nuclear plant maintenance - amazon s3 · capital reinvestment for life ... leaky wire/ wifi...

Steve WoodsSenior Vice President, Nuclear Engineering

Ontario Power GenerationNuclear Power Council

September 1, 2016

Nuclear Plant MaintenanceThe Next Ten Years

2

Current State

High Plant SafetyHigh Plant ReliabilityLow Maintenance Backlogs

Also Increased CostStrong CompetitionValue of Nuclear Power

Unrecognized?

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Today's Challenges

Realization of the Nuclear PromiseNew Build (US and Worldwide)Refurbishment/Major Component

Replacement (Canada)Capital Reinvestment for Life

ExtensionWorkplace DemographicsPublic Perception of Nuclear

Power

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Opportunities – Looking to the Future

New and Life-Extended Units In ServiceAdvances in Technology and

Data Analytics (Another) New Generation

Entering the Workforce

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Leadership…..Collaboration…..Transformation

Leadership: Inspiring a New Attitude and CultureCollaboration: Working Together Innovation: Technology Development and Adoption

Viability of Nuclear Power

EDF Maintenance and Engineering Challenges

Michel MASCHI,VP R&D Generation & Engineering

EPRI NPCNew Orleans August 2016

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KEY CHALLENGE FOR MAINTENANCEIN NUCLEAR POWER PLANTS

• Increase nuclear generationOutage management

• LTO programGrand carénage project51 B€ [2014 – 2025]

T W.h

EDF fleet planned decennial outages

| 3Copyright EDF | Juin 2013

EDF Fleet Major Overhaul [2014-2025]Grand Carénage project

I&C modernization

Turbinehall

Turbinerenovation

Condensorrenovation

Generator :rotor renovationandstator replacement

Steamgeneratorreplacement

Cooling towerstackingreplacement

Fire alarmsrenovation

Main transformersreplacement

Training campus

Contractorscampus

New building forproject teams

Emergency back-updiesels

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Reducing outage durationImprove outage preparation and pre job briefing through extensive use of virtual reality - pilot project at Cattenom (3rd decennial outage 2016)

Direct measurement of clearance

Automated localisation and recognition of equipment reference

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Maintenance and Long Term OperationIdentification of life limiting issuesKnowledge and tools for maintenance optimisation of critical components

4 R&D objectivesNon replaceable components : reactorvessel and containment

Replaceable components : SG, I&C, cables …

Materials aging - understanding and anticipation : fatigue, corrosion, embrittlment …

Advanced monitoring systems and tools for non destructive examination

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LTO - Non-replaceable components New methodologies and/or modifications to explain or get complementary margins vs criteria

Reactor Vessel: . Gain on fracture toughness

through warm pre-stressing effect (scientific justification and AFCEN codification)

Reactor Containment : . VERCORS 1/3 mock-up for

leakage assessment and monitoring and coatings scenarios evaluation

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LTO – Monitoring and DiagnosticsNon destructive examination - Advanced monitoring

Non Destructive Evaluation of SG : . Multi-element probe performance

modelling . Eddy current rotating probe

performance modelling on realistic SCC cracks

Advanced monitoring : . Big Data Analytics for maintenance

(cases based diagnostics and deep learning)

. Diesels : acyclism measurements . E-monitoring roll-out

Scot GreenleeExelon Generation Senior Vice President

Engineering & Technical Services

Nuclear Power Council Advisory MeetingSeptember 1, 2016

Wireless Plant Health Monitoring

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Why Wireless Equipment Monitoring? Reduction in total cost of maintenance

o Enable more condition based maintenance (reduction/elimination of time based maintenance)

o Extended time between costly equipment rebuilds

o Early detection of incipient failures to prevent costly plant events/catastrophic failures

Improve worker/engineering productivity in data collection/analysis

o Reduce analysis time and improve quality of analysis

o Centralization of data reviews

o Utilization of software for data analysis, including troubleshooting

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How Computers can do the Work

Tag Level Advisories

Failure Diagnostic

Predictive Model

Failure Profile Failure Profile Failure Profile

SensorData

“Something’s Changed”

“Apparent Cause”

Dynamic Priority Assignment / Escalation

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The Digital Transformation

Cyber security

Obtain Data• Sensors• Instrumentation

Transport Data• Site network

Utilize Data• Transform to intelligent

information

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Right Sensors at Right Location…

Understanding the available technology/tools:– Define existing wireless platforms and capability– Establish rules of thumb for applications (specific to component and failure modes)– Identify cost effective solutions for application

Wireless Sensors:– Research and development of modular wireless sensors– Develop a common design specification for installation (design once install many)– Define what are the key characteristics for sensors:

o Battery life more than 2 years

o Flexibility of frequency and bandwidth tailored to environment

o Technology allows a variety of sensors

o Etc.

– Standardize how to measure the cost/benefit of wireless sensor use

Data Acquisition Needs

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Utility Network-Wireless/Leaky Wire (DAS)

Guidance on how to implement distributed antenna system (DAS) into existing plant: With or without existing Wi-Fi backbone

Optimal way to integrate with radio systems

Work with industry to resolve cyber security concerns

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Wireless Sensors

Leaky Wire/ WiFi

ComputersData Historian

Pattern Recognition

Digital Worker (eWP)

Rad ProSensors

Thermography/Acoustic

Continuous Monitoring

Sensors

APM(Integration of Data sources, Advanced Analytics,

Machine Language, etc.)Technology not demonstrated

Centralized Monitoring

Future of Advanced Performance Monitoring

AMS BridgePredictive Data

Plant Engineer

WORK ORDER DATA

LEGEND• IMPLEMENTED (continue to develop) • NOT IMPLEMENTED (proven benefit)

• NOT PROVEN YET TO PROVIDE BENEFIT

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Transform Data to Intelligent Information

Work with utilities and vendors to establish right approach to using software and artificial intelligence to transform data into intelligent information

Better detection, analysis and prioritization through various software tools:

– Machine Language: Improved analytical/diagnostic tools to define the potential severity of the conditions

– Advanced Pattern Recognition (APR): Develop the use of existing APR tools and integration of prognostic health monitoring to enable prioritization of alarm conditions

– Asset Performance Management (APM): Integrate industry failure mode and mechanism data including the EPRI data

– Other tools: Evaluate other techniques and software tools to improve the computer technology

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© 2016 Electric Power Research Institute, Inc. All rights reserved.

Jim HeishmanSenior Program Manager

Nuclear Power Council Advisory MeetingSeptember 1, 2016

The Future of Preventive Maintenance

Basis at EPRI

2© 2016 Electric Power Research Institute, Inc. All rights reserved.

Agenda

History of Nuclear Maintenance Applications Center (NMAC) Maintenance Related Products

Current State of Preventive Maintenance Basis Database (PMBD)

Future of Preventive Maintenance

3© 2016 Electric Power Research Institute, Inc. All rights reserved.

History – NMAC Mission Statement

NMAC serves as an international forum delivering proven, practical techniques and methods to reduce operating and maintenance costs and improve equipment reliability.

AudienceMaintenance, Engineering,

Work Planning, Field Technicians

4© 2016 Electric Power Research Institute, Inc. All rights reserved.

Equipment Reliability Working Group International

Equipment Reliability Working Group

Maintenance Planning Users

Group

Equipment Reliability Collaboration Hub for

Industry PMs

PM Users Group Maintenance Rule Users Group

5© 2016 Electric Power Research Institute, Inc. All rights reserved.

Improved Technical Content Delivery:Component Guides and Applications

6© 2016 Electric Power Research Institute, Inc. All rights reserved.

Current State – PM Basis Database

Provides:– Baseline PM tasks and intervals from industry experience– Tools to analyze the technical basis– Identifies failure modes exposed by strategy– A living repository for industry PM experience– A unifying structure for EPRI products– Favors a condition-based vs. time-based maintenance

strategy

PMBD provides a foundation for PM strategy based on the Reliability Centered Maintenance (RCM) process

7© 2016 Electric Power Research Institute, Inc. All rights reserved.

PMBD Web Services

(>350 Templates)

PMBD Web-Based

Interface Created

ContinuedTemplate

Development(>150)

PMBD Access

Database Created

EPRI Leads Application of RCM to

Power Industry

RCM Developedin Airline Industry

38 Original PM

Templates Published

PMBD Client-

Server CD Version

Published

PM Basis Database History

1960’s–70’s 1980’s 1995–1998 2000 2004 2013 20162006

8© 2016 Electric Power Research Institute, Inc. All rights reserved.

PMBD Vulnerability Calculation and Outputs

Low Voltage Switchgear Template

9© 2016 Electric Power Research Institute, Inc. All rights reserved.

Looking to the Future of Preventive Maintenance

Improving PM performance in real time through:– Integration of Cost Data to analyze your

maintenance strategies (<6 Months)– Adjustments based on accumulating

failure data (not just a mathematical prediction, 1.5 years)

– Real Time Data Integration (wireless sensors and process inputs, 3+ years)

10© 2016 Electric Power Research Institute, Inc. All rights reserved.

Together…Shaping the Future of Electricity