Concepts and Tools for Maintenance Optimization Support · Concepts and Tools for Maintenance...
Transcript of Concepts and Tools for Maintenance Optimization Support · Concepts and Tools for Maintenance...
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
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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
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2
3
4 CONCLUSION
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Nuclear and Renewables: a Well-Rounded Offer
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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)
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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
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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
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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
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Installed Base Business Division Organization
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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
Modernisation on I&C and Electrical Systems
(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
Modernisation on I&C and Electrical Systems
(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
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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
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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
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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
Concepts & Products for Maintenance Optimization General Information
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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
Concepts & Products for Maintenance Optimization General Information
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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
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Maintenance Scenario Testing
Economic Model
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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
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Concepts & Products for Maintenance Optimization
SG Cleanliness
SG Cleanliness Concept
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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
Concepts & Products for Maintenance Optimization
C³
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3
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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
Concepts & Products for Maintenance Optimization
Film Forming Amines (FFA)
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Concepts & Products for Maintenance Optimization
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
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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
Concepts & Products for Maintenance Optimization
Component & System Monitoring & Diagnostics with
COMSY
3
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Concepts & Products for Maintenance Optimization
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
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Concepts & Products for Maintenance Optimization
M&D Tools
EQUIPMENT
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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
…
Concepts & Products for Maintenance Optimization
Areva Tools for Component and System M&D
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Diagnostic
Data Collection
State Detection
Pre-processing
Monitoring & Diagnostic
Historical Data Base
Reports/Actions
SENSORS
►Integrated and unified platforms
are recommended
Concepts & Products for Maintenance Optimization
Areva Tools for Component and System M&D
3
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Concepts & Products for Maintenance Optimization
Areva Tools for Component and System M&D
3
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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
Concepts & Products for Maintenance Optimization
Rotating Machines
3
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SIPLUG
SIPLUG
SIPLUG
SIPLUG
Modules
CANEthernetbridge
...
Service interface
ADAM
users
Office PCs
CAN
bus
Plant LAN (Ethernet)
ADAM SIPLUG
Concepts & Products for Maintenance Optimization
Valve M&D
3
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Controlled Area Workshop
Networked
Solution
Mobile
Solution
Concepts & Products for Maintenance Optimization
Valve M&D
3
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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
Concepts & Products for Maintenance Optimization
Leakage Detection
3
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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
Concepts & Products for Maintenance Optimization
Control Rod System
3
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Sensor location
Concepts & Products for Maintenance Optimization
Fatigue Monitoring System (FAMOS)
3
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A
gap
A
curr
APSDref (contact pipe/building)
APSDcurr (pipe free)
Concepts & Products for Maintenance Optimization
Vibration Monitoring System
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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
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Concepts & Products for Maintenance Optimization
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
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Concepts & Products for Maintenance Optimization
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
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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
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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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