Acceptance testing of the eddy current probes for measurement of aluminum hydroxide coating thickness on K West Basin fuel elements

During a recent visual inspection campaign of fuel elements stored in the K West Basin, it was noted that fuel elements contained in sealed aluminum canisters had a heavy translucent type coating on their surfaces (Pitner 1997a). Subsequent sampling of this coating in a hot cell (Pitner 1997b) and analysis of the material identified it as aluminum hydroxide. Because of the relatively high water content of this material, safety related concerns are raised with respect to long term storage of this fuel in Multi-Canister Overpacks (MCOs). A campaign in the basin is planned to demonstrate whether this coating can be removed by mechanical brushing (Bridges 1998). Part of this campaign involves before-and-after measurements of the coating thickness to determine the effectiveness of coating removal by the brushing machine. Measurements of the as-deposited coating thickness on multiple fuel elements are also expected to provide total coating inventory information needed for MCO safety evaluations. The measurement technique must be capable of measuring coating thicknesses on the order of several mils, with a measurement accuracy of 0.5 mil. Several different methods for quantitatively measuring these thin coatings were considered in selecting the most promising approach. Ultrasonic measurement was investigated, but it was determined that due to the thin coating depth and the high water content of the material, the signal would likely pass directly through to the cladding without ever sensing the coating surface. X-ray fluorescence was also identified as a candidate technique, but would not work because the high gamma background from the irradiated fuel would swamp out the low energy aluminum signal. Laser interferometry could possibly be applied, but considerable development would be required and it was considered to be high risk on a short term basis. The consensus reached was that standard eddy current techniques for coating thickness measurement had the best chance for success in this endeavor. If proper placement and alignment of the eddy current measurement probe on the coating could be achieved, the thickness of this non-conductive coating over the conductive fuel cladding (Zircaloy 2) should be measurable based on magnetic stand-off aspects. Eddy current devices are routinely used to measure paint coating thicknesses on metal surfaces in this regard. The purpose of this report is to document the development and acceptance testing of the eddy current system conducted to qualify its use for the measurement of aluminum hydroxide coating thicknesses on fuel stored in the K West Basin