОСТ 8505-80
ГОСТ 1571-82
ГОСТ 9940-76
ГОСТ 2603-79
ГОСТ 5962-67
ГОСТ 18300-72
ГОСТ 17299-78
ГОСТ 982-80
ГОСТ 21285-75
ГОСТ 19608-84
ТУ 6-14-922-80
по 1 категории
качества
ТУ 6-14-37-80
ТУ 88ГССР 01-78
ТУ 6-10-749-79
ТУ 6-10-750-79
ГОСТ 33-79
ГОСТ 10689-75
ГОСТ 11680-76
ГОСТ 9412-77
ГОСТ 3-75
ТУ 88УССР 206-39-87
ТУ 6-15-904-79
ТУ 6-15-1360-82
Применение. В случае применения дефектоскопических материалов
по другим стандартам и техническим условиям это должно быть
согласовано с головной отраслевой материаловедческой
организацией или авторами методики.
(fig.2)
PDF created with pdfFactory trial version www.pdffactory.com

(fig.3)
(fig.4)
The nature of dye allowed to construct
penetrants, which includes such opposite on the
properties komponents, as water and kerosene,
lubricants and alcohol et cetera. Materials and
technology of finding out microflaws of
submicrometer sizes are as a result developed
including on the rough surfaces (fig.4). The specialists
of “NIKIMT” are set high radiation firmness of
penetrant “PC-KOLOR”, that allowed him to use it
for distance televisional non-destructive control of
elements of the 1st contour of nuclear reactors systems.
In SE “KOLORAN” the production of dye penetrans
“PC-KOLOR” is organized, which during 20 years
apply on domestic and foreign NPP.
Harmlessness and ecological safety of
penetrants “PC-KOLOR” is confirmed the
sanitary-hygenic conclusion of Ministry of
helth safety of Ukraine, in obedience to
which they can be applied including in
food industry (fig.3).

1.2. Development of high temperature dye penetrants.
It was executed within the framework of project “SHOYAT” (System of storage of exhaust nuclear
fuel) with the purpose of leadthrough of capillary control of the weld-fabricated container for storage
of exhaust nuclear fuel (fig.5).
(fig.5)
(fig.6)
In accordance with developed in welding
Institute, named by E.O. Paton technology of
assembling the lid of such container is welded
on in a few passage-ways, after each check up
the hot welding by capillary method. Therefore
SE “KOLORAN” elaborated materials and
technology of the high temperature dye
penetrant control , which are also produced by
our enterprise. All park of containers, set to the
present on Zaporozhia NPP, passed non-destructive
control with the use of high temperature “PC-KOLOR”
dye penetrant (fig.6).

1.3. Development of means for leakage revealing in the “tank for keeping of boric acid
solution”.
One of elements of the system of safety of NPP is the so-called “tank of boron”. It is intended
for storage of plenty of water solution of boric acid, applied in an emergency situation for stopping
out nuclear reaction. A “tank of boron” is a hall, facing by stainless steel with 8-10 mm thickuess. In
connection with the use of the hand welding ther quality of the weld-fabricated connections, as a rule,
is unsatisfactorily. And the considerable losses of solution of boric acid which gets in the drainage
system appear because of presence of large number of through defects, and then it comes outside of the
station. Thereby there is radiation contamination of environment. Thus possible norms on losses from
the system of the coniferous “tank-boron” arrive at hundreds of litres per a day.
Therefore the task to develop effective and simple method leakaze revealing of “tank of
boron” was put before SE “KOLORAN”. This task we succeeded to decide within the framework of
capillary method of non-destructive control, developing compositions, chemically reactive on water
solution of boric acid. Such “developer” is inflicted on the weld-fabricated joints into a tank after
removal of solution and drying of surface. Penetrant-solution of boric acid takes out by developer
from defects. The painted indicator “trace,”, appears as a result of chemical reaction and defect could
be find out. The offered method is comfortable and practically does not influence on the technology of
exploitation and repair and is not expensive. During the row of years it is used on Zaporozhia NPP
in the process of the planned repair of “tank boron”.
(fig.7)
1.4. Development of facilities of
magneto particles inspection (MPI).
From 1989 our enterprise together with
the department NDT of the Institute of
welding, named by E.O. Paton, is
engaged in creation of new technologies,
rigging and materials for MPI.
We produce modernized devices on
permanent magnets, which are completed
with standard specimens the calibrated
defects and materials for MPI. Many years
they used on NPP during exploitation and
repair.

1.5.Application of thermography for control of internal corrosion and thickness of pipelines.
All examples of works described higher, executed SE “KOLORAN” for non-destructive control of
systems of NPP, are based on visual registration of defects with the use of different materials and
devices. Therefore fully appropriately, that for control of wear of pipelines NPP we applied a IR
apparatus, allowing to register the thermal field of object.
Presently the basic method measure of walls thickness of pipelines because of corrosive-erosive
wear is ultrasonic method. It is supposed by the contact of sensor with the surface of
pipeline, I.e. local sampling test, that reduces his productivity sharply.
(fig.8)
In conditions of OP “Zaporozhia NPP”
pipelines, tested earlier by UT melhod, were
inspected. Application of thermography
confirmed thickness lost of wall of pipelines
confidently (fig.9). By IR-thermografhic
control it is possible to find out corrosive
shells and thickness lost of walls a depth
more than 40 % of wall thicknesses, I.e. it is
confirme that sensitiveness IR thermografhic
control is higher of sizes of defects, possible
for secure work of pipes.
This failing allows to remove application of IR
method. In process, executed jointly with the
Kharkov National university of radioelectronics,
the specimen of imperfect pipelines, cut out
during repair of constructions OP “Yuzhno-
Ukrainian NPP, were investigatied” (fig.8). The
got results confirm the conclusion of foreign
researchers about perspective of application of
thermography for non-destructive control of
erosive-corrosive shells and lost thickness of
pipeline’s walls.
(fig.9)
In the letter of SE NAEK “Energyatom” is confirmed expedience of further works on
application of thermography with the purpose of exposure of corrosive-erosive damages and
prognostication of remaining resource of equipment and pipelines of NPP.

1.6. Finding out flows in the system of pumpings aggregates of GNC- 195 M.
Impermeability of many aggregates and systems of NPP is a necessary for their normal
operating condition. A prime example, confirmative it, is the system of cooling of engine of VASES –
215 pumpings aggregates. From bad quality of welding of pipelines and loss of cooling liquid –
lubricant repeatedly there was a situation, fraught a fire at the station. In this connection before
SE “KOLORAN” the task of timely discovery of losses of heat exchage material from the system of
cooling of engine of pumpings aggregates OP “Yuzhno-Ukrainian NPP” was put.
For the decision of task of verification of impermeability of the systems of cooling of electric
motor we use the method of luminescent penetrants. A luminofor , which will well dissolve in
lubricant and possesses a quantum output near to one, was synthesized. The offered luminofor and
penetrant on it basis behaves to the IV class of toxic substances (ГОСТ 12.1.005-88). Addition in an
amount 1-3 grammes of luminofor on the litre of lubricant provides visual registration of leakade with
a high sensitiveness (PNAE G-7-019-89 the “Compatible methodic of control of basic materials,
weld-fabricated connections equipment and pipelines of NPP. Control of impermeability), that allows
in shot time to find out the losses of lubricant from the system of cooling of electric motor and
eliminate possibility of origin of fire.
1.7. Non-destructive control of pipes of NPP heat changers.
A question about a discovery and repair of through defects gets up during exploitation of NPP
heat exchange apparatuses (condensers, air cooling et cetera). So during work of turbine steam is
condensed on heat-exchange tubes, which, form a cooling surface that divides steam and aquatic parts
of condenser. During exploitation due to corrosion and erosion the thin-walled tubes maden from a
copper-nickeliferous alloy are easily damaged and the “bouquet” of admixtures, presented in cooling
technical water, contaminates info a runback. Thermophysical descriptions of steamgenerator get
worse as a result.
Yet more sharply the question of control of impermeability stands during exploitation of MCP
(main circulation pump). The electric motor of pump cools down by air. Air cools down in air cooling
by technical water from a pond-cooler. Under influence of erosive-corrosive processes in pipe walls
through defects form (fig.10, 11). As a result water gets on the puttee of electric motor, that results in
a short circuit.
(fig.10, 11)

Therefore extraordinarily important for providing of effective work of heat changers is an
exposure of the initial stages of forming of through defects.
To that aim SE “KOLORAN” and NPP department of Welding Institute, named by
E.O. Paton, offered equipment and technology, allowing to conduct monitoring of the state of art of
heat-exchange tubes and timely discovery of mikroleakages in tubes walls. For this purpose we use
complex apporoach of NDT by:
– “Acoustic Eye” defectoscope (fig. 12,13), which allows to detect such defects as
pitting, erosion, leaks, blockages and so on. Inspection time of one tube independently
of it’s longitude and diameter is about 30 second due to computer programme,
– virtual Eddy current defectoscope “Wirlwind” (fig.14), which allows to confirm
defect’s presence and was elaborated with special computer programme,
– examination of defects by use in addition an endoscope, which produced by ourselves
(fig.15,16). By such device it can be examined inside wall of the tube, during Eddy
current testing,
– define leaks by“pipe leaktester” (fig.17. 18), which is based on manomentry method.
Such complex intends for quick testing of heatexchager with exact definition of defect’s type
(fig. 12) (fig. 13)
(fig.14)

(fig.15) (fig.16)
(fig. 17) (fig. 18)
2. Repair of imperfect heat-exchange tubes.
For the removal of defects of tubes constructions State Enterprise “KOLORAN” offered the
followings non-standard technologies.
2.1 Repair of through defects by the method of soludering. The method of soldering of defects found
application mainly for repair oil and gas pipelines without their stop. It is suggested to use this method
by us for repair of heat-exchange tubes in the case when access is impossible to the outward surface. A
mikroheating element is for this purpose constructed combined with a device for causing of low
temperature solder (<1000 C), such instrument allows to conduct the removal of flows inside tubes.
2.2.Repair of through defects with the use of anaerobic sealants.
Many repair tasks, arising up in the process of exploitation of equipment NPP, can be decided
with the use of polymeric anaerobic compositions. These materials widely use in an aviation and
rocket production, on a railway transport, in shipbuilding et cetera. Liquid in the initial state polymeric
compositions harden in absence of air, for example, in through defects (flows), in screw-thread
connections et cetera Thereby, for example, they can be used and as effective glue.
In connection with that at tubes repair access to the surface is possible only from the side of pipe
board, we are offer technology of repair of through defects in the walls of tubes by imposition on the
area of defect from within a compression, fixed on-the-spot anaerobic glue. For realization of such
technology we developed a device, pinning and gluing pressure-sealing material to the internal
surface of tube (fig.19).

(fig. 19) (fig. 20)
As a result of setting of experimental party of compressions on tubes defects of condenser TG K-
1000-60 OP “Zaporozhia NPP” was confirmed perspective of this method of repair of through defects
of heat-exchange tubes.
2.3. Application of electrochemical coverages for anticorrosive and antierosive defence and
repair of constructions of NPP.
It was suggested by us for protecting from erosion to inflict on an internal surface electrochemical
coverage, containing nanoparticles of diamond. Technology of causing of such coverage is developed
for an internal tubes surface. On fig.20 the sight of tube is presented with the protective coverage.
At the thickness from 10 to 30 mkm protective cover possesses mechanical durability, which exceeds
durability of tubes alloy.
The results of researches of physical and chemical properties of protective cover are below
resulted.
Research objects:
8 metal-backer coverages on the standards of alloy of СUNIVE and electric copper, differentiating
between itself by terms of causing, closeness of current, temperature of electrolyte, composition of
electrolyte, lining type and presence of antifactious additions.
Research methods:
Physical and chemical descriptions of the presented standards were tested in a laboratory on
development of paint and composition materials of firm ISI by a personnel, passing the special
preparation for work on an equipment, answering the standard of ASTM.
Description of exclusive methods is resulted in protocol of tests and in an appendix with
description of methods and applied devices.
The results of tests are resulted in the enclosed protocol.
PROTOCOL
of tests of standards of sheeting on copper plate.
Methods of tests.
[1] – Thickness of coverage is measured the electronic gaugemeter of DUALSCOPE MP 40 with the
measuring head of ED of firm Helmut Fischer Gmbh+co.KG in the mode of Nc/nf (cover on
unmagnetic conducting plate).
Note. The unevenness of thickness of coverage exceeds 100%. In the table of results the thickness of
area of coverages is indicated on which a test was conducted on elasticity. [2] – Adgeziya of coverage
to copper plate is measured on ASTM D 3359-02 Standart Test Methods for Measuring Adhesion to
by Tare Test. (Higher index – 5 marks correspond an index 1.1 for GOST, a worst index is 0 marks). A

test is conducted with the use of device of Cross-cut-tester Model 5120 firms of BYK- Gardner and
ribbons of Scotch 898.
[3] – Hardness of coverage is measured on ASTM D 3363-00 Standart Test Methods for Film
Hardness by Pencil Test with the use of set of slate-pencils of PH 5802 firms Byk-gardner. Hardness
of Scratch is indicated in the table of results of tests (marings).
[4] – Elasticity of coverage at squeezing out is measured on the method of firm Erichsen GMBH with
the use of device of Erichsen Midel 202 C. By character * results are indicated where destruction of
copper plate had happened.
[5] – Firmness of coverage to the abrasive wear by means of bombardment a shot is tested on the
method of firm Erichsen GMBH on the device of Stone Hammer Blow Testing Instrument Model 508.
The scale of estimation includes 10 degrees from 0-1 (higher estimation) to 5 (the worst result). In a
table the results of estimation of degree of damage of coverage after bombardment of 1 kg of cast-iron
shot are indicated during 20 with at accelerating pressure of 2 Barins.
Results of tests.
Index Method Values of indexes for the standards of coverages
1 2 3 4 5 6 7 8
Thickness of
coverage, mkm
[1] 10,2 28,4 17,6 18,6 19,4 20,1 29,5 19,9
Agdeziya of
coverage, mark
[2] 5 5 5 5 5 5 5 5
Hardness on a
graphite scale
[3] Higher
10Н
Higher
10Н
Higher
10Н
Higher
10Н
Higher
10Н
Higher
10Н
Higher
10Н
Higher
10Н
Elasticity at
squeezing out, mm
[4] 9,4 6,9 8,2 2,3* 3,8* 7,9* 6,3* 8,9
Firmness to the
abrasive wear,
mark the
[5] 1-2 1 1 1 1-2 1-2 1 1-2
Abrasive wear in a
water environment
[6] 2 1-2 1-2 1-2 2 2 1 2
The tests showed stability of sheeting by 5 % Nacl during 120 hours.
Conclusions:
On the basis of the got results, most preferable to application pilot-scale, there is a standard of
coverage 7, rotining the greatest ball at the tests of abrasive firmness in a liquid environment, here
possessing mechanical durability higher than durability of alloy.
Thereby causing of the developed electrochemical coverage provides the assured defence of
metal of heat-exchange tubes.
Corrosion and erosion protection of equipment NPP.
Along with development of the new high-efficiency means of anticorrosion defence our
enterprise produces and supplies customers on NPP with exclusive paints, including radiation-proof
coverages and protective materials of the special purpose.
As an example it is possible to point materials for preservation of the weld-fabricated connections on
the period between repairs. On existent technology before the leadthrough of the planned non-destructive
control of the weld-fabricated connections one must conduct their mechanical cleaning.
Thus you damage the roller of strengthening of the weld-fabricated connections.
On a task the laboratory of metals SD “Zaporozhia NPP” by our enterprise was developed
technology of preservation of the weld-fabricated connection on the period between repairs. For this
purpose after the leadthrough of next cycle of non-destructive control the weld-fabricated sutures
protectes by heat-resistant (to 3500 C), moisture-proof coverage, which guarantees a corrosion
protection up to next repair (on 1-4 years).
To form such cover we form special heat-resistent defence, which is firmed in radiation’s
conditions.

(fig. 21)
Before next repair a “cocoon” easily retires
(fig.21) and control is conducted without
mechanical cleaning. Such technology,
guarding the weld-fabricated sutures, got a
high estimation on Zaporozhia NPP.
Anticorrosion defence of weld-fabricated
connections was applied during several years
in industrial condition.
At the working temperature of the weld-fabricated
sutures less than 1000 C we
suggest to use for preservation between
repair’s period heat-shrinkage tapes.
All described works demand for the realization fundamental testing and metrology base. In this
connection at SE “KOLORAN” was created and accreditated testing laboratory (fig. 22), and also
attestation of SE “KOLORAN” was conducted as the Head metrology service the National academy
of sciences of Ukraine (Certificate ¹ 2T – AN from 17.03.2008 fig. 23).
(fig.22) (fig.23)
Conclusions:
1. The results of works, executed by State Enterprise of “KOLORAN” IPC NAN of
Ukraine on the requests of enterprises of atomic industry, resulted in a report are inserted
to a branch documents (Universal methodice PNAE G-7-18-89, PNAE G-7-19-89) and
used in the process of exploitation of NPP.
During 20 year state enterprise “KOLORAN” is the leader of Ukraine in elaboration and
рroduction of different means for Non-destructive testing, repaire and defence of NPP
constructions.

2. In obedience to the letter of the 1th Vice-president of State Enterprise NAEK
“Energyatom” expedience of continuation of works of SE “KOLORAN” is confirmed on
development of the systems of diagnostics and monitoring of the state of equipment and
pipelines of NPP with the use of thermography and interest in their introduction in
subdivisions of NAEK “Energyatom”.
3. Developed by SE “KOLORAN” technical decisions in area of diagnostics of the state,
repair and defence of heat-exchange tubes of condensers and cooling systems of NPP got
the positive estimation of the World association of organizations, which use the atomic
stations. In the decision of Seminar of specialists of VAO NPP from 25.11.2009 (Odessa)
perspective of the offered solutions is marked for the corrosion and erosion protection of
heat transfer surfaces of condensers of turbines.

STATE ENTERISE “KOLORAN”

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