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Concepts and Tools for Maintenance Optimization Support

Maintenance Optimization to Improve Nuclear Power Plant Performance IAEA Technical Meeting hosted by WNA

Jean-Paul Bombail

Torsten Koslowski

London, September 8 – 10, 2014

All rights are reserved, see liability notice. AREVA Installed Base - WNA Maintenance Optimization Workshop - 2014/09 - AREVA Proprietary -

RESTRICTED AREVA - © AREVA -

PRODUCTS AND TECHNOLOGIES FOR MAINTENANCE - A COMPREHENSIVE SURVEY

CONCEPTS AND PRODUCTS FOR MAINTENANCE OPTIMIZATION

General information

Samples

Steam Generator Cleaning & Conservation Concept

Component and System Monitoring

Diagnostic and Monitoring Tools (predictive)

Preventive and Curative Maintenance Tools

INTRODUCTION OF AREVA

Content

1

2

3

4 CONCLUSION



Nuclear and Renewables: a Well-Rounded Offer

1



Organization of the Group

Mining

Business

Group

Front End

Business

Group

Reactors

& Services

Business

Group

Back End

Business

Group

Renewable

Energies

Business

Group

Engineering & Projects Op

era

tio

ns

Dep

art

me

nts

Executive Management Board

Corporate Departments

Regions (Germany, North America and Asia)

1



Large Projects Nuclear

Measurement

Installed

Base

Propulsion &

Research

Reactors(*)

BU

SIN

ES

S

DIV

ISIO

NS

Manufacturing

Products & Technology

OP

ER

AT

ION

AL

DIV

ISIO

NS

SUPPORT FUNCTIONS

Strategy

Finance

Human Resources

Legal

Communication

Information

Systems

REGIONS

Asia

Europe

US

OPERATIONAL SUPPORT

FUNCTIONS

I&C

Supply Chain

Management

Operational

Performance

Sales

(*): Direct report to AREVA CEO

Business Group

Reactors & Services

Reactors & Services BG Organization

1



Installed Base Business Division

Reactors in operation

Delivering services, solutions and products for

maintenance, modernization and lifetime extension

New builds

Supplying equipment and commissioning

Servicing 250+ all designs reactors worldwide

Scope of Work

1



Global presence and local delivery

Around 5,000 professionals in 9 countries on more than 20* sites

*major sites only

South Africa

Canada

USA

Brazil

China

Angra

Cape Town

Benicia/CA

San Jose/CA

Forth Worth/TX

Paris

Lyon

Rungis

Val de Reuil

Chalon-sur-Saône

Sully-sur-Loire

Cadarache

Erlangen

Offenbach

Karlstein

Helsingborg

Karlskrona

Germany France

Sweden

Spain Beijing

Shanghai

Shenzhen

Zaragoza

Tarragona

Toronto

Global Expertise for Local Customers Installed Base Locations

Cranberry Township, PA

Lynchburg/VA

Charlotte/ NC

Marlborough/CT

Alpharetta/GA

1



Installed Base Business Division Organization

1

AREVA NP Lesedi - Nuc Serv.

Plant upgrades(IBU-F)

IB-F

Modernisation on I&C and Electrical Systems

(IBL-F)

Outage Services(IBO-F)

Component Repair& Replacement

(IBR-F)

Plant Studies(IBE-F)

Field Operations(IBI-F)

Technical Support Unit(IBM-F)

Mobile Equipments

Services

(IBJ-F)

IB Global Sales Organization (IBGS)

Installed Base Bus. Division

Executive Assistant


(IBL-A)

IB-T

Outage Services /Component Repair &

Replacement(IBO-G)

Non Desctructive Examination(IBN-F)

IBN

Non Destructive Examination(IBN-G)

Non Destructive Examination(IBN-A)

IB-C

ACNS

WECAN SEID

SUPPORT

FUNCTIONS

Strategy & R&D(IBS)

HR

(IBH)

Finance(IBK)

Resources Planning(IBP)

CI & Quality(IBQ)

Supply Chain(IBA)

Project Management Office

(IBPM)

Health & Safety(IBHS)

AREVA NP Services Canada

Outage Services(IBO-A)

Component Repair& Replacement

(IBR-A)

Plant Upgrades (IBU-A)

Plant Studies(IBE-A)

IB-A

SGT


(IBL-G)

Plant Upgrades (IBU-G)

AREVA NP Services Spain

AREVA NP Uddcomb AB

Plant Studies(IBE-G)

IB-G

Field Operations

(IBI-G)

Legal



Products & Technologies for Maintenance

A comprehensive Survey ►CHEMISTRY SERVICES

►Decontamination (CORD®, AMDATM)

►Coating & Adhesive Technology

►Power Plant Chemistry

►SG cleaning (chemical & SIVABLAST)

►Surface Technology, Specifications

►OUTAGE SERVICES

►Outage Service PWR & BWR, consulting

►Visual Examination and Observation

►Refuelling and vessel services

►Steam Generator Service and inspection

►Primary Component & System Service

►Equipment Development and Design

►QUALITY SERVICES and

ENGINEERING SUPPORT

►Modification design..Engineering assessment

►Supplier Assessments

►Non Destructive Examination

►Pre-Inspection and In service inspection

►Production Control

►Spare part supply

► ES /I&C SERVICES

►ES / I&C Services (OEM & Non-OEM)

►Integr. I&C Projects (Safety&non-Safety)

►Services on Motors, Drives & Actuators

►Aging & Obsolescence Mgmt., Consulting

►Spare & Ware Part Mgmt. ERVA

►MONITORING & DIAGNOSIS

►Valve Diagnostic (VD)

►Loose Part Monitoring System (LPMS)

►Vibration Monitoring System (VMS)

►Leak Detection (LD)

►Diagnostic of Rotating Machinery (DIROM)

►MECHANICAL SERVICES

►Component Services & Repair and Replacement

►Welding Competence Center

►Integrated Maintenance

►Heat exchangers and tanks maintenance

►Rotating machines including RCP maintenance

and services

A wide range of solutions including maintenance optimization support

2



Concepts & Products for Maintenance Optimization General Information

Many concepts already exist for plant reliability improvement, maintenance programs and task optimization

IAEA , WANO, INPO guidelines etc.

RCM process

Risk informed maintenance

Asset management

…..

Usually, the operators are responsible for the reliability and the maintenance program of the plant

Areva can support them with its expertise in

Plant design

Maintenance services

3



Potential support from AREVA in

Maintenance optimization or by implementing improvement

processes

Methodological support, such as benchmarking, training…

Dedicated resources

Technical and technological expertise

Study of failure modes, definition of monitoring means

Definition of parameters to understand and monitor the status and the

reliability of the equipment and systems

Analysis of periodical testing to checking trends in components and

systems


3



Potential support from AREVA in

Technical and technological expertise (continued)

Feasibility studies, availability

Economical relevance of treatment of identified vulnerability point

Modification studies: physical modifications, documentary modification

(maintenance procedures, periodical testing…)

Definition and implementation of dedicated testing

Implementation of modification including the requalification tests

Tools for monitoring and diagnostic

Implementation of dedicated tools with integrated platform

Analysis of signals and trends

Contingency plans for identified risks

Emergent issue solving (not anticipated through risk analysis): curative

maintenance


3



SG

AMP

Reactive

Informative

Proactive

Operational Excellence

Monitoring and Control

ND Inspection / Oxide Mapping and Data

TH Modeling / Heat transfer

SG Operation & Corrosion Data Measuremt.

Deposit Analysis / Visual Inspection Results

Repair and Service

Tube pulling / Plugging

Foreign Part Removal

Chemistry Consultation

Low Inventory Chem. Cleaning

Sludge Lancing

Upper Bundle Flush

Chemical Cleaning

SG Exchange

Modeling and Expertise

SG Database

Overview of all SG Data

Concepts & Products for Maintenance Optimization

Steam Generator Asset Management

3

All rights are reserved, see liability notice.

Maintenance Scenario Testing

Economic Model

AREVA Installed Base - WNA Maintenance Optimization Workshop - 2014/09 - AREVA Proprietary -


SG Thermal Performance Tool

Steam Temperature History

Steam Pressure History

Deposit Composition

Tube Degradation History

Sludge Lance Performance

Deposit Locations (Mapping)

Maintenance Costs

Performance nformation

Cleaning Options

Industry Data Bases

“Hx TOOL”

“AM TOOL”

MAESTRO

Optimized

Maintenance

Planning

Concepts & Products for Maintenance Optimization SG Asset Management MAESTRO Calculation

3




SG Cleanliness

SG Cleanliness Concept

3


Each plant and each SG has its own

history and particular condition

The applied cleaning scenario should

consider these aspects as well as

application constraints like outage

schedule, critical path, etc.

AREVA’s customized chemical cleaning

concept

Offers a variety of cleaning technologies.

This makes it possible to tailor the

mechanical and chemical cleaning

exactly to the plants needs.

UBF

TSL / IBL

Ch

em

ica

l C

lea

nin

g

Customized Chemical Cleaning (C3)

Chemical cleaning

tailored exactly to the

plant’s needs


C³



3



Complementing an adequate pH strategy, the application of film-forming amines

is a field-proven measure to counteract corrosion

Formation of an adherent hydrophobic,

temperature-resistant film

The film acts as a shield that limits the access

of water and hydrated species to the metal or

metal oxide surface

Decreased corrosion rate by inhibiting the mass

transfer between surface and solution

Imparts a hydro-phobic character while the

amine group bounds to the metal

FFA Application – Principles & Basics


Film Forming Amines (FFA)

3




Warehouse Information System (WIS)

Short-term

Mid-term Long-term

Recording of

Experiences

Modification of

Maintenance

Strategies

Maintenance

Activities

Maintenance

Strategy

Preparation of

Maintenance

Maintenance

Planning

Evaluation of

Maintenance

Reports

Implementation

of Strategy

Maintenance

Documentation

Writing of

Work

Orders

► Graphical planning:

► Workflow integration

►Paperless documentation

►Strategy manager

►Manpower/work order planning

3

D:/Data/WIS-Projekt/WIS/0181 Vorträge, Präsentationen/Archiv/070509RB Berichtseingabe.avi



Analysis of

Inspection Results

Unnecessary

Inspection

Required

Inspection or

Maintenance

Lifetime

Prediction

COMSY

Documentation

Modelling

• Material

• Design

•Operation

•..

Lifetime

adjustment

Condition Oriented

Ageing and Plant Life

Monitoring SYstem


Component & System Monitoring & Diagnostics with

COMSY

3




Preventive maintenance programs:

Services and tools are designed and used with the following requirements:

Industrial safety

Dose reduction

Time reduction including increased reliability

FME policy

Skilled and trained personnel

Accurate and adequate procedures

Predictive maintenance programs

Additional requirements for diagnostic and monitoring tools:

As little intrusive as possible

Trend analysis for diagnosis

Automatic pre-diagnosis

Curative maintenance program:

Develop solutions and contingency plans according the lessons learned and risk

analysis results

3




M&D Tools

EQUIPMENT

3



The available technologies can be combined

Vibration acquisition

Power measurement

Current analysis

Lubricant chemistry analysis

Infrared thermography

Force measurement

Acoustical measurement

Physical parameter measurement (pressure, temperature, flow,

strength)

Ultrasonics

…


Areva Tools for Component and System M&D

3



Diagnostic

Data Collection

State Detection

Pre-processing

Monitoring & Diagnostic

Historical Data Base

Reports/Actions

SENSORS

►Integrated and unified platforms

are recommended



3





3



Booster-Pump Gear Drive Main-Pump

Detection of faults on short-circuit rotor-bar

Symptom: drop in coherence between rot. speed and current

and significant peak in current spectrum

Action: maintenance of drive

COH

0.0

0.5

1.0

FFT

0.0

0.5

1.0

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0

Hz


Rotating Machines

3



SIPLUG

SIPLUG

SIPLUG

SIPLUG

Modules

CANEthernetbridge

...

Service interface

ADAM

users

Office PCs

CAN

bus

Plant LAN (Ethernet)

ADAM SIPLUG


Valve M&D

3



Controlled Area Workshop

Networked

Solution

Mobile

Solution


Valve M&D

3



Leakage detection with 4

sectors of sensors

profile

d'humidité

FLÜS

Tube with sensors

ecapteurs Tube without sensors

RST

sectors

I II III IV Test

peak


Leakage Detection

3



RGL 53 (Position sensors)

RGL 52 (Rod Drop Time)

RGL 51(CRDMs)

Eclipse (upper internal guide tube wear )

Jasper bench (control rods)

Due to data combination and trend analysis it is possible to better anticipate the

evolution of the component’s or system’s availability


Control Rod System

3



Sensor location


Fatigue Monitoring System (FAMOS)

3



A

gap

A

curr

APSDref (contact pipe/building)

APSDcurr (pipe free)


Vibration Monitoring System

3


Loose parts monitoring system

Tasks

Monitoring of the primary circuit for

loose or loosened parts

Diagnosis Features

Sensitive detection and recording

of loose parts events with

enhanced evaluation software






preventive / curative maintenance tools

AVARIS (Valve repair)

Rework of

Cover Flanges

Repair of

Self-Sealing

Closure Heads

Machining of Guide

Rails

Exchange of Body

Seat Rings

Rework of

Cover Seal Areas

Rework of Bore Holes

Repair of Body Seat Surfaces

AVARIS

CNC Machining

Technology

AVARIS

TIG Welding Head

AVARIS

Tactile 3D

Measurement

3




preventive / curative maintenance tools

Reactor pit leakage detection and repair by adhesive solutions

Liner Leakage

Dry or Underwater Leak Detection

Repair by using

adhesive technology

including difficult

geometry area treatment

3



Profound experience and knowledge of the systems

and components combined with new technologies is a

sound basis for the development of new technologies and

tools to

Improve the maintenance strategy of systems and components

Increase the predictive maintenance share

Conclusion

4


Editor and Copyright [Date]: AREVA GmbH – Paul-Gossen-Straße 100 – 91052 Erlangen, Germany. It is prohibited to reproduce the present publication in its entirety or partially in whatever form without prior consent. Legal action may be taken against any infringer and/or any person breaching the aforementioned prohibitions.

Subject to change without notice, errors excepted. Illustrations may differ from the original. The statements and information in this brochure are for advertising purposes only and do not constitute an offer of contract. They shall neither be construed as a guarantee of quality or durability, nor as warranties of merchantability and fitness for a particular purpose. These statements are based on information that was available to us at the date of publication. Only the terms of individual contracts shall be authoritative for type, scope and characteristics of our products and services.



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