10 Hanes Applying Advanced Technologies to Improve NPP ...

Lew Hanes, ConsultantJoe Naser, EPRI

Plant Productivity Improvement Through Advanced Technology - Group Kickoff MeetingJune 29-30, 2010

Applying Advanced Technologies to Improve NPP Productivity

2© 2010 Electric Power Research Institute, Inc. All rights reserved.

Presentation Overview

• Why apply advanced technologies?• Aviation and medical case studies

• Overview of EPRI projects involving advanced technology visualization tools


Why Apply Advanced Technologies?

Make usable huge increase in data/informationSensors Data base access

Computers Communications



Help reduce information overload and support decision-making (improve situation awareness; avoid errors: mode, fixation, keyhole, etc.)



Overcome information overload, e.g., visualization technology can show views and relationships not possible otherwise

View of Core By 2-D or 2.5-D Picture By 1000 Words?



Workers will be retiring or going to new plants, and incoming and next generation workers will expect this technology - many are using it now


Case Study: Applying Advanced Technology in Aviation Industry• FAA implementing NexGen technology to modernize aviation airspace system

• Performance-Based Navigation (PBN): a key NexGen component providing

Area Navigation (RNAV)

Required Navigation Performance (RNP)

• Many airlines have or will upgrade aircraft and procedures to take advantage of this technology


Area Navigation (RNAV)Description

RNAV enables aircraft to fly any desired flight path: From flights via waypoints to point-to-point flights

Before RNAV: Via waypoints After RNAV: Point-to-pointShown: ORD to MEM


Required Navigation Performance (RNP) Description

• RNP is RNAV with the addition of

Performance monitoring and aircraft control: aircraft track accuracy ≤ 10 meters; time of arrival accuracy at any flight point ≤ 10 seconds

Capability to alert crew to deviations

• Provides automated descents and approaches

After RNP: Automated continuous descent arrival profile Before RNP: Manual

“drive and dive” arrival profile


Investment, Cockpit Upgrades, and Other Changes

• invested $175 million to take advantage of FAA PBN technology

• Upgraded cockpits: FMCs, GPS, Displays

• Provided automation, procedures, and RNP scenario training for 6000 pilots: ground school, flight simulator, PC-based simulation program

• Worked extensively with pilots to gain acceptance

Before upgrade

After upgrade


Changed Concept of Operations and Pilot’s Role

• Implementation changed concept of operations from manual to primarily automated flight control

• Pilot’s role and tasks changed

From manually flying to programming FMC, monitoring flight conditions and aircraft status, andtaking over when needed or wanted

Workload reduced, but with potential to lose some alertness and manual skills

Manual flying reduced with greater attention to situation awareness and decision-making


Benefits: Safety, Fuel, andEnvironment• Improved safety benefits

Precise guidance reduces risk of hitting obstacles, such as mountains or structures

Improved situation awareness results in faster pilot response and fewer errors

• Fuel consumption and environment benefits

Each trip leg reduced by 3 miles (1 minute) saving 88 gallons fuel, 275 lb CO2, 1 lb NOx

Test flight showed 6% fuel and CO2 savings


Benefits: Passenger andEconomic• Passenger benefits

Shorter flight durations

Smoother ride due to continuous descent

• Economic benefits due to annual reductions

90.6 million gallons across fleet with savings of $207 million (based on 4th quarter 2010 cost)

CO2 emissions by 1.9 billion pounds

$207 million fuel savings will recoup $175 million investment in less than one year


1- Lessons Learned from Aviation Industry Case Study• Consider opportunities for improvement when changes are made (FAA PBN upgrade occurred independent of Southwest Airlines)

• Identify what is most important that could be achieved (safety and economic gains)

• Identify and evaluate change options, e.g.,

Limited (737-700s only with low costs)

Across fleet (737-300 upgrades expensive)

• User input and buy-in essential but difficult (pilots strongly resisted upgrade at first)


2- Lessons Learned from Aviation Industry Case Study

• Many issues must be considered in making decision about actions to take, if any

Obtain OE from others (e.g., Alaska Airlines)

Conduct tests to develop data (e.g., flight)

Identify positive and negative impacts (e.g., on safety--loss of manual skills, alertness)

Identify and evaluate required infrastructure changes and impact (e.g., training, procedures)

Perform cost-benefit and ROI calculations


Case Study: Applying Advanced Technology in Medical Industry• Medical industry introducing many new systems incorporating advanced technology

• Most systems extremely beneficial for patients, but some may create new avenues for errors, with devastating consequences

• New York State analyzed 621 incidents (2001-2010) involving radiotherapy systems

Radiation missed all or part of target: 46% of cases

Wrong dose administered: 41% of cases

Wrong patient involved: 8% of cases


Serious Incident with Varian Linear Accelerator System

• Automated system delivers Intensity-Modulated Radiation Therapy

Computer-controlled X-ray accelerators distribute precise radiation doses to malignant tumors

Radiation delivery pattern determined by software that performs optimization and treatment simulation

Customized radiation maximizes tumor dose while protecting surrounding normal tissue resulting in better tumor targeting and lessened side effects

System uses smart-beam technology provided by 120 computer-controlled metal leaves (multileaf collimator) to shape and modulate radiation beam


Preparing Linear Accelerator System

o Programs and saves instructions: beam radiation dose, treatment area digital image, instructions that guide multileaf collimator

o Checks machine calibration, verifies correct dose delivered to proper location, system safety

o May run test before treatment to verify computer programmed correctly (customary but not mandatory at hospital where incident occurred)

• Medical physicist has key responsibilities

Creates treatment plan based on radiation oncologist prescription


Administering the Radiation Treatment

• Patient typically receives several treatments spread over several days

• Radiation therapistsPrepare patient and position patient on treatment table

Operate system from behind shielded enclosure

Watch patient on closed-circuit TV during treatment


Incident Scenario (1)

• Patient successfully received four treatments for tongue cancer, as prescribed

• Treatment plan revised to protect patient’s teeth

• Medical physicist created a revised plan Tried to save plan when computer displayed error message asking if changes should be saved before program aborted—answer was “yes”

Radiation oncologist approved the new plan

• During plan revision patient arrived; therapists prepped patient and placed a mask over his face



• After 30 minutes and two computer crashes several radioactive beams turned on

• Treatment repeated on each of next two days

• Medical physicist then ran test to check if patient was being radiated as prescribed

Results were horrifying: multileaf collimator that should focus beam on tumor was wide open, and patient received 7 times prescribed dose

Patient’s entire neck, from base of skull to larynx, had been exposed



• Remaining treatments were cancelled, and patient and wife told of serious overdose and that no cure existed

• Patient given pain medicine; was barely able to sleep or swallow; and endured incessant hiccupping, vomiting, a feeding tube, etc.

• Patient died in less than 2 years


Possible Causes (1) (“guesses” based on newspaper reports; official records sealed)

• Design errorsSoftware required three instructions to be entered in

correct sequence and saved; no alert or alarm that input not saved with computer crashes

No fail-safe mechanism or alarm--computer sent corrupted commands to control unit resulting in collimator completely open (worst possible position)

• Organizational errorsDid not require treatment plan to be verified as accurate, or radiation therapist to monitor display

Inadequate procedures, checklists, and training


Possible Causes (2) (“guesses” based on newspaper reports; official records confidential)• Medical physicist human errors

Did not verify that instructions successfully saved, or treatment plan accurate before use

Continuation bias or “press-on-it is”– perceived time pressure to prepare revised plan since patient being prepped, and radiation oncologist waiting to review and approve plan revision before treatment

• Radiation therapist (2 present) human errorLack of situation awareness, fixation error—

therapists fixated attention on patient concerned about him vomiting in mask and choking, and ignored display showing collimator wide open


Consequences

• Investigators blamed both hospital for failing to catch the error, and Varian for flawed software

• New York City fined hospital $1,000, and financial settlement negotiated with family

• Radiation oncologist no longer treats patients (case drove him to retire, according to a friend)

• Extensive media coverage resulting in greatly increased FDA and manufacturer attention (based on this and many similar incidents)

Fail-safe design and procedures included by 2012


1- Lessons Learned from Medical Industry Case Study

• Advanced technology may be extremely beneficial, but also may create new avenues for errors, with devastating consequences

Manual input often required to program automation, and errors must be found and corrected in advance of system operation

Different and sometimes new personnel functions, tasks, and actions may be created resulting from new concept of operations, maintenance, planning

New high-risk scenarios may be created based on advanced technology capabilities and applications


2- Lessons Learned from Medical Industry Case Study

• OE in other industries can provide valuable insights to consider when applying advanced technology, e.g., new types of errors and how they can be handled

• Important to apply HFE during all phases of design, evaluation, V&V

• Important to provide personnel with adequate procedures, checklists, training

• Should apply recent guidelines applicable to advanced technology rather than “traditional”guidance alone (e.g., NUREGs 0711 and 0700)


Projects Involving Advanced Technology Visualization Tools

• Graphical visualization period began about 1500

• Leonardo da Vinci created first use of visualization as a scientific tool to study a turbulent flow

• EPRI began Visualization R&D projects in 2003

Performed demonstrations with three utilitiesShowed results and obtained feedback from several utilities

Free water jet issuing from a square hole into a pool


EPRI Projects Involving Advanced Technology Visualization Tools

Technology supporting visualization allowing a user to interact with and thereby affect results of a computer-simulated 3-D real or imaginary environment (in both 2.5-D and 3-D)

2.5-D: Created by perspective renditions

3-D: Created by stereo presentations


Facility Evaluation: Callaway Site Control Room Upgrade

• At Callaway site used VR tools to create photo-realistic-appearing control room model showing planned upgrade

• Evaluated model in both 2.5-D (on PCs and screen) and 3-D (in CAVE and on Visi-Wall)

• Evaluation determined how model might be used, if design met NRC human factors guidelines, etc.

• Utility personnel took part in evaluation, and identified numerous VR applications


Facility Evaluation Results

• Model created quickly and at low cost--3-D CAD file was available

• Useful for conceptual design, evaluation, and to get feedback

• Valuable for familiarization and orientation

• Successfully applied a tool to evaluate against NRC guidelines

• Very favorable comments about use and value by plant personnel

• 2.5-D model adequate


Possible Benefits: Facility Design and Evaluation Virtual Models

• Eliminate or reduce need for expensive physical mockups

• Improve design quality by having virtual model available duringconceptual design phase

Cheaply evaluate alternative designsObtain user feedback early in designVerify against guidelines, e.g., human factorsEvaluate and eliminate design deficiencies in virtual model rather than physical mockup

• Model may be used almost anywhere to support evaluations, for orientation, etc.

Not acceptable


Work Planning and Training at Comanche Peak Site

• At Comanche Peak site demonstrated use of 2.5-D VR to support activities in pressurizer room prior to weld overlay work

Work planning prior to room preparationsWorker orientation and training before entry to

prepare room and take radiation measurementsCapture undocumented knowledge from experts to

make available to othersWelder training prior to weld overlay start


Work Planning and Training Results

• Models created quickly and at low cost—laser scans were available

• Pressurizer room VR model found cost-effective~$3K benefit

• Shielding workers~50% less dose• RP techs – significantly less dose• Reasons for dose avoidance: use

for training; to obtain data; to plan, e.g., shielding placement

Fewer entries into pressurizer“Hot spot” knowledge

9.5 inch


Comments Provided by Site Personnel

• VR can effectively support outage, facility modification, maintenance and walkdown work planning

• Especially valuable for parts of the plantInaccessible with the plant at powerContaining radiation or other contaminants (can reduce or eliminate entries)Congested with equipment, piping, etc., requiring time to find location and take needed actions, e.g., make measurements

• Model reusable in future with additional benefits


Possible Benefits: Work Planning Virtual Models

• Eliminate or reduce need to enter parts of plant while at power, that contain radiation, are congested, etc.

Obtain information from model to support outage, maintenance, and facility modification planning, e.g., design of shielding, scaffoldingReduce need for walkdownsTake measurements using modelPerform equipment interference checksTrain workers before entry, e.g., routes, “hot spots” to avoid

Measure

Read tag ID


AOV Maintenance Training at Comanche Peak

At Comanche Peak site demonstrated use of 2.5-D to support Air-Operated Valve (AOV) maintenance training


AOV Maintenance Training Results

• Model cost high, but reduced to ~$865, if 3-D CAD files available and commercial authoring software used to add interactive features

• ~5-10% time savings to perform maintenance• Reduced rad dose due to less time in room• Huge savings possible if can eliminate

Physical model used for trainingMajor errors causing power reduction

• Model may be used repeatedly in future• Useful for JIT, instructor and self-training

Modelling software


Valve Maintenance Training Results

• Useful for inspection, preventive maintenance, repair, and equipment upgrade and removal activities

• Models may include conditions not possible with physical mockups

• Models may be used anywhere compatible computer is available

• Model usable in future at ~ no cost• Very useful for preparing for tasks in

radiation and difficult access areas• Do not need an exact model to train on


Possible Benefits: Maintenance Training Virtual Models

• Eliminate need for physical mockups (e.g., valves, pumps); big $ savings

• Reduce time to maintain and reduce error occurence due to better training

Animation shows how to perform actionsLinks to expertise and documents valuable

• Reduce exposure, if radiation present• Virtual model may be used

Almost anywhere providing training flexibilityReused when needed in the futureEasily modified when equipment is upgraded


Knowledge Elicitation and Presentation at Comanche PeakAt Comanche Peak site demonstrated use of VR models to elicit tacit knowledge from experts to support • Pressurizer room

model for work planning and training prior to weld overlay

• AOV model for maintenance technician training Video camera used to capture

expert’s knowledge while he interacts with virtual model


Knowledge Elicitation and Presentation Results, and Possible Benefits• Very effective and low cost tool

for capturing and presenting valuable knowledge (~$900)

• Stimulated recall of valuable tacit knowledge not recalled with traditional methods

• Valuable for delivering expertise; users liked immediate access by label click

• Users saw value in ease of adding expertise and links to additional information sources

• Video delivery very well liked—users could see and hear expert (preferred to written material)

High dose sources


Current Power Plant VR Applications: Fort Calhoun Nuclear Power Plant• Plant is planning to upgrade control

room, and create four virtual modelsCurrent control roomAfter two intermediate upgradesAfter upgrade completed showing end-point vision

• Use models to visualize, interact, and evaluate plans before implementation

Orient personnel to planned changesObtain input about potential design problemsSupport finalizing interface specification


Possible VR Uses Identified by Nuclear Utility Personnel

Listed in EPRI 1011303• Training and education

in plant fundamentals• Maintenance training and support• Design and evaluate new and

upgraded facilities• Minimize exposure to radiation and other

undesirable conditions• Support capture and delivery of valuable

worker knowledge• Virtual tours and route planning, e.g., first time

outage workers


Possible Additional VR Uses

• NDE training and testing• Virtual training for security and

emergency response teams• Support collaboration between sites• Virtual maintenance and task

proficiency evaluation • Reactor core visualization• Personnel radiation tracking and

monitoring• View and evaluate facility

construction plan over time


Some Lessons Learned

• Choice of 2-D, 2.5-D or 3-D depends on task and user visualization needs

• Less costly 2.5-D adequate for most nuclear applications, but 3-D cost

• Cost of developing VR modelsLow, if 3-D CAD files or laser scans available, and commercial authoring software usedHigh, if modeling software used to create 3-D files

• Important to perform cost-benefit analysis to determine if VR is justified

CostBenefit


Some Criteria for Selecting Tasks Justifying VR Use

• Large economic and/or safety benefits, if user performance improved (less work time, dose, probability of error, etc.)

• Human performance is a problem

Many Tasks

Screen Select ones with most value • Task requires visualization and human

performance improved with VR• Virtual models produced at acceptable cost• Cost/ benefit justification for providing VR• Need to train new workers and outage workers• Utility has infrastructure to support VR use


Questions?

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